infiniti G37-09-Coupe4

BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY

SECTION

GW

GLASS & WINDOW SYSTEM

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CONTENTS SYMPTOM DIAGNOSIS ............................... 2

WINDSHIELD GLASS ....................................... 11

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SQUEAK AND RATTLE TROUBLE DIAGNOSES ................................................................ 2

Exploded View .........................................................11 Removal and Installation .........................................11 Inspection ................................................................13

Work Flow ................................................................. 2 Inspection Procedure ................................................ 4 Diagnostic Worksheet ............................................... 6

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SIDE WINDOW GLASS .................................... 14 H

PRECAUTION ............................................... 8


PRECAUTIONS ................................................... 8

REAR WINDOW GLASS .................................. 16

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ................................................................... 8 Precaution for Procedure without Cowl Top Cover...... 8 Precaution for Battery Service .................................. 8 Handling for Adhesive and Primer ............................ 8


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PREPARATION ........................................... 10

Exploded View .........................................................18 Removal and Installation .........................................18 Inspection and Adjustment ......................................19

PREPARATION ..................................................10

DOOR REGULATOR ........................................ 21

Special Service Tools ............................................ 10 Commercial Service Tools ..................................... 10

Exploded View .........................................................21 Removal and Installation .........................................21 Disassembly and Assembly .....................................21 Inspection and Installation .......................................22

REMOVAL AND INSTALLATION ............... 11

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DOOR GLASS ................................................... 18 GW

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Revision: 2009 October

GW-1

2009 G37 Coupe

SQUEAK AND RATTLE TROUBLE DIAGNOSES < SYMPTOM DIAGNOSIS >

SYMPTOM DIAGNOSIS SQUEAK AND RATTLE TROUBLE DIAGNOSES Work Flow

INFOID:0000000004676909

SBT842

CUSTOMER INTERVIEW Interview the customer if possible, to determine the conditions that exist when the noise occurs. Use the Diagnostic Worksheet during the interview to document the facts and conditions when the noise occurs and any customer comments. Refer to GW-6, "Diagnostic Worksheet". This information is necessary to duplicate the conditions that exist when the noise occurs. • The customer may not be able to provide a detailed description or the location of the noise. Attempt to obtain all the facts and conditions that exist when the noise occurs (or does not occur). • If there is more than one noise in the vehicle, perform a diagnosis and repair the noise that the customer is concerned about. This can be accomplished by performing a test drive with the customer. • After identifying the type of noise, isolate the noise in terms of its characteristics. The noise characteristics are provided so that the customer, service adviser, and technician use the same language when describing the noise. • Squeak – (Like tennis shoes on a clean floor) Squeak characteristics include the light contact / fast movement / brought on by road conditions / hard surfaces = high-pitched noise / softer surfaces = low-pitched noises / edge to surface = chirping • Creak – (Like walking on an old wooden floor) Creak characteristics include firm contact / slow movement/twisting with a rotational movement / pitch dependent on materials / often brought on by activity. • Rattle – (Like shaking a baby rattle) Rattle characteristics include fast repeated contact / vibration or similar movement / loose parts/missing clip or fastener / incorrect clearance. • Knock – (Like a knock on a door) Knock characteristics include hollow sounds / sometimes repeating / often brought on by driver action. • Tick – (Like a clock second hand) Tick characteristics include gentle contacting of light materials / loose components / can be caused by driver action or road conditions. • Thump – (Heavy, muffled knock noise) Thump characteristics include softer knock / dull sounds often brought on by activity. • Buzz – (Like a bumblebee) Buzz characteristics include high frequency rattle / firm contact. • Often the degree of acceptable noise level varies depending upon the person. A noise that a technician may judge as acceptable may be very irritating to a customer. • Weather conditions, especially humidity and temperature, may have a great effect on noise level.

DUPLICATE THE NOISE AND TEST DRIVE


GW-2

2009 G37 Coupe

SQUEAK AND RATTLE TROUBLE DIAGNOSES < SYMPTOM DIAGNOSIS > If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information on the Diagnostic Worksheet regarding the conditions or location of the noise. This information can be used to duplicate the same conditions when the repair is reconfirmed. If the noise can be duplicated easily during the test drive, do the following with the vehicle stopped to help identify the source of the noise. 1) Close a door. 2) Tap or push/pull around the area where the noise appears to be coming from. 3) Rev the engine. 4) Use a floor jack to recreate vehicle “twist”. 5) At idle, apply engine load (electrical load, half-clutch on M/T models, drive position on A/T models). 6) Raise the vehicle on a hoist and hit a tire with a rubber hammer. • Drive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs. • If it is difficult to duplicate the noise, drive the vehicle slowly on an undulating or rough road to stress the vehicle body.

CHECK RELATED SERVICE BULLETINS After verifying the customer concern or symptom, check ASIST for Technical Service Bulletins (TSBs) related to the concern or symptom. If a TSB relates to the symptom, follow the procedure to repair the noise.

LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE Narrow down the noise to a general area. To help pinpoint the source of the noise, use a listening tool (Chassis ear: J-39570, engine ear, and mechanics stethoscope). 2. Narrow down the noise to a more specific area and identify the cause of the noise by: • Removing the component(s) in the area(s) that is / are suspected to be the cause of the noise. Do not use too much force when removing clips and fasteners, otherwise clips and fasteners can be broken or lost during the repair, creating a new noise. • Tapping or pushing/pulling the component(s) that is / are suspected to be the cause of the noise. Do not tap or push/pull the component(s) with excessive force, otherwise the noise is eliminated only temporarily. • Feeling for a vibration by hand by touching the component(s) that is / are suspected to be the cause of the noise. • Placing a piece of paper between components that are suspected to be the cause of the noise. • Looking for loose components and contact marks. Refer to GW-4, "Inspection Procedure".

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REPAIR THE CAUSE • • -

If the cause is a loose component, tighten the component securely. If the cause is insufficient clearance between components: Separate components by repositioning or loosening and retightening the components, if possible. Insulate components with a suitable insulator such as urethane pads, foam blocks, felt cloth tape, or urethane tape. A NISSAN Squeak and Rattle Kit (J-43980) is available through the authorized NISSAN Parts Department. CAUTION: Never use excessive force as many components are constructed of plastic and may be damaged. NOTE: Always check with the Parts Department for the latest parts information. The following materials are contained in the NISSAN Squeak and Rattle Kit (J-43980). Each item can be ordered separately as needed. URETHANE PADS [1.5 mm (0.059 in) thick] Insulates connectors, harness, etc. • 76268-9E005: 100 × 135 mm (3.937 × 5.315 in) • 76884-71L01: 60 × 85 mm (2.362 × 3.346 in) • 76884-71L02: 15 × 25 mm (0.591 × 0.984 in) INSULATOR (Foam blocks) Insulates components from contact. Can be used to fill space behind a panel. • 73982-9E000: 45 mm (1.772 in) thick, 50 × 50 mm (1.969 × 1.969 in) • 73982-50Y00: 10 mm (0.394 in) thick, 50 × 50 mm (1.969 × 1.969 in) INSULATOR (Light foam block) 80845-71L00: 30 mm (1.18 in) thick, 30 × 50 mm (1.181 × 1.969in) FELT CLOTHTAPE Revision: 2009 October

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GW-3

2009 G37 Coupe

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SQUEAK AND RATTLE TROUBLE DIAGNOSES < SYMPTOM DIAGNOSIS > Used to insulate where movement does not occur. Ideal for instrument panel applications. • 68370-4B000: 15 × 25 mm (0.591 × 0.984 in) pad • 68239-13E00: 5 mm (0.197 in) wide tape roll The following materials, not found in the kit, can also be used to repair squeaks and rattles. UHMW (TEFLON) TAPE Insulates where slight movement is present. Ideal for instrument panel applications. SILICONE GREASE Used in place of UHMW tape that is visible or does not fit. Only lasts a few months. SILICONE SPRAY Used when grease cannot be applied. DUCT TAPE Used to eliminate movement.

CONFIRM THE REPAIR After repair is complete, test drive the vehicle to confirm that the cause of noise is repaired by test driving the vehicle. Operate the vehicle under the same conditions as when the noise originally occurred. Refer to the notes on the Diagnostic Worksheet.

Inspection Procedure

INFOID:0000000004676910

Refer to Table of Contents for specific component removal and installation information.

INSTRUMENT PANEL Most incidents are caused by contact and movement between: 1. The cluster lid A and instrument panel 2. Acrylic lens and combination meter housing 3. Instrument panel to front pillar garnish 4. Instrument panel to windshield 5. Instrument panel mounting pins 6. Wiring harnesses behind the combination meter 7. A/C defroster duct and duct joint These incidents can usually be located by tapping or moving the components to duplicate the noise or by pressing on the components while driving to stop the noise. Most of these incidents can be repaired by applying felt cloth tape or silicon spray (in hard to reach areas). Urethane pads can be used to insulate wiring harness. CAUTION: Never use silicone spray to isolate a squeak or rattle. If the area is saturated with silicone, the recheck of repair becomes impossible.

CENTER CONSOLE Components to check include: 1. Shifter assembly cover to finisher 2. A/C control unit and cluster lid C 3. Wiring harnesses behind audio and A/C control unit The instrument panel repair and isolation procedures also apply to the center console.

DOORS Check the following items: 1. Finisher and inner panel making a slapping noise 2. Inside handle escutcheon connection to door finisher 3. Wiring harnesses tapping 4. Door striker out of alignment causing a popping noise on starts and stops Tapping, moving the components, or pressing on them while driving to duplicate the conditions can isolate many of these incidents. The areas can usually be insulated with felt cloth tape or insulator foam blocks from the NISSAN Squeak and Rattle Kit (J-43980) to repair the noise.

TRUNK Trunk noises are often caused by a loose jack or loose items put into the trunk by the customer. In addition check for the following items: Revision: 2009 October

GW-4

2009 G37 Coupe

SQUEAK AND RATTLE TROUBLE DIAGNOSES < SYMPTOM DIAGNOSIS > 1. Trunk lid dumpers out of adjustment 2. Trunk lid striker out of adjustment 3. Trunk lid torsion bars knocking together 4. A loose license plate or bracket Most of these incidents can be repaired by adjusting, securing, or insulating the item(s) or component(s) causing the noise.

SUNROOF/HEADLINING Noises in the sunroof / headlining area can often be traced to one of the following items: 1. Sunroof lid, rail, linkage, or seals making a rattle or light knocking noise 2. Sunvisor shaft shaking in the holder 3. Front or rear windshield touching headlining and squeaking Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these incidents. Repairs usually consist of insulating with felt cloth tape.

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SEATS When isolating seat noise it is important to note the position the seat is in and the load placed on the seat when the noise occurs. These conditions should be duplicated when verifying and isolating the cause of the noise. Causes of seat noise include: 1. Headrest rods and holder 2. A squeak between the seat pad cushion and frame 3. The rear seatback lock and bracket These noises can be isolated by moving or pressing on the suspected components while duplicating the conditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component or applying urethane tape to the contact area.

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UNDERHOOD

Some interior noise may be caused by components under the hood or on the engine wall. The noise is then transmitted into the passenger compartment. J Causes of transmitted underhood noise include: 1. Any component mounted to the engine wall 2. Components that pass through the engine wall GW 3. Engine wall mounts and connectors 4. Loose radiator mounting pins 5. Hood bumpers out of adjustment L 6. Hood striker out of adjustment These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best method is to secure, move, or insulate one component at a time and test drive the vehicle. Also, engine RPM M or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or insulating the component causing the noise. N

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GW-5

2009 G37 Coupe


Diagnostic Worksheet

INFOID:0000000004676911

PIIB8741E


GW-6

2009 G37 Coupe

SQUEAK AND RATTLE TROUBLE DIAGNOSES < SYMPTOM DIAGNOSIS > A

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GW-7

2009 G37 Coupe

PRECAUTIONS < PRECAUTION >

PRECAUTION PRECAUTIONS Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"

INFOID:0000000004249710

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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. Information necessary to service the system safely is included in the “SRS AIR BAG” and “SEAT BELT” 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 “SRS AIR BAG”. • 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 harness connectors.

PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS WARNING: • When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing serious injury. • When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the battery, and wait at least 3 minutes before performing any service.

Precaution for Procedure without Cowl Top Cover

INFOID:0000000004249711

When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc.

PIIB3706J

Precaution for Battery Service

INFOID:0000000004688908

Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interference between the window edge and the vehicle when the door is opened/closed. During normal operation, the window slightly raises and lowers automatically to prevent any window to vehicle interference. The automatic window function will not work with the battery disconnected.

Handling for Adhesive and Primer

INFOID:0000000004249712

• Do not use an adhesive which is past its usable date. 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. • Open the seal of the primer and adhesive just before application. Discard the remainder. Revision: 2009 October

GW-8

2009 G37 Coupe

PRECAUTIONS < PRECAUTION > • Before application, be sure to shake the primer container to stir the contents. If any floating material is found, do not use it. • If any primer or adhesive contacts the skin, wipe it off with gasoline or equivalent and wash the skin with soap. • When using primer and adhesive, always observe the precautions in the instruction manual.

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GW-9

2009 G37 Coupe

PREPARATION < PREPARATION >

PREPARATION PREPARATION Special Service Tools

INFOID:0000000004636319

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

Description

(J-39570) Chassis ear

Locates the noise

SIIA0993E

(J-43980) NISSAN Squeak and Rattle Kit

Repairs the cause of noise

SIIA0994E

Commercial Service Tools

INFOID:0000000004636320

Tool name

Description

Engine ear

Locates the noise

SIIA0995E

Suction lifter

Holds the door glass

PIIB1805J

Remover tools

Removes the clips, pawls and metal clips

JMKIA3050ZZ


GW-10

2009 G37 Coupe

WINDSHIELD GLASS < REMOVAL AND INSTALLATION >

REMOVAL AND INSTALLATION

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WINDSHIELD GLASS Exploded View

INFOID:0000000004498888

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N JMKIA3460GB

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Windshield molding

2.

Spacer

3.

Windshield glass

4.

Dam rubber (upper, lower)

5.

Mirror base

6.

Insulator

7.

Roof panel

8.

Primer

9.

Front pillar finisher

10. Dash upper cross member

11. Cowl top cover

13. Front pillar outer upper

14. Front pillar garnish

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12. Adhesive

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Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation

INFOID:0000000004498889

REMOVAL 1.

Remove the front pillar garnish (LH/RH). Refer to INT-14, "Removal and Installation".


GW-11

2009 G37 Coupe

WINDSHIELD GLASS < REMOVAL AND INSTALLATION > 2. Remove partially the headlining (front edge). Refer to the following. • For normal roof. Refer to INT-22, "NORMAL ROOF : Removal and Installation". • For sunroof. Refer to INT-24, "SUNROOF : Removal and Installation". 3. Remove the front wiper arm and blade. Refer to WW-93, "Removal and Installation". 4. Remove the roof side molding (LH/RH). Refer to EXT-31, "Removal and Installation". 5. Remove the cowl top cover. Refer to EXT-21, "Removal and Installation". 6. Apply protective tape around the windshield glass to protect the painted surface from damage. 7. Remove glass using piano wire or power cutting tool (A) and an inflatable pump bag (B) after removing moldings.

PIIB5779E

NOTE: Mark the body and the glass with matching marks if the windshield glass is reused. WARNING: Always wear safety glasses and heavy gloves to help prevent glass splinters from entering your eyes or cutting your hands when cutting the glass from the vehicle. CAUTION: • Never use a cutting knife or power cutting tool when the windshield 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.

INSTALLATION • The dam rubber should be installed in position. • Use a genuine Nissan Urethane Adhesive Kit (if available) or equivalent and follow the instructions furnished 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 the skin and 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-93, "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. Adhere carefully 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. • The vehicle should not be driven for at least 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.


GW-12

2009 G37 Coupe

WINDSHIELD GLASS < REMOVAL AND INSTALLATION >

Inspection

INFOID:0000000004498890

A

REPAIRING WATER LEAKAGE FOR WINDSHIELD GLASS Leakage can be repaired without removing 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 glass area while pushing glass outward. Apply primer (if necessary) and then urethane adhesive to the leakage point to stop the leakage.

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GW-13

2009 G37 Coupe

SIDE WINDOW GLASS < REMOVAL AND INSTALLATION >

SIDE WINDOW GLASS Exploded View

INFOID:0000000004498891

JMKIA1196GB

1.

Side window glass

2.

Spacer

3.

Adhesive

4.

Primer

5.

Rear pillar finisher

6.

Rear fender

7.

Weatherstrip body side



INFOID:0000000004498892

REMOVAL 1. 2.

3.

Remove the rear pillar finisher. Refer to INT-14, "Removal and Installation". Remove the headlining. Refer to the following. • For normal roof. Refer to INT-22, "NORMAL ROOF : Removal and Installation". • For sunroof. Refer to INT-24, "SUNROOF : Removal and Installation". Apply protective tape around the side window to protect the painted surface from damage.


GW-14

2009 G37 Coupe

SIDE WINDOW GLASS < REMOVAL AND INSTALLATION > 4. Remove the side window glass using piano wire or power cutting tool and an inflatable pump bag. WARNING: Always wear safety glasses and heavy gloves to help prevent glass splinters from entering your eyes or cutting your hands when cutting the glass from the vehicle. 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.

INSTALLATION

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• Use a genuine Nissan Urethane Adhesive Kit (if available) or equivalent and follow the instructions furnished 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 the skin and 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. Adhere carefully 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. • The vehicle should not be driven for at least 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

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INFOID:0000000004498893

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REPAIRING WATER LEAKAGE FOR SIDE WINDOW GLASS Leakage can be repaired without removing 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 side window glass area while pushing glass outward. Apply primer (if necessary) and then urethane adhesive to the leakage point to stop the leakage.

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GW-15

2009 G37 Coupe

REAR WINDOW GLASS < REMOVAL AND INSTALLATION >

REAR WINDOW GLASS Exploded View

INFOID:0000000004498894

JMKIA1197GB

1.

Rear window glass

2.

Dam rubber

3.

4.

Roof panel

5.

Primer

6.

Spacer Adhesive

7.

Body side outer panel

8.

Waist rear

9.

Headlining



INFOID:0000000004498895

REMOVAL 1. 2.

Remove the trunk lid finisher inner. Refer to INT-29, "Removal and Installation". Remove the connectors and grounds for the rear window defogger.


GW-16

2009 G37 Coupe

REAR WINDOW GLASS < REMOVAL AND INSTALLATION > 3. Remove glass using piano wire or power cutting tool (A) and an inflatable pump bag (B) after removing molding using pliers.

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PIIB5779E

NOTE: Mark the body and the glass with matching marks if a rear window glass is reused. WARNING: Always wear safety glasses and heavy gloves to help prevent glass splinters from entering your eyes or cutting your hands when cutting the glass from the vehicle. 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.

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INSTALLATION

• The dam rubber should be installed in position. • Use a genuine Nissan Urethane Adhesive Kit (if available) or equivalent and follow the instructions furnished with it. H • Open a door window while the urethane adhesive is curing. This prevents the glass from being forced out by passenger compartment air pressure when all door windows are closed. • The molding must be installed securely so that it is in position and leaves no clearance. I • 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: J • 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 the skin and eyes. • Use in an open, well ventilated location. Never breathe the vapors. They may be harmful if inhaled. GW 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 rear window in case of an accident. L 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. Adhere carefully to the expiration or manufacture date printed on the box. M • 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. • The vehicle should not be driven for at least 24 hours or until the urethane adhesive is completely cured. Curing time varies depending on temperature and humidity. The curing time increases N under lower temperature and lower humidity.

Inspection

INFOID:0000000004498896

O

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 rear window glass area while pushing glass outward. Apply primer (if necessary) and then urethane adhesive to the leakage point to stop the leakage.


GW-17

2009 G37 Coupe

P

DOOR GLASS < REMOVAL AND INSTALLATION >

DOOR GLASS Exploded View

INFOID:0000000004498897

JMKIA3043ZZ

1.

Door glass assembly

4.

Corner piece assembly

2.

Power window motor

3.


Module assembly

INFOID:0000000004498898

REMOVAL 1. 2. 3. 4.

Remove the door finisher. Refer to INT-11, "Removal and Installation". Disconnect the door speaker harness connector. Operate the power window main switch to raise or lower the door window until the glass mounting bolts can be seen. Remove the glass mounting bolts (A) and loosen slightly the bolt (B).

JMKIA3045ZZ


GW-18

2009 G37 Coupe

DOOR GLASS < REMOVAL AND INSTALLATION > 5. Hold securely the door glass and pull it out of the sash to remove the door glass. NOTE: Do not raise the glass at the top upper of the door after the door glass is removed.

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B

C JMKIA1200ZZ

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6.

Remove the door mirror assembly. Refer to MIR-18, "DOOR MIRROR ASSEMBLY : Removal and Installation". 7. Remove the door inside seal. 8. Remove the door glass run. 9. Remove the front lower sash nuts, and then remove the front lower sash. 10. Remove the corner piece bolts, and then remove the corner piece.

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INSTALLATION Install in the reverse order of removal.

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Inspection and Adjustment

INFOID:0000000004498899

SYSTEM INITIALIZATION

H 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. I • 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. J • Operation of the regulator assembly as a unit. • Removal and installation of the door glass. • Removal and installation of the body side weather-strip and door weather-strip. • Disconnection and connection of the minus terminal of battery. GW Initialization Follow the steps below after installing each component to the vehicle. 1. Disconnect the minus terminal of battery or disconnect power window switch harness connector tempo- L rarily. Then reconnect after at least 1 minute. 2. Close the door. M 3. Turn ignition switch ON. 4. Operate power window switch to make over a half of the window open area. 5. Press the power window switch in the up direction (auto close position) and hold. Continue holding the N switch even when window is completely closed and then release after 3 seconds.

6.

Inspect the anti-pinch system function. NOTE: Initialization may be cancelled with continuous opening and closing operation. In this case, initialize the system.

O

INSPECT THE FUNCTION OF THE ANTI-PINCH SYSTEM 1. Open fully the door glass. 2. Place a wooden piece (wooden hammer handle, etc.) at near fully closed position. 3. 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 2 seconds and then stops. • The glass should not be raised with power window main switch operated while it is reversing or lowering. CAUTION: Revision: 2009 October

GW-19

2009 G37 Coupe

P

DOOR GLASS < REMOVAL AND INSTALLATION > • Be careful not to be pinched. • Check that the auto up function is normal before the inspection following the system initialization.

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 body side weather-strip 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 body side weather-strip is not parallel. • Raise the glass fully and adjust the glass top end and body side welt fitting with the adjusting bolt (B), (C), or (D) as shown in the figure below.

JMKIA3044ZZ

NOTE: • Always start at adjusting bolt (B). If the desired angle is not achieved, then proceed to adjusting bolt (C) and (D) respectively. • Turn the adjusting bolt clockwise to move the door glass upper end outward. • Turn the adjusting bolt anticlockwise to move the door glass upper end inward. • Adjustment process with adjusting bolt (D) is the inverse of adjusting bolt (B) and (C). • When adjusting with adjusting bolt (D), turn the adjusting bolt clockwise to move the door glass upper end inward, then anticlockwise to move the door glass upper end outward.


GW-20

2009 G37 Coupe

DOOR REGULATOR < REMOVAL AND INSTALLATION >

DOOR REGULATOR

A

Exploded View

INFOID:0000000004498900

B

C

D

E

F

G

H

I JMKIA3043ZZ

1.

Door glass assembly

4.

Corner piece assembly

2.

Power window motor


3.

Module assembly

J

INFOID:0000000004498901

GW

REMOVAL 1. 2. 3.

Remove the door glass. Refer to GW-18, "Removal and Installation". Disconnect power window motor harness connector. Remove the module assembly mounting bolts shown by the arrows, both seals (B) and then remove the nuts under the seals.

L

M

N

O JMKIA1202ZZ

4.

P

Remove the module assembly from the door panel.


Disassembly and Assembly

INFOID:0000000004498902

DISASSEMBLY Revision: 2009 October

GW-21

2009 G37 Coupe

DOOR REGULATOR < REMOVAL AND INSTALLATION > Remove the power window motor from the module assembly.

ASSEMBLY Assemble in the reverse order of disassembly.

Inspection and Installation

INFOID:0000000004498903

Inspection after Removal Check the regulator assembly for the following items. Replace or grease it if a malfunction is detected. • Wire wear • Regulator deformation

JMKIA1203ZZ

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. • Operation of the regulator assembly as a unit. • Removal and installation of the door glass. • Removal and installation of the body side weather-strip and door weather-strip. • Disconnection and connection of the minus terminal of battery. Initialization Follow the steps below after installing each component to the vehicle. 1. Disconnect the minus terminal of battery or disconnect power window switch harness connector temporarily. Then reconnect after at least 1 minute. 2. Close the door. 3. Turn ignition switch ON. 4. Operate power window switch to make over a half of the window open area. 5. 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 3 seconds. 6. 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 1. Fully open the door glass. 2. Place a wooden piece (wooden hammer handle, etc.) at near fully closed position. 3. 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 2 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. • Check that the auto up function is normal before the inspection following the system initialization.

FITTING INSPECTION • Check that the glass is fit securely into the sash groove. Revision: 2009 October

GW-22

2009 G37 Coupe

DOOR REGULATOR < REMOVAL AND INSTALLATION > • Lower slightly the glass [approximately 10 to 20 mm (0.394 to 0.787 in)] and check that the clearance to the body side weather-strip 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 body side weather-strip is not parallel. • Raise the glass fully and adjust the glass top end and body side welt fitting with the adjusting bolt (B), (C), or (D) as shown in the figure below.

A

B

C

D

JMKIA3044ZZ

NOTE: • Always start at adjusting bolt (B). If the desired angle is not achieved, then proceed to adjusting bolt (C) and (D) respectively. • Turn the adjusting bolt clockwise to move the door glass upper end outward. • Turn the adjusting bolt anticlockwise to move the door glass upper end inward. • Adjustment process with adjusting bolt (D) is the inverse of adjusting bolt (B) and (C) • When adjusting with adjusting bolt (D), turn the adjusting bolt clockwise to move the door glass upper end inward, then anticlockwise to move the door glass upper end outward.

E

F

G

H

I

J

GW

L

M

N

O

P


GW-23

2009 G37 Coupe

VENTILATION, HEATER & AIR CONDITIONER

SECTION

HA

HEATER & AIR CONDITIONING SYSTEM

A

B

C

D

E

CONTENTS BASIC INSPECTION .................................... 3

General Precautions ................................................21

DIAGNOSIS AND REPAIR WORKFLOW .......... 3

PREPARATION ........................................... 22

Work Flow ................................................................. 3

PREPARATION ................................................. 22

G

Special Service Tool ................................................22 Commercial Service Tool ........................................25 Sealant or/and Lubricant .........................................25

H

SYSTEM DESCRIPTION .............................. 4 REFRIGERATION SYSTEM ............................... 4 System Diagram ........................................................ 4 System Description ................................................... 4 Component Parts Location ........................................ 5 Component Description ............................................. 6

SYMPTOM DIAGNOSIS ............................... 7

F

PERIODIC MAINTENANCE ........................ 26 REFRIGERANT ................................................. 26 HA Collection and Charge .............................................26

LUBRICANT ...................................................... 30

J

K

Symptom Table ....................................................... 10

Description ...............................................................30 Adjustment ...............................................................30 Lubricant Adjusting Procedure for Components Replacement Except Compressor ...........................30 Lubricant Adjusting Procedure for Compressor Replacement ...........................................................31

PRECAUTION .............................................. 11

REFRIGERATION SYSTEM ............................. 33

PRECAUTIONS ..................................................11

Inspection ................................................................33 Performance Chart ..................................................33 Refrigerant Leakages ..............................................34

REFRIGERATION SYSTEM SYMPTOMS .......... 7 Trouble Diagnosis For Unusual Pressure ................. 7 Symptom Table ......................................................... 7

COMPRESSOR SYSTEM SYMPTOMS .............10

L

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ................................................................. 11 Precaution Necessary for Steering Wheel Rotation after Battery Disconnect ................................... 11 Precaution for Battery Service ................................ 12 Precaution for Procedure without Cowl Top Cover.... 12 Precautions For Xenon Headlamp Service ............. 12 Working with HFC-134a (R-134a) ........................... 12 General Refrigerant Precaution .............................. 13 Refrigerant Connection ........................................... 13 Service Equipment .................................................. 17

FLUORESCENT LEAK DETECTOR ................ 35 Inspection ................................................................35

N

ELECTRICAL LEAK DETECTOR .................... 36 Inspection ................................................................36

O

REMOVAL AND INSTALLATION ............... 39 COMPRESSOR ................................................. 39

COMPRESSOR ..................................................20


General Precautions ............................................... 20

COOLER PIPE AND HOSE .............................. 41

LEAK DETECTION DYE ....................................21

Exploded View .........................................................41


M

HA-1

2009 G37 Coupe

P

LOW-PRESSURE FLEXIBLE HOSE AND PIPE 2 ... 41 LOW-PRESSURE FLEXIBLE HOSE AND PIPE 2 : Removal and Installation ...................................... 41

REFRIGERANT PRESSURE SENSOR .................... 49 REFRIGERANT PRESSURE SENSOR : Removal and Installation .................................................... 49

HIGH-PRESSURE FLEXIBLE HOSE ....................... 42 HIGH-PRESSURE FLEXIBLE HOSE : Removal and Installation ....................................................... 43

HEATER & COOLING UNIT ASSEMBLY ......... 50

HIGH-PRESSURE PIPE 1 ......................................... 43 HIGH-PRESSURE PIPE 1 : Removal and Installation .......................................................................... 43 LOW-PRESSURE PIPE 1 AND HIGH-PRESSURE PIPE 2 ........................................................................ 45 LOW-PRESSURE PIPE 1 AND HIGH-PRESSURE PIPE 2 : Removal and Installation ............... 45

Exploded View ........................................................ 50 HEATER & COOLING UNIT ASSEMBLY ................ 52 HEATER & COOLING UNIT ASSEMBLY : Removal and Installation ............................................. 52 HEATER CORE ......................................................... 53 HEATER CORE : Removal and Installation ............ 53 EVAPORATOR .......................................................... 54 EVAPORATOR : Removal and Installation ............. 54

Exploded View ........................................................ 47

EXPANSION VALVE ................................................. 55 EXPANSION VALVE : Removal and Installation ... 55

CONDENSER ............................................................ 47 CONDENSER : Removal and Installation .............. 47

SERVICE DATA AND SPECIFICATIONS (SDS) .......................................................... 56

CONDENSER PIPE ASSEMBLY .............................. 47 CONDENSER PIPE ASSEMBLY : Removal and Installation .............................................................. 47

SERVICE DATA AND SPECIFICATIONS (SDS) ................................................................. 56

CONDENSER .................................................... 47

LIQUID TANK ............................................................ 48 LIQUID TANK : Removal and Installation ............... 48


Compressor ............................................................ 56 Lubricant ................................................................. 56 Refrigerant .............................................................. 56 Engine Idling Speed ................................................ 56 Belt Tension ............................................................ 56

HA-2

2009 G37 Coupe

DIAGNOSIS AND REPAIR WORKFLOW < BASIC INSPECTION >

BASIC INSPECTION

A

DIAGNOSIS AND REPAIR WORKFLOW Work Flow

INFOID:0000000004494902

B

DETAILED FLOW

1.LISTEN TO CUSTOMER COMPLAINT

C

Listen to customer complaint. (Get detailed information about the conditions and environment when the symptom occurs.)

D

>> GO TO 2.

2.VERIFY THE SYMPTOM WITH OPERATIONAL CHECK

E

Verify the symptom with operational check. Refer to HAC-5, "Description & Inspection". F

>> GO TO 3.

3.GO TO APPROPRIATE TROUBLE DIAGNOSIS Go to appropriate trouble diagnosis (Refer to HAC-102, "Diagnosis Chart By Symptom" below).

G

>> GO TO 4.

4.REPAIR OR REPLACE

H

Repair or replace the specific parts. HA

>> GO TO 5.

5.FINAL CHECK J

Final check. Is the inspection result normal? YES >> INSPECTION END NO >> GO TO 3.

K

L

M

N

O

P


HA-3

2009 G37 Coupe

REFRIGERATION SYSTEM < SYSTEM DESCRIPTION >

SYSTEM DESCRIPTION REFRIGERATION SYSTEM System Diagram

INFOID:0000000004651656

JPIIA1366GB

System Description

INFOID:0000000004651657

REFRIGERANT CYCLE Refrigerant Flow The refrigerant flows from the compressor, through the condenser with liquid tank, through the evaporator, and back to the compressor. The refrigerant evaporation in the evaporator is controlled by an externally equalized expansion valve, located inside the evaporator case. Freeze Protection To prevent evaporator from freezing up, the evaporator air temperature is monitored, and the voltage signal to the unified meter and A/C amp. makes the A/C relay go OFF and stop 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 makes the A/C relay go OFF and stops the compressor when pressure on the high-pressure side detected by refrigerant pressure sensor is over approximately 3,119 kPa (31.8 kg/cm2, 452 psi), or below approximately 118 kPa (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 refrigerant in the system increases to an unusual level [more than 3,800 kPa (38.8 kg/ cm2, 551 psi)].


HA-4

2009 G37 Coupe


Component Parts Location

INFOID:0000000004494905

A

ENGINE COMPERTMET B

C

D

E

F

G

H

HA

J

K

L JSIIA1435ZZ

1.

Compressor

4.

Liquid tank

2.

Condenser

3.

Refrigerant pressure sensor

M

PASSENGER COMPERTMENT N

O

P


HA-5

2009 G37 Coupe


JSIIA1436ZZ

1.

Expansion valve

2.

Evaporator

3.

Blower motor

Component Description

INFOID:0000000004494906

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 matter in refrigerant, and stores temporarily liquid refrigerant.


Refer to EC-520, "Description".

Expansion valve

Transforms high-pressure liquid refrigerant to mist form low-pressure liquid refrigerant by drawing function.

Evaporator

The mist form liquid refrigerant transforms to gas by evaporation by the air conveyed from blower motor. The air is cooled by the heat by evaporation.

Blower motor

Takes in air in the vehicle or fresh outside air, provides it forcedly to the air conditioner, and conveys it inside the vehicle.


HA-6

2009 G37 Coupe

REFRIGERATION SYSTEM SYMPTOMS < SYMPTOM DIAGNOSIS >

SYMPTOM DIAGNOSIS

A

REFRIGERATION SYSTEM SYMPTOMS Trouble Diagnosis For Unusual Pressure

INFOID:0000000004651861

Diagnose using a manifold gauge whenever 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 (usual) pressure range. Refer to above table (Ambient air temperature-to-operating pressure table) since the standard (usual) pressure, however, differs from vehicle to vehicle.

Symptom Table

INFOID:0000000004651862

Gauge indication

Both high- and low-pressure sides are too high.

AC359A

Refrigerant cycle

Probable cause

The pressure returns to normal is reduced soon after water is splashed on condenser.

Excessive refrigerant charge in refrigeration cycle.

Air suction by cooling fan is insufficient.

Insufficient condenser cooling performance. ↓ 1. Condenser fins are clogged. 2. Improper fan rotation of cooling fan.

• Low-pressure pipe is not cold. • When compressor is stopped, high-pressure reading quickly drops by approximately 196 kPa (2 kg/cm2, 28 psi). It then decreases gradually thereafter. Engine tends to overheat.

B

C

D

Corrective action

E Reduce refrigerant until specified pressure is obtained.

F • Clean condenser. • Check and repair cooling fan if necessary.

G

H 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.

• 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 open a litnear the evaporator outlet. tle compared with the speci• Low-pressure pipe is somefication. times covered with frost. ↓ Improper expansion valve adjustment.

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, liquid tank is not so 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.

O

P AC360A


HA-7

2009 G37 Coupe

REFRIGERATION SYSTEM SYMPTOMS < 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 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 as compared with areas near 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-34, "Refrigerant Leakages".

There is a big temperature difference between expansion valve inlet and outlet while the valve itself is frosted.

Expansion valve closes a little compared with the specification. ↓ 1. Improper expansion valve adjustment. 2. Malfunctioning expansion valve. 3. Outlet and inlet may be clogged.

• Remove foreign particles 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-73, "Diagnosis Procedure". • Replace compressor. • Repair evaporator fins. • Replace evaporator. • Check blower motor circuit. Refer to HAC-57, "Diagnosis Procedure".

AC356A

Both high- and low-pressure sides are too low.

AC353A

Air flow volume is not enough or is too low.


Corrective action

HA-8

2009 G37 Coupe

REFRIGERATION SYSTEM SYMPTOMS < SYMPTOM DIAGNOSIS > Gauge indication Low-pressure side sometimes becomes negative.

Refrigerant cycle

Probable cause

Corrective action

A • Air conditioning system does not function and does not cyclically cool the compartment air. • The system constantly functions for a period of time after compressor is stopped and restarted.

Refrigerant does not discharge cyclically. ↓ Moisture is frozen at expansion valve outlet and inlet. ↓ Water is mixed with refrigerant.

• Drain water from refrigerant or replace refrigerant. • Replace liquid tank.

High-pressure side is closed and refrigerant does not flow. ↓ Expansion valve or liquid tank is frosted.

Leave the system at rest until no frost is present. Start it again to check whether or not the malfunction is caused by water or foreign particles. • Cooling is initially okay if water is the cause. Then the water freezes causing a blockage. Drain water from refrigerant or replace refrigerant. • Remove expansion valve and remove the particles with dry and compressed air (not shop air) if due to foreign particles. • Replace expansion valve if either of the above methods cannot correct the malfunction. • Replace liquid tank. • Check lubricant for contamination.

B

C

AC354A

Low-pressure side becomes negative. Liquid tank or front/rear side of expansion valve’s pipe is frosted or wet with dew.

AC362A

D

E

F

G

H

HA

J

K

L

M

N

O

P


HA-9

2009 G37 Coupe

COMPRESSOR SYSTEM SYMPTOMS < SYMPTOM DIAGNOSIS >

COMPRESSOR SYSTEM SYMPTOMS Symptom Table

INFOID:0000000004651863

Follow the next table and perform trouble diagnosis if there is a compressor unit malfunction (internal noise, insufficient cooling). Symptom

Inspection method

Check list

Result Both high- and lowpressure sides are

Noise from compressor unit When A/C is ON. (rattling or rolling sound)

Cooker system internal pressure

temporarily while driving.*2

High/low-pressures hunt.*2

Check compressor oil condition.

Sample compressor oil and judge.

Compressor body

Check rotation of compressor. If sized or stuck, sample compressor oil and judge.

Cooler system internal pressure

Check with a manifold gauge. Sample compressor oil and judge if the difference between high-pressure and low-pressure is small or if they are almost the same.

—

—

Insufficient cooling*1

Outlet air temperature rises

Check with manifold gauge

high.*2

Refer to the criteria shown in compressor lubricant.

—

Action Recharge with proper amount of refrigerant. Replace compressor only.

Diagnostic result 1: Replace compressor only. Diagnostic result 2: Replace compressor and liquid tank.

Replace compressor only.

*1: First conduct inspection according to trouble diagnosis for each malfunction. Refer to HAC-103, "Inspection procedure". *2: Applicable to variable capacity compressor only.

JSIIA0927GB


HA-10

2009 G37 Coupe


PRECAUTION

A

PRECAUTIONS Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"

B

INFOID:0000000004703537


PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS

C

D

E

F

G

H

WARNING: • When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) HA with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing serious injury. • When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the J battery, and wait at least 3 minutes before performing any service.

Precaution Necessary for Steering Wheel Rotation after Battery Disconnect INFOID:0000000004703538

NOTE: • Before removing and installing any control units, first turn the push-button ignition switch to the LOCK position, then disconnect both battery cables. • After finishing work, confirm that all control unit connectors are connected properly, then re-connect both battery cables. • Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results. For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and cannot be turned. If turning the steering wheel is required with the battery disconnected or discharged, follow the operation procedure below before starting the repair operation.

OPERATION PROCEDURE 1.

2. 3. 4.

Connect both battery cables. NOTE: Supply power using jumper cables if battery is discharged. Turn the push-button ignition switch to ACC position. (At this time, the steering lock will be released.) Disconnect both battery cables. The steering lock will remain released with both battery cables disconnected and the steering wheel can be turned. Perform the necessary repair operation.


HA-11

2009 G37 Coupe

K

L

M

N

O

P

PRECAUTIONS < PRECAUTION > 5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock when the push-button ignition switch is turned to LOCK position.) 6. Perform self-diagnosis check of all control units using CONSULT-III.


INFOID:0000000004703539



INFOID:0000000004703540


PIIB3706J

Precautions For Xenon Headlamp Service

INFOID:0000000004703552

WARNING: Comply with the following warnings to prevent any serious accident. • Disconnect the battery cable (negative terminal) or the power supply fuse before installing, removing, or touching the xenon headlamp (bulb included). The xenon headlamp contains high-voltage generated parts. • Never work with wet hands. • Check the xenon headlamp ON-OFF status after assembling it to the vehicle. Never turn the xenon headlamp ON in other conditions. Connect the power supply to the vehicle-side connector. (Turning it ON outside the lamp case may cause fire or visual impairments.) • Never touch the bulb glass immediately after turning it OFF. It is extremely hot. CAUTION: Comply with the following cautions to prevent any error and malfunction. • Install the xenon bulb securely. (Insufficient bulb socket installation may melt the bulb, the connector, the housing, etc. by high-voltage leakage or corona discharge.) • Never perform HID circuit inspection with a tester. • Never touch the xenon bulb glass with hands. Never put oil and grease on it. • Dispose of the used xenon bulb after packing it in thick vinyl without breaking it. • Never wipe out dirt and contamination with organic solvent (thinner, gasoline, etc.).

Working with HFC-134a (R-134a)

INFOID:0000000004653049

CAUTION: • CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. Compressor malfunction is likely to occur if the refrigerants are mixed, refer to “CONTAMINATED REFRIGERANT” below. To determine the purity of HFC-134a (R-134a) in the vehicle and recovery tank, use Refrigerant recovery/recycling recharging equipment and Refrigerant Identifier. • Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. Compressor malfunction is likely to occur if lubricant other than that specified is used. • The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following handling precautions must be observed: - Cap (seal) immediately the component to minimize the entry of moisture from the atmosphere when removing refrigerant components from a vehicle.


HA-12

2009 G37 Coupe

PRECAUTIONS < PRECAUTION > - Never remove the caps (unseal) until just before connecting the components when installing refrigerant components to a vehicle. Connect all refrigerant loop components as quickly as possible to minimize the entry of moisture into system. - Use only the specified lubricant from a sealed container. Reseal immediately containers of lubricant. Lubricant becomes moisture saturated and should not be used without proper sealing. - Never allow lubricant (NISSAN A/C System Oil Type S) to come in contact with styrene foam parts. Damage may result.

CONTAMINATED REFRIGERANT Take appropriate steps shown below if a refrigerant other than pure HFC-134a (R-134a) is identified in a vehicle: • Explain to the customer that environmental regulations prohibit the release of contaminated refrigerant into the atmosphere. • Explain that recovery of the contaminated refrigerant could damage service equipment and refrigerant supply. • Suggest the customer return the vehicle to the location of previous service where the contamination may have occurred. • In case of repairing, recover the refrigerant using only dedicated equipment and containers. Never recover contaminated refrigerant into the existing service equipment. Contact a local refrigerant product retailer for available service if the facility does not have dedicated recovery equipment. This refrigerant must be disposed of in accordance with all federal and local regulations. In addition, replacement of all refrigerant system components on the vehicle is recommended. • The air conditioner warranty is void if the vehicle is within the warranty period. Please contact Nissan Customer Affairs for further assistance.

General Refrigerant Precaution

A

B

C

D

E

F

G

INFOID:0000000004653050

H

WARNING: • Never breathe A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove HFC-134a (R-134a) from the A/C system, using certified service equipment meeting HA requirements of SAE J-2210 [HFC-134a (R-134a) recycling equipment], or J-2209 [HFC-134a (R-134a) recovery equipment]. Ventilate work area before resuming service if accidental system discharge occurs. Additional health and safety information may be obtained from refrigerant and lubricant J manufacturers. • Never release refrigerant into the air. Use approved recovery/recycling recharging equipment to capture the refrigerant each time an air conditioning system is discharged. • Wear always eye and hand protection (goggles and gloves) when working with any refrigerant or air K conditioning system. • Never store or heat refrigerant containers above 52°C (126°F). • Never heat a refrigerant container with an open flame; Place the bottom of the container in a warm L pail of water if container warming is required. • Never intentionally drop, puncture, or incinerate refrigerant containers. • Keep refrigerant away from open flames: poisonous gas is produced if refrigerant burns. • Refrigerant displaces oxygen, therefore be certain to work in well ventilated areas to prevent suffo- M cation. • Never pressure test or leakage test HFC-134a (R-134a) service equipment and/or vehicle air conditioning systems with compressed air during repair. Some mixtures of air and HFC-134a (R-134a) N have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers. O

Refrigerant Connection

INFOID:0000000004653080

A new type refrigerant connection has been introduced to all refrigerant lines except the following location. • Expansion valve to evaporator • Refrigerant pressure sensor to liquid tank

ABOUT ONE-TOUCH JOINT Description • One-touch joints are pipe joints which do not require tools during piping connection. • Unlike conventional connection methods using union nuts and flanges, controlling tightening torque at connection point is not necessary.


HA-13

2009 G37 Coupe

P

PRECAUTIONS < PRECAUTION > • Use a disconnector when removing a pipe joint. Component Parts

RJIA4383J

Functions Of Component Parts

1

Pipe (Male-side)

• Retains O-rings. • Retains garter spring in cage (A).

2

Garter spring

Anchors female-side piping.

3

Indicator ring

When connection is made properly, this is ejected from male-side piping. (This part is no longer necessary after connection.)

4

O-ring

Seals connection point. (Not reusable)

5

Pipe (Female-side)

• Seals connection by compressing O-rings. • Anchors piping connection using flare (B) and garter spring.

NOTE: • Garter spring cannot be removed from cage of male-side piping. • Indicator ring remains near piping connection point, however, this is not a malfunction. (This is to check piping connection during factory assembly.)

Removal

SJIA0106E

1. 2.

Clean piping connection point, and set a disconnector. Slide disconnector in axial direction of piping, and stretch garter spring with tapered point of disconnector.


HA-14

2009 G37 Coupe

PRECAUTIONS < PRECAUTION > 3. Slide disconnector farther so that inside diameter of garter spring becomes larger than outside diameter of female-side piping flare. Then male-side piping can be disconnected.

A

Installation B

C

D

E

F SJIA0107E

1. 2. 3.

Clean piping connection points, and insert male-side piping into female-side piping. G Push inserted male-side piping harder so that female-side piping flare stretches garter spring. Garter spring seats on flare if inside diameter of garter spring becomes larger than outside diameter of female-side piping flare. Then, it fits in between male-side piping cage and female-side piping flare to H anchor piping connection point. NOTE: When garter spring seats on flare, and fits in between male-side piping cage and female-side piping flare, it clicks. HA CAUTION: • Female-side piping connection point is thin and easy to deform. Slowly insert the male-side piping straight in axial direction. J • Insert piping securely until a click is heard. • After piping connection is completed, pull male-side piping by hand to make sure that connection does not come loose. K

O-RING AND REFRIGERANT CONNECTION

L

M

N

O

P


HA-15

2009 G37 Coupe


JSIIA0004ZZ

F.

Former type refrigerant connection :

N.

New type refrigerant connection

O.

One-touch joint

O-ring size

CAUTION: The new and former refrigerant connections use different O-ring configurations. Never confuse Orings since they are not interchangeable. Refrigerant may leak at the connection if a wrong O-ring is installed. O-Ring Part Numbers and Specifications Connection type

One-touch joint

Piping connection point

O-ring size

92473 N8221

2

φ16

Low-pressure flexible hose to low-pressure pipe 2

92473 N8221

2

φ16

High-pressure pipe 1 to high-pressure pipe 2

92471 N8221

2

φ8

Condenser pipe assembly to high-pressure flexible hose

92472 N8221

2

φ12

Condenser pipe assembly to high-pressure pipe 1

92471 N8221

2

φ8

Inlet

92472 N8210

1

φ12

Outlet

92471 N8210

1

φ8

Low-pressure pipe 1 to expansion valve

92473 N8210

1

φ16

High-pressure pipe 2 to expansion valve

92471 N8210

1

φ8

Compressor to low-pressure flexible hose

92474 N8210

1

φ19

Compressor to high-pressure flexible hose

92472 N8210

1

φ12

Inlet

Liquid tank to Condenser

Outlet

Expansion valve to evaporator


HA-16

92471 N8210

1 1

φ8

J2476 89956

1

φ10

Inlet

92475 71L00

1

φ12

Outlet

92475 72L00

1

φ16

Refrigerant pressure sensor to liquid tank Former

QTY

Low-pressure pipe 1 to low-pressure pipe 2

Condenser to condenser pipe assembly

New

Part number

2009 G37 Coupe

PRECAUTIONS < PRECAUTION > WARNING: Check that all refrigerant is discharged into the recycling equipment and the pressure in the system is less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it. CAUTION: Observe the following when replacing or cleaning refrigerant cycle components. • Store it in the same way at it is when mounted on the car when the compressor is removed. Failure to do so will cause lubricant to enter the low-pressure chamber. • Use always a torque wrench and a back-up wrench when connecting tubes. • Plug immediately all openings to prevent entry of dust and moisture after disconnecting tubes. • Connect the pipes at the final stage of the operation when installing an air conditioner in the vehicle. Never remove the seal caps of pipes and other components until just before required for connection. • Allow components stored in cool areas to warm to working area temperature before removing seal caps. This prevents condensation from forming inside A/C components. • Remove thoroughly moisture from the refrigeration system before charging the refrigerant. • Replace always used O-rings. • Apply lubricant to circle of the O-rings shown in illustration when connecting tube. Be careful not to apply lubricant to threaded portion. Name

: NISSAN A/C System Oil Type S

A

B

C

D

E

F

• O-ring must be closely attached to the groove portion of tube. • Be careful not to damage O-ring and tube when replacing the O-ring. • Connect tube until a click can be heard. Then tighten the nut or bolt by hand. Check that the O-ring is installed to tube correctly. • Perform leakage test and make sure that there is no leakage from connections after connecting line. Disconnect that line and replace the O-ring when the refrigerant leaking point is found. Then tighten connections of seal seat to the specified torque.

G

H

HA

J

K

L

M RHA861F

Service Equipment

INFOID:0000000004653051

N

Be certain to follow the manufacturer’s instructions for machine operation and machine maintenance. Never introduce any refrigerant other than that specified into the machine.

O

RECOVERY/RECYCLING RECHARGING EQUIPMENT

ELECTRICAL LEAK DETECTOR Be certain to follow the manufacturer’s instructions for tester operation and tester maintenance.

VACUUM PUMP


HA-17

2009 G37 Coupe

P

PRECAUTIONS < PRECAUTION > The lubricant contained inside the vacuum pump is not compatible with the specified lubricant for HFC-134a (R-134a) A/C systems. The vent side of the vacuum pump is exposed to atmospheric pressure. So the vacuum pump lubricant may migrate out of the pump into the service hose. This is possible when the pump is switched OFF after evacuation (vacuuming) and hose is connected to it. To prevent this migration, use a manual valve placed near the hoseto-pump connection, as per the following. • Vacuum pumps usually have a manual isolator valve as part of the pump. Close this valve to isolate the service hose from the pump. • Use a hose equipped with a manual shut-off valve near the pump end for pumps without an isolator. Close the valve to isolate the hose from the pump. • Disconnect the hose from the pump if the hose has an automatic shut-off valve. As long as the hose is connected, the valve is open and lubricating oil may migrate. Some one-way valves open when vacuum is applied and close under no vacuum condition. Such valves may restrict the pump’s ability to pull a deep vacuum and are not recommended.

RHA270DA

MANIFOLD GAUGE SET Be certain that the gauge face indicates HFC-134a or R-134a. Be sure the gauge set has 1/2″-16 ACME threaded connections for service hoses. Confirm the set has been used only with refrigerant HFC-134a (R-134a) and specified lubricants.

SHA533D

SERVICE HOSES Be certain that the service hoses display the markings described (colored hose with black stripe). All hoses must equip positive shutoff devices (either manual or automatic) near the end of the hoses opposite to the manifold gauge.

RHA272D

SERVICE COUPLERS


HA-18

2009 G37 Coupe

PRECAUTIONS < PRECAUTION > Never attempt to connect HFC-134a (R-134a) service couplers to the CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers do not properly connect to the CFC-12 (R-12) system. However, if an improper connection is attempted, discharging and contamination may occur. Shut-off valve rotation

A/C service valve

Clockwise

Open

Counterclockwise

Close

A

B

C RHA273D

D

REFRIGERANT WEIGHT SCALE Verify that no refrigerant other than HFC-134a (R-134a) and specified lubricants have been used with the scale. The hose fitting must be 1/2″-16 ACME if the scale controls refrigerant flow electronically.

E

F

G RHA274D

CHARGING CYLINDER

H Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder’s top valve when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an electronic scale or of quality recycle/recharge equipment. HA

J

K

L

M

N

O

P


HA-19

2009 G37 Coupe

COMPRESSOR < PRECAUTION >

COMPRESSOR General Precautions

INFOID:0000000004653085

CAUTION: • Plug all openings to prevent moisture and foreign matter from entering. • Store it in the same way at it is when mounted on the car when the compressor is removed. • Follow “Maintenance of Lubricant Quantity in Compressor” exactly when replacing or repairing compressor. Refer to HA-30, "Description". • Keep friction surfaces between clutch and pulley clean. Wipe it off by using a clean waste cloth moistened with thinner if the surface is contaminated with lubricant. • Turn the compressor shaft by hand more than five turns in both directions after compressor service operation. This distributes equally lubricant inside the compressor. Let the engine idle and operate the compressor for one hour after the compressor is installed. • Apply voltage to the new one and check for normal operation after replacing the compressor magnet clutch.


HA-20

2009 G37 Coupe

LEAK DETECTION DYE < PRECAUTION >

LEAK DETECTION DYE

A

General Precautions

INFOID:0000000004653089

CAUTION: • The A/C system contains a fluorescent leak detection dye used for locating refrigerant leakages. An ultraviolet (UV) lamp is required to illuminate the dye when inspecting for leakages. • Wear always fluorescence enhancing UV safety goggles to protect eyes and enhance the visibility of the fluorescent dye. • The fluorescent dye leak detector is not a replacement for an electrical leak detector (SST: J-41995). The fluorescent dye leak detector should be used in conjunction with an electrical leak detector (SST: J-41995) to pin-point refrigerant leakages. • Read and follow all manufacture’s operating instructions and precautions prior to performing the work for the purpose of safety and customer’s satisfaction. • A compressor shaft seal should not necessarily be repaired because of dye seepage. The compressor shaft seal should only be repaired after confirming the leakage with an electrical leak detector (SST: J-41995). • Remove always any remaining dye from the leakage area after repairs are completed to avoid a misdiagnosis during a future service. • Never allow dye to come into contact with painted body panels or interior components. Clean immediately with the approved dye cleaner if dye is spilled. Fluorescent dye left on a surface for an extended period of time cannot be removed. • Never spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.). • Never use more than one refrigerant dye bottle [1/4 ounce (7.4 cc)] per A/C system. • Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Never use HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system, or CFC-12 (R-12) leak detection dye in HFC-134a (R-134a) A/C system, or A/C system damage may result. • The fluorescent properties of the dye remains for three or more years unless a compressor malfunction occurs.

B

C

D

E

F

G

H

HA

IDENTIFICATION NOTE: Vehicles with factory installed fluorescent dye have a green label. Vehicles without factory installed fluorescent dye have a blue label.

J

IDENTIFICATION LABEL FOR VEHICLE Vehicles with factory installed fluorescent dye have the identification label on the front side of hood.

K

L

M

N

O

P


HA-21

2009 G37 Coupe


PREPARATION PREPARATION Special Service Tool

INFOID:0000000004653092

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. HFC-134a (R-134a) Service Tool and Equipment

• Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/ or its lubricant. • Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/ lubricant. • Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid mixed use of the refrigerants/lubricant. • Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs and compressor malfunction may result. Tool number (Kent-Moore No.) Tool name

Description

(J-45815) Disconnector tool set

Disconnect one-touch joint connection

RJIA0391J

(ACR2005-NI) ACR5 A/C Service Center

Function: Refrigerant recovery, recycling and recharging

WJIA0293E

(J-41995) Electrical leak detector

Power supply: DC 12 V (Battery terminal)

AHA281A


HA-22

2009 G37 Coupe

PREPARATION < PREPARATION > Tool number (Kent-Moore No.) Tool name

Description

(J-43926) Refrigerant dye leak detection kit Kit includes: (J-42220) UV lamp and UV safety goggles (J-41459) HFC-134a (R-134a) dye injector Use with J-41447, 1/4 ounce bottle (J-41447) HFC-134a (R-134a) fluorescent leak detection dye (Box of 24, 1/4 ounce bottles) (J-43872) Refrigerant dye cleaner

A

B

C Power supply: DC 12 V (Battery terminal)

D

E ZHA200H

F Power supply: DC 12 V (Battery terminal) For checking refrigerant leakage when fluorescent dye is equipped in A/C system Includes: UV lamp and UV safety goggles

(J-42220) UV lamp and UV safety goggles

H

SHA438F

Application: For HFC-134a (R-134a) PAG oil Container: 1/4 ounce (7.4 cc) bottle (Includes self-adhesive dye identification labels for affixing to vehicle after charging system with dye.)

(J-41447) HFC-134a (R-134a) fluorescent leak detection dye (Box of 24, 1/4 ounce bottles)

G

HA

J

SHA439F

K (J-41459) HFC-134a (R-134a) dye injector Use with J-41447, 1/4 ounce bottle

For injecting 1/4 ounce of fluorescent leak detection dye into A/C system

SHA440F

(J-43872) Refrigerant dye cleaner

L

M

N

For cleaning dye spills

O SHA441F

P


HA-23

2009 G37 Coupe


Description

Identification: • The gauge face indicates HFC-134a (R134a). Fitting size: Thread size

(J-39183) Manifold gauge set (with hoses and couplers)

• 1/2″-16 ACME

RJIA0196E

Hose color: • Low-pressure side hose: Blue with black stripe • High-pressure side hose: Red with black stripe • Utility hose: Yellow with black stripe or green with black stripe Hose fitting to gauge:

Service hoses • High-pressure side hose (J-39501-72) • Low-pressure side hose (J-39502-72) • Utility hose (J-39476-72) S-NT201

Service couplers • High-pressure side coupler (J-39500-20) • Low-pressure side coupler (J-39500-24)

• 1/2″-16 ACME

Hose fitting to service hose: M14 x 1.5 fitting is optional or permanently attached.

S-NT202

For measuring of refrigerant Fitting size: Thread size

(J-39650) Refrigerant weight scale

1/2″-16 ACME

S-NT200

Capacity: • Air displacement: 4 CFM • Micron rating: 20 microns • Oil capacity: 482 g (17 oz.) Fitting size: Thread size

(J-39649) Vacuum pump (Including the isolator valve)

• 1/2″-16 ACME S-NT203


HA-24

2009 G37 Coupe


Commercial Service Tool

INFOID:0000000004653093

A Tool name

Description

B

C Checking for refrigerant purity and system contamination

Refrigerant identifier equipment

D

E

RJIA0197E

F Power tool

For loosening bolts and nuts

G PBIC0190E

Sealant or/and Lubricant

INFOID:0000000004653094

H

HFC-134a (R-134a) Service Tool and Equipment

• Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/ HA or its lubricant. • Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/ lubricant. J • Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid mixed use of the refrigerants/lubricant. • Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs and K compressor malfunction may result. Tool name

Description

Container color: Light blue Container marking: HFC-134a (R134a) Fitting size: Thread size

HFC-134a (R-134a) refrigerant

• Large container 1/2″-16 ACME

L

M

N

S-NT196

Type: Polyalkylene glycol oil (PAG), type S (DH-PS) Application: HFC-134a (R-134a) swash plate compressors (NISSAN only) Capacity: 40 m (1.4 US fl oz., 1.4 Imp fl oz.)

NISSAN A/C System Oil Type S (DH-PS)

S-NT197


HA-25

2009 G37 Coupe

O

P

REFRIGERANT < PERIODIC MAINTENANCE >

PERIODIC MAINTENANCE REFRIGERANT Collection and Charge

INFOID:0000000004653096

SETTING OF SERVICE TOOLS AND EQUIPMENT Discharging Refrigerant

JSIIA0238ZZ

1.

Shut-off valve

2.

A/C service valve

3.

Recovery/recycling recharging equipment

Evacuating System and Charging Refrigerant

JSIIA0239ZZ

1.

Shut-off valve

2.

A/C service valve

3.

Recovery/recycling recharging equipment

4.

Refrigerant container (HFC-134a)

5.

Weight scale (J-39650)

6.

Vacuum pump (J-39649)

7.

Manifold gauge set (J-39183)

A.

Preferred (best) method

B.

Alternative method

C.

For charging

Procedure Revision: 2009 October

HA-26

2009 G37 Coupe

REFRIGERANT < PERIODIC MAINTENANCE > WARNING: Never breathe A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove HFC-134a (R-134a) from A/C system using certified service equipment meeting requirements of SAE J-2210 [HFC-134a (R-134a) recycling equipment] or J-2209 [HFC-134a (R-134a) recovery equipment]. Ventilate work area before resuming service if accidental system discharge occurs. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.

1.CHECK A/C SYSTEM

A

B

C

1. 2.

Check that A/C system operates normally. Refer to HAC-5, "Description & Inspection". Check if there is a large amount of leakage of refrigerant or lubricant. CAUTION: Never perform the lubricant return operation if a large amount of leakage of lubricant is detected. Is the inspection result normal? YES >> GO TO 2. NO-1 >> Check for refrigerant leakage. Refer to HA-35, "Inspection". NO-2 >> If using electrical leak detector (SST: J-41995). Refer to HA-36, "Inspection".

2.LUBRICANT RETURN OPERATION 1. 2. 3.

D

E

F

Start the engine and run it as follows. Engine speed: Idle – 1,200 rpm A/C switch: ON Fan speed: Maximum position Set temperature: Full hot Intake position: Recirculation (REC) Perform lubricant return operation for approximately 10 minutes. Stop the engine.

G

H

HA

>> GO TO 3.

3.CHECK RECOVERY/RECYCLING RECHARGING EQUIPMENT 1.

Operate recovery/recycling recharging equipment. CAUTION: • Follow the instructions of the manufacturer for the handling or maintenance of the equipment. • Never fill the equipment with undesignated refrigerant. 2. Check the gauge pressure of recovery/recycling recharging equipment. Is there pressure? YES >> GO TO 4. NO >> GO TO 5.

J

K

L

4.DISCHARGE REFRIGERANT INSIDE PIPES Discharge the refrigerant from the high-pressure hose and low-pressure hose of recovery/recycling recharging equipment.

M

N

>> GO TO 5.

5.CONNECT RECOVERY/RECYCLING RECHARGING EQUIPMENT 1. 2.

O

Remove the service valve caps from the vehicle. Connect recovery/recycling recharging equipment to the service valves.

P

>> GO TO 6.

6.DISCHARGE REFRIGERANT FROM THE VEHICLE Operate recovery/recycling recharging equipment to discharge the refrigerant from the vehicle. >> GO TO 7.

7.REMOVE ANY REMAINING REFRIGERANT Revision: 2009 October

HA-27

2009 G37 Coupe

REFRIGERANT < PERIODIC MAINTENANCE > Evacuate air for approximately 10 minutes or more to remove any remaining refrigerant integrated to the compressor oil, etc. >> GO TO 8.

8.REPLACE OR REPAIR REFRIGERANT SYSTEM PARTS 1.

2.

Replace or repair the malfunctioning part. CAUTION: • Always use a new O-ring for the parts that the cooler system was removed. • Apply compressor oil to the O-rings of piping when installing the piping. However, never apply it to the threads. Adjust the compressor oil amount according to the replaced parts. Refer to HA-30, "Description". >> GO TO 9.

9.EVACUATE AIR FROM THE REFRIGERANT SYSTEM Evacuate air from the refrigerant system for approximately 25 minutes or more. CAUTION: Evacuate air for at least approximately 15 minutes or more if the parts are replaced. >> GO TO 10.

10.CHECK AIRTIGHTNESS OF REFRIGERANT SYSTEM Check the airtightness of the refrigerant system for approximately 25 minutes or more. CAUTION: Check the airtightness for at least approximately 15 minutes or more if the parts are replaced. Does the pressure decrease? YES >> GO TO 11. NO >> GO TO 8.

11.CHECK REFRIGERANT LEAKAGE 1. 2. 3.

Connect refrigerant recovery/recycling recharging equipment or manifold gauge set (SST: J-39183). Charge the refrigerant of approximately 200 g (7.05 oz) to the refrigerant system. Check for refrigerant leakage. Refer to HA-35, "Inspection". NOTE: When using electrical leak detector (SST: J-41995). Refer to HA-36, "Inspection". Is the inspection result normal? YES >> GO TO 12. NO >> Repair or replace parts according to the inspection results.

12.CHARGE REFRIGERANT 1. 2. 3.

Connect recovery/recycling recharging equipment or manifold gauge set (SST: J-39183). Evacuate air again. Charge the specified amount of refrigerant to the refrigerant system. >> GO TO 13.

13.CHECK REFRIGERANT LEAKAGE Check for refrigerant leakage again. Refer to HA-35, "Inspection". NOTE: When using electrical leak detector (SST: J-41995). Refer to HA-36, "Inspection". Is the inspection result normal? YES >> GO TO 14. NO >> GO TO 6.

14.CHECK OPERATION Check the A/C system for normal operation. Refer to HA-33, "Inspection". Revision: 2009 October

HA-28

2009 G37 Coupe

REFRIGERANT < PERIODIC MAINTENANCE > Is the inspection result normal? YES >> GO TO 15. NO >> Repair or replace parts according to the inspection results.

A

15.CHECK RECOVERY/RECYCLING RECHARGING EQUIPMENT 1. 2. 3.

Disconnect recovery/recycling recharging equipment or manifold gauge set (SST: J-39183). Discharge the refrigerant from the high-pressure hose and low-pressure hose of the recovery/recycling recharging equipment. Install the service valve caps. >> INSPECTION END

B

C

D

E

F

G

H

HA

J

K

L

M

N

O

P


HA-29

2009 G37 Coupe

LUBRICANT < PERIODIC MAINTENANCE >

LUBRICANT Description

INFOID:0000000004653097

MAINTENANCE OF LUBRICANT QUANTITY The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compressor when replacing any component or after a large refrigerant leakage occurred. It is important to maintain the specified amount. The following malfunctions may result if lubricant quantity is not maintained normally: • Lack of lubricant: May lead to a seized compressor. • Excessive lubricant: Inadequate cooling (thermal exchange interference)

LUBRICANT Name

: NISSAN A/C System Oil Type S

Adjustment

INFOID:0000000004653098

LUBRICANT RETURN OPERATION Adjust the lubricant quantity according to the test group shown below.

1.CHECK A/C SYSTEM 1. 2.

Check that A/C system operates normally. Refer to HAC-5, "Description & Inspection". Check if there is a large amount of leakage of refrigerant or lubricant. CAUTION: Never perform the lubricant return operation if a large amount of leakage of lubricant is detected. Is the inspection result normal? YES >> GO TO 2. NO-1 >> Check for refrigerant leakage. Refer to HA-35, "Inspection". NO-2 >> If using electrical leak detector (SST: J-41995). Refer to HA-36, "Inspection".

2.PERFORM LUBRICANT RETURN OPERATION 1. 2. 3.

Start the engine, and run it as following. Engine speed: Idle – 1,200 rpm A/C switch: ON Fan speed: Maximum position Set temperature: Full hot Intake position: Recirculation (REC) Perform lubricant return operation for approximately 10 minutes. Stop the engine. >> GO TO 3.

3.REPAIR OR REPLACE MALFUNCTIONING PART 1. 2.

Repair or replace the malfunctioning part. Perform the lubricant adjustment depending on the replaced part.

Except compressor >>Refer to HA-30, "Lubricant Adjusting Procedure for Components Replacement Except Compressor". Compressor >>Refer to HA-31, "Lubricant Adjusting Procedure for Compressor Replacement".

Lubricant Adjusting Procedure for Components Replacement Except Compressor INFOID:0000000004653099

Add the correct amount of lubricant to the system after replacing any of the following major components. Amount of lubricant to be added:


HA-30

2009 G37 Coupe

LUBRICANT < PERIODIC MAINTENANCE > Lubricant to be added to system Replaced part

A

Amount of lubricant m (US fl oz., Imp fl oz.)

Remarks

Evaporator

75 (2.5, 2.6)

—

Condenser

35 (1.2, 1.2)

—

Liquid tank

10 (0.3, 0.4)

—

30 (1.0, 1.1)

Large leakage

—

Small leakage *1

In case of refrigerant leakage

B

C

D

*1: No addition of lubricant is needed if the refrigerant leakage is small.

Lubricant Adjusting Procedure for Compressor Replacement 1.

2.

3. 4. 5. 6. 7. 8. 9.

INFOID:0000000004653100

E Check recovery/recycling recharging equipment gauges before connecting recovery/recycling recharging equipment to vehicle. No refrigerant pressure should be displayed. Recover refrigerant from equipment lines if NG. F Connect recovery/recycling recharging equipment to vehicle. Confirm refrigerant purity in supply tank using recovery/recycling recharging equipment and refrigerant identifier. Refer to HA-12, "Working with HFC-134a (R-134a)" if NG. Confirm refrigerant purity in vehicle A/C system using recovery/recycling recharging equipment and refrig- G erant identifier. If NG, refer to HA-12, "Working with HFC-134a (R-134a)". Discharge refrigerant into the recovery/recycling recharging equipment. Measure lubricant discharged into H the recovery/recycling recharging equipment. Drain the lubricant from the old (removed) compressor into a graduated container and recover the amount of lubricant drained. HA Drain the lubricant from the new compressor into a separate. Then clean container. Measure an amount of new lubricant installed equal to amount drained from old compressor. Add this lubricant to new compressor through the suction port opening. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant J to new compressor through the suction port opening. Add another 5 m (0.2 US fl oz., 0.2 Imp fl oz.) of lubricant at this time if the liquid tank also needs to be K replaced.

L

M

N

O

P


HA-31

2009 G37 Coupe

LUBRICANT < PERIODIC MAINTENANCE > Do not add this 5 m (0.2 US fl oz., 0.2 Imp fl oz.) of lubricant when replacing the compressor only.

RJIA3578E


HA-32

2009 G37 Coupe

REFRIGERATION SYSTEM < PERIODIC MAINTENANCE >

REFRIGERATION SYSTEM

A

Inspection

INFOID:0000000004653101

1.CHECK BLOWER MOTOR OPERATION

B

Check blower motor operation. Refer to HAC-56, "Component Function Check". Is the inspection result normal? YES >> GO TO 2. NO >> Repair or replace the parts according to the inspection results.

C

2.CHECK COMPRESSOR OPERATION

D

Check compressor operation. Refer to HAC-60, "Component Function Check". Is the inspection result normal? YES >> GO TO 3. NO >> Repair or replace the parts according to the inspection results.

E

3.CHECK REFRIGERANT CYCLE PRESSURE Connect recovery/recycling recharging equipment to the vehicle and perform the diagnosis with the gauge pressure. Refer to HA-7, "Trouble Diagnosis For Unusual Pressure". Is the inspection result normal? YES >> Perform the performance test. Refer to HA-33, "Performance Chart". NO >> Repair or replace the parts according to the inspection results.

Performance Chart

INFOID:0000000004653102

F

G

H

TEST CONDITION HA

Testing must be performed as per the following:

Vehicle condition

Indoors or in the shade (in a well-ventilated place)

Doors

Closed

Door windows

Open

Hood

Open

Set temperature

Full cold

Mode switch

J

K

(Ventilation) set

Intake switch

(Recirculation) set

Fan speed

Maximum speed set

Engine speed

Idle speed

L

M

Operate the air conditioning system for 10 minutes before taking measurements.

TEST READING Recirculating-to-discharge Air Temperature Table

N

Inside air (Recirculating air) at blower assembly inlet Relative humidity %

50 – 60

60 – 70


Discharge air temperature at center ventilator °C (°F)

Air temperature °C (°F)

O

20 (68)

6.3 – 7.9 (43 – 46)

25 (77)

10.6 – 12.8 (51 – 55)

30 (86)

14.8 – 17.6 (59 – 64)

35 (95)

19.0 – 22.3 (66 – 72)

20 (68)

7.9 – 9.4 (46 – 49)

25 (77)

12.8 – 14.9 (55 – 59)

30 (86)

17.6 – 20.3 (64 – 69)

35 (95)

22.3 – 25.7 (72 – 78)

HA-33

P

2009 G37 Coupe

REFRIGERATION SYSTEM < PERIODIC MAINTENANCE > Ambient Air Temperature-to-operating Pressure Table

Ambient air Relative humidity %

High-pressure (Discharge side)

Low-pressure (Suction side)

Air temperature °C (°F)

kPa (kg/cm2, psi)

kPa (kg/cm2, psi)

20 (68)

768 – 940 (7.8 – 9.6, 111.4 – 136.3)

180 – 220 (1.8 – 2.2, 26.1 – 31.9)

25 (77)

925 – 1,131 (9.4 – 11.5, 134.1 – 164.0)

218 – 267 (2.2 – 2.7, 31.6 – 38.7)

30 (86)

1,082 – 1,322 (11.0 – 13.5, 156.9 – 191.7)

258 – 314 (2.6 – 3.2, 37.4 – 45.5)

35 (95)

1,238 – 1,513 (12.6 – 15.4, 179.5 – 219.4)

296 – 362 (3.0 – 3.7, 42.9 – 52.5)

40 (104)

1,395 – 1,704 (14.2 – 17.4, 202.3 – 247.1)

335 – 408 (3.4 – 4.2, 48.6 – 59.2)

50 – 70

Refrigerant Leakages

INFOID:0000000004653103

Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow extra inspection time in these areas when using either an electrical leak detector or fluorescent dye leak detector [refrigerant dye leak detection kit (SST: J-43926)]. Confirm the leakage with an electrical leak detector if dye is observed. It is possible a prior leakage was repaired and not properly cleaned. Do not stop when one leakage is found but continue checking for additional leakages at all system components and connections when searching for leakages. Move the probe along the suspected leakage area at 1 to 2 inches per second and no further than 1/4 inch from the component when searching for refrigerant leakages using an electrical leak detector. CAUTION: Moving the electrical leak detector probe slower and closer to the suspected leakage area improves the chances of finding a leakage.


HA-34

2009 G37 Coupe

FLUORESCENT LEAK DETECTOR < PERIODIC MAINTENANCE >

FLUORESCENT LEAK DETECTOR Inspection

A INFOID:0000000004653104

CHECKING SYSTEM FOR LEAKAGES USING THE FLUORESCENT LEAK DETECTOR Check A/C system for leakages using the UV lamp and safety goggles (SST: J-42220) in a low sunlight area (area without windows preferable). Illuminate all components, fittings and lines. The dye appears as a bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain opening indicates an evaporator core assembly (tubes, core or expansion valve) leakage. 2. Use an adjustable mirror or wipe the area with a clean shop rag or cloth, with the UV lamp for dye residue if the suspected area is difficult to see. 3. Remove any residual dye using dye cleaner (SST: J-43872) to prevent future misdiagnosis after the leakage is repaired. 4. Perform a system performance check and verify the leakage repair with an approved electrical leak detector. NOTE: Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be checked are clean. Clean with a dry cloth or blow off with shop air. Do not allow the sensor tip of the detector to contact with any substance. This may also cause false readings and may damage the detector.

B

1.

DYE INJECTION (This procedure is only necessary when recharging the system or when the compressor has seized and was replaced.) 1. 2. 3. 4. 5.

6.

7.

8.

C

D

E

F

G

H

Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.52 kg/cm2, 50 psi). HA Pour one bottle [1/4 ounce (7.4 cc)] of the A/C refrigerant dye into the injector tool (SST: J-41459). Connect the injector tool to the A/C low-pressure side service valve. Start the engine. Then A/C switch ON. J Inject one bottle [1/4 ounce (7.4 cc)] of fluorescent dye through the low-pressure service valve using dye injector tool (SST: J-41459) (refer to the manufacture’s operating instructions) when the A/C operating (compressor running). K Disconnect the injector tool from the service valve with the engine still running. CAUTION: Be careful when replacing the A/C system or a component, pour the dye directly into the open sysL tem connection and proceed with the service procedures. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the leakage size, operating conditions and location of the leakage, it may take from minutes to days for the M dye to penetrate a leakage and become visible. Attach a blue label if necessary. N

O

P


HA-35

2009 G37 Coupe

ELECTRICAL LEAK DETECTOR < PERIODIC MAINTENANCE >

ELECTRICAL LEAK DETECTOR Inspection

INFOID:0000000004653105

PRECAUTIONS FOR HANDLING LEAK DETECTOR Use an electrical leak detector (SST: J-41995) or equivalent when performing a refrigerant leakage check. Ensure that the instrument is calibrated and set properly per the operating instructions. The leak detector is a delicate device. Read the operating instructions and perform any specified maintenance for using the leak detector properly.

AHA281A

1.

Position probe approximately 3 mm (0.12 in) away from point to be checked.

JSIIA1099GB

2.

Circle each fitting completely with probe when testing.

SHA706E

3.

Move probe along component approximately 25 to 50 mm (1 to 2 in)/sec.

SHA708EA

CHECKING PROCEDURE Check that there is no refrigerant vapor, shop chemicals, or cigarette smoke in the vicinity of the vehicle to prevent inaccurate or false readings. Perform the leakage test in calm area (low air/wind movement) so that the leaking refrigerant is not dispersed. 1. Stop the engine. Revision: 2009 October

HA-36

2009 G37 Coupe

ELECTRICAL LEAK DETECTOR < PERIODIC MAINTENANCE > 2. Connect a suitable A/C manifold gauge set (SST: J-39183) to the A/C service valves. 3.

4.

Check if the A/C refrigerant pressure is at least 345 kPa (3.45 bar, 3.52 kg/cm2, 50 psi) above 16°C (61°F). Recover/evacuate and recharge the system with the specified amount of refrigerant if less than specification. NOTE: Leakages may not be detected since the system may not reach 345 kPa (3.45 bar, 3.52 kg/cm2, 50 psi) at temperatures below 16°C (61°F). Perform the leakage test in the numerical as shown in the figure. [high-pressure side (compressor discharge “a” to evaporator inlet “j”) to low-pressure side (evaporator drain hose “k” to shaft seal “p”)] Clean the component to be checked and move the leakage detected probe completely around the connection/component.

A

B

C

D

E

F

G

H

HA

J

K JSIIA0890GB

5. 6. 7. 8. a. b.

NOTE: Check the following carefully. Service valves • Check all around the service valves. Ensure service valve caps are secured on the service valves (to prevent leakages). • Wipe any residue from valves to prevent any false readings by leak detector after removing manifold gauge set (SST: J-39183) from service valves. Cooling unit (Evaporator) • Turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the cooling unit with engine OFF. • Wait a minimum of 10 minutes accumulation time (refer to the manufacturer’s recommended procedure for actual wait time) before inserting the leak detector probe into the drain hose. • Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water or dirt that may be in the drain hose. Verify at least once by blowing compressed air into area of suspected leakage, then repeat check as outlined above if a leak detector detects a leakage. If a leakage is found, but continue checking for additional leakages at all system components. When leakages are not found, go to next step. Start the engine. Set the A/C control as per the following: A/C switch: ON Air flow: VENT (Ventilation)


HA-37

2009 G37 Coupe

L

M

N

O

P

ELECTRICAL LEAK DETECTOR < PERIODIC MAINTENANCE > c. Intake door position: Recirculation d. Temperature setting: Full cold e. Fan speed: Maximum speed set 9. Run engine at 1,500 rpm for at least 2 minutes. 10. Stop the engine and perform leakage check again, steps 4 – 6. Refrigerant leakages should be checked immediately after stopping the engine. Begin with the leak detector at the compressor. The pressure on the high-pressure side drops gradually after refrigerant circulation stops and pressure on the low-pressure side rises gradually, as shown in the graph. Some leakages are more easily detected when pressure is high.

SHA839E

11. Check recovery/recycling recharging equipment gauges before connecting recovery/recycling recharging equipment to vehicle. No refrigerant pressure should be displayed. Recover refrigerant from equipment lines if pressure is displayed, and then refrigerant purity. 12. Confirm refrigerant purity in supply tank using recovery/recycling recharging equipment and refrigerant identifier. 13. Confirm refrigerant purity in vehicle A/C system using recovery/recycling recharging equipment and refrigerant identifier. 14. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or component if necessary. 15. Evacuate and recharge A/C system and perform the leakage test to confirm no refrigerant leakages. 16. Perform A/C performance test to ensure system works normally.


HA-38

2009 G37 Coupe

COMPRESSOR < REMOVAL AND INSTALLATION >


A

COMPRESSOR Exploded View

INFOID:0000000004494935

B

C

D

E

F

G

JSIIA1428GB

1.

Compressor

H



INFOID:0000000004648406

HA

REMOVAL 1. 2. 3. 4. 5. 6. 7. 8.

Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Remove air cleaner case (LH) and air duct (LH). Refer to EM-27, "Exploded View". Remove engine undercover, using power tools. Drain engine coolant from radiator. Refer to CO-7, "Draining". Remove cooling fan assembly. Refer to CO-16, "Exploded View". Remove drive belt. Refer to EM-13, "Exploded View". Remove radiator hose (lower). Refer to CO-13, "Exploded View". Remove mounting nuts (A) from low-pressure flexible hose (1) and high-pressure flexible hose (2). CAUTION: Cap or wrap the joint of the A/C piping and compressor with suitable material such as vinyl tape to avoid the entry of air.

J

K

L

M

N

O JSIIA0090ZZ

P


HA-39

2009 G37 Coupe

COMPRESSOR < REMOVAL AND INSTALLATION > 9. Disconnect compressor (ECV) connector (A). 10. Disconnect compressor (magnet clutch) connector (B).

JSIIA0021ZZ

11. Remove mounting bolts (A) from compressor (1), using power tools. 12. Remove the compressor from top of the vehicle.

JSIIA0022ZZ

INSTALLATION Installation is basically the reverse order of removal. CAUTION: • Replace O-rings with new ones. Then apply compressor oil to them when installing. • Check for leakages when recharging refrigerant. • Check tension of the drive belt after installing compressor. Refer to EM-13, "Checking".

Inspection

INFOID:0000000004653536

CHECK DISC TO PULLEY CLEARANCE Check the clearance (B) between pulley assembly (1) and clutch disc (2) along the entire periphery with a feeler gauge (A). Standard

: Refer to HA-56, "Compressor".

Replace compressor if specified clearance is not obtained.

SJIA1918E


HA-40

2009 G37 Coupe

COOLER PIPE AND HOSE < REMOVAL AND INSTALLATION >

COOLER PIPE AND HOSE

A

Exploded View

INFOID:0000000004494938

Refer to HA-13, "Refrigerant Connection".

B

C

D

E

F

G

H

HA

J JSIIA1403GB

K 1.

Blower unit

2.

O-ring

3.

Low-pressure pipe 2

4.

Low-pressure flexible hose

5.

Compressor

6.

Radiator & condenser assembly

7.

High-pressure flexible hose

8.

High-pressure pipe 1

9.

Heater & cooling unit assembly

10. Expansion valve

11. Evaporator

L

12. High-pressure pipe 2

13. Low-pressure pipe 1

M


LOW-PRESSURE FLEXIBLE HOSE AND PIPE 2 LOW-PRESSURE FLEXIBLE HOSE AND PIPE 2 : Removal and Installation

N

INFOID:0000000004648418

REMOVAL

O

1. 2. 3. 4.

P

Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Remove engine cover. Refer to EM-25, "Exploded View". Remove air cleaner case (LH) and air duct (LH). Refer to EM-27, "Exploded View". Remove cowl top cover. Refer to EXT-21, "Exploded View".


HA-41

2009 G37 Coupe

COOLER PIPE AND HOSE < REMOVAL AND INSTALLATION > 5. Remove mounting bolt (A) from low-pressure flexible hose bracket (1).

JSIIA0023ZZ

6.

Disconnect one-touch joint between low-pressure pipe 1 (1) and low-pressure pipe 2 (2) with disconnector (A) (SST: J-45815). CAUTION: Cap or wrap the joint of the A/C piping with suitable material such as vinyl tape to avoid the entry of air.

JSIIA0091ZZ

7.

8. 9.

Disconnect one-touch joint between low-pressure pipe 2 (1) and low-pressure flexible hose (2) with disconnector (A) (SST: J45815). CAUTION: Cap or wrap the joint of the A/C piping with suitable material such as vinyl tape to avoid the entry of air. Remove low-pressure pipe 2 clip (B). Remove low-pressure pipe 2.

JSIIA0024ZZ

10. Remove mounting nut (A) from low-pressure flexible hose (1). CAUTION: Cap or wrap the joint of the A/C piping and compressor with suitable material such as vinyl tape to avoid the entry of air. 11. Remove low-pressure flexible hose.

JSIIA0025ZZ

INSTALLATION Installation is basically the reverse order of removal. CAUTION: • Replace O-rings with new ones. Then apply compressor oil to them when installing. • Female-side piping connection is thin and easy to deform. Slowly insert the male-side piping straight in axial direction. • Insert piping securely until a click is heard. • After piping connection is completed, pull male-side piping by hand to check that connection does not come loose. • Check for leakages when recharging refrigerant.

HIGH-PRESSURE FLEXIBLE HOSE Revision: 2009 October

HA-42

2009 G37 Coupe

COOLER PIPE AND HOSE < REMOVAL AND INSTALLATION >

HIGH-PRESSURE FLEXIBLE HOSE : Removal and Installation

INFOID:0000000004649269

A

REMOVAL 1. 2. 3. 4.

Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Remove engine cover. Refer to EM-25, "Exploded View". Remove air cleaner case (LH) and air duct (LH). Refer to EM-27, "Exploded View". Remove mounting bolt (A) from high-pressure flexible hose bracket (1).

B

C

D

E

JSIIA0026ZZ

5.

Disconnect one-touch joint between high-pressure flexible hose (1) and condenser pipe assembly (2) with disconnector (A) (SST: J-45815). CAUTION: Cap or wrap the joint of the A/C piping with suitable material such as vinyl tape to avoid the entry of air.

F

G

H

HA JSIIA0027ZZ

6.

J

Remove mounting nut (A) from high-pressure flexible hose (1), and then remove high-pressure flexible hose. CAUTION: Cap or wrap the joint of the A/C piping and compressor with suitable material such as vinyl tape to avoid the entry of air.

K

L

JSIIA0086ZZ

M


HIGH-PRESSURE PIPE 1 HIGH-PRESSURE PIPE 1 : Removal and Installation

INFOID:0000000004649270

REMOVAL 1.

Remove low-pressure flexible hose and pipe 2. Refer to HA-41, "Exploded View".


HA-43

2009 G37 Coupe

N

O

P

COOLER PIPE AND HOSE < REMOVAL AND INSTALLATION > 2. Remove mounting bolt (A) from high-pressure flexible hose bracket (1).

JSIIA0026ZZ

3.

Remove high-pressure pipe 1 (1) from vehicle clips (A).

JSIIA0028ZZ

4.

Disconnect one-touch joint between high-pressure pipe 1 (1) and high-pressure pipe 2 (2) with disconnector (A) (SST: J45815). CAUTION: Cap or wrap the joint of the A/C piping with suitable material such as vinyl tape to avoid the entry of air.

JSIIA0092ZZ

5.

Disconnect one-touch joint between high-pressure pipe 1 and condenser pipe assembly with disconnector (A) (SST: J-45815). CAUTION: Cap or wrap the joint of the A/C piping with suitable material such as vinyl tape to avoid the entry of air.

JSIIA0188ZZ

6. 7.

Remove vacuum hose. Refer to BR-37, "Exploded View". Remove high-pressure pipe 1.

INSTALLATION Installation is basically the reverse order of removal. CAUTION: • Replace O-rings with new ones. Then apply compressor oil to them when installing. • Female-side piping connection is thin and easy to deform. Slowly insert the male-side piping straight in axial direction. • Insert piping securely until a click is heard. • After piping connection is completed, pull male-side piping by hand to check that connection does not come loose. Revision: 2009 October

HA-44

2009 G37 Coupe

COOLER PIPE AND HOSE < REMOVAL AND INSTALLATION > • Check for leakages when recharging refrigerant.

LOW-PRESSURE PIPE 1 AND HIGH-PRESSURE PIPE 2

A

LOW-PRESSURE PIPE 1 AND HIGH-PRESSURE PIPE 2 : Removal and Installation INFOID:0000000004649271

B

REMOVAL 1.

2. 3. 4. 5.

6.

Set the temperature at 18.0°C (60°F). CAUTION: The angle may be out, when installing the air mix door motor to the air mix door, unless the above procedure is performed. Disconnect the battery cable from the negative terminal. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Remove cowl top cover. Refer to EXT-21, "Exploded View". Disconnect one-touch joint between low-pressure pipe 1 (1) and low-pressure pipe 2 (2) with disconnector (A) (SST: J-45815). CAUTION: Cap or wrap the joint of the A/C piping with suitable material such as vinyl tape to avoid the entry of air. Disconnect one-touch joints between high-pressure pipe 1 (3) and high-pressure pipe 2 (4) with disconnector (SST: J-45815). CAUTION: Cap or wrap the joint of the A/C piping with suitable material such as vinyl tape to avoid the entry of air.

C

D

E

F

G

H

JSIIA0037ZZ

7. 8. 9. 10. 11. 12.

Remove foot grille (right). Refer to VTL-10, "Exploded View". Remove blower unit. Refer to VTL-16, "Exploded View". Remove air mix door motor (passenger side). Refer to HAC-120, "Exploded View". Remove mode door motor. Refer to HAC-120, "Exploded View". Remove main link (right) and max. cool door link (right). Refer to HAC-120, "Exploded View". Remove mounting screws (A), and then remove evaporator cover (1).

HA

J

K

L

M JSIIA0093ZZ

N

13. Remove mounting bolt (A), and then remove low-pressure pipe 1 (1) and high-pressure pipe 2 (2). CAUTION: Cap or wrap the joint of the A/C piping and expansion valve with suitable material such as vinyl tape to avoid the entry of air.

O

P

JSIIA0029ZZ

INSTALLATION Installation is basically the reverse order of removal. Revision: 2009 October

HA-45

2009 G37 Coupe

COOLER PIPE AND HOSE < REMOVAL AND INSTALLATION > CAUTION: • Replace O-rings with new ones. Then apply compressor oil to them when installing. • Female-side piping connection is thin and easy to deform. Slowly insert the male-side piping straight in axial direction. • Insert piping securely until a click is heard. • After piping connection is completed, pull male-side piping by hand to check that connection does not come loose. • Check for leakages when recharging refrigerant.


HA-46

2009 G37 Coupe

CONDENSER < REMOVAL AND INSTALLATION >

CONDENSER

A

Exploded View

INFOID:0000000004494945

B

C

D

E

F

G JSIIA0012GB

1.


2.

O-ring

3.

Liquid tank bracket

4.

Liquid tank

5.

Bracket

6.

Condenser pipe assembly

7.



H

HA

CONDENSER CONDENSER : Removal and Installation

INFOID:0000000004649330

J

REMOVAL 1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. 2. Remove radiator & condenser assembly. Refer to CO-13, "Exploded View". CAUTION: Be careful not to damage core surface of radiator & condenser assembly/

K

L


M

N

O

CONDENSER PIPE ASSEMBLY CONDENSER PIPE ASSEMBLY : Removal and Installation

INFOID:0000000004649331

REMOVAL 1. 2. 3.

Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Remove bumper fascia assembly. EXT-12, "Exploded View". Remove air cleaner case (LH) and air duct (LH). Refer to EM-27, "Exploded View".


HA-47

2009 G37 Coupe

P

CONDENSER < REMOVAL AND INSTALLATION > 4. Disconnect one-touch joint between high-pressure flexible hose (1) and condenser pipe assembly (2) with disconnector (A) (SST: J-45815). CAUTION: Cap or wrap the joint of the A/C piping with suitable material such as vinyl tape to avoid the entry of air. 5. Disconnect one-touch joints between high-pressure pipe 1 (3) and condenser pipe assembly with disconnector (A) (SST: J45815). CAUTION: Cap or wrap the joint of the A/C piping with suitable material such as vinyl tape to avoid the entry of air. 6.

JSIIA0095ZZ

Remove mounting bolt (A) from condenser pipe assembly (1).

JSIIA0088ZZ

7. 8.

Remove mounting bolt (A) from condenser pipe assembly (1). Remove condenser pipe assembly.

JSIIA0030ZZ


LIQUID TANK LIQUID TANK : Removal and Installation

INFOID:0000000004649332

REMOVAL 1. 2. 3.

Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Remove front grille. Refer to EXT-19, "Exploded View". Clean liquid tank and its surrounding area. Then remove dust and rust from liquid tank. CAUTION: Be sure to clean carefully.


HA-48

2009 G37 Coupe

CONDENSER < REMOVAL AND INSTALLATION > 4. Remove mounting bolts (A) from liquid tank (1). 5. Remove liquid tank.

A

B

C JSIIA0094ZZ

D

INSTALLATION Install liquid tank, and then install liquid tank bracket on condenser. CAUTION: • Check that liquid tank bracket is securely installed at protrusion of condenser. (Check that liquid tank bracket does not move to a position below center of liquid tank.) • Replace O-rings of the A/C piping with new ones. Then apply compressor oil to them when installing. • Check for leakages when recharging refrigerant.

REFRIGERANT PRESSURE SENSOR REFRIGERANT PRESSURE SENSOR : Removal and Installation

INFOID:0000000004649333

E

F

G

REMOVAL 1. 2.

Remove liquid tank. Refer to HA-47, "Exploded View". Fix the liquid tank (1) with a vise (A). Remove the refrigerant pressure sensor (2) with a wrench (B). CAUTION: Be careful not to damage liquid tank.

H

HA

J

K JSIIA0075ZZ

INSTALLATION

L

Installation is basically the reverse order of removal. CAUTION: • Apply compressor oil to O-ring of refrigerant pressure sensor when installing. • Check for leakages when recharging refrigerant.

M

N

O

P


HA-49

2009 G37 Coupe

HEATER & COOLING UNIT ASSEMBLY < REMOVAL AND INSTALLATION >

HEATER & COOLING UNIT ASSEMBLY Exploded View

INFOID:0000000004494950

REMOVAL

JSIIA1408GB

1.

Blower unit

2.


3.

Steering member

4.

Instrument stay (left)

5.

Instrument panel assembly

6.

Instrument stay (right)


DISASSEMBLY


HA-50

2009 G37 Coupe

HEATER & COOLING UNIT ASSEMBLY < REMOVAL AND INSTALLATION > A

B

C

D

E

F

G

H

HA

J

K

L JPIIA1459GB

1.

Ventilator seal

2.

Ventilator door

3.

Defroster seal

4.

Defroster door (right)

5.

Packing

6.

Foot duct (right)

7.

Ventilator door spring

Foot door lever

M

8.

Ventilator door lever

9.

10. Foot door link

11.

Main link sub

12. Ventilator door link

13. Main link

14.

Mode door motor bracket

15. Mode door motor

16. Evaporator cover

17.

Low-pressure pipe 1

18. Cooler pipe grommet

19. High-pressure pipe 2

20.

O-ring

21. Expansion valve

22. Evaporator

23.

Insulator

24. Drain hose

25. Evaporator cover adapter

26.

Heater pipe bracket

27. Heater pipe grommet

28. Heater core

29.

Heater pipe cover

30. Packing

31. Case packing

32.

Heater & cooling unit case (left)

33. Air mix door adapter

34. Air mix door motor (driver side)

35.

J-nut

36. Front heater duct

37. Aspirator hose

38.

Aspirator

39. Foot duct (left)

40. Defroster door (left)

41.

Packing

42. Center case

43. Foot door (left)

44.

Rear ventilator door

45. Foot door (right)

46. J-nut

47.

Max. cool door lever

48. Defroster door lever


HA-51

N

O

P

2009 G37 Coupe

HEATER & COOLING UNIT ASSEMBLY < REMOVAL AND INSTALLATION > 49. Defroster door link

50. Max. cool door link

51. Intake sensor

52. Intake sensor bracket

53. Air mix door motor (passenger side)

54. Air mix door adapter

55. Heater & cooling unit case (right)

56. Max. cool door (right)

57. Max. cool door (left)

58. Air mix door (Slide door) Refer to GI-4, "Components" for symbols in the figure.

HEATER & COOLING UNIT ASSEMBLY HEATER & COOLING UNIT ASSEMBLY : Removal and Installation

INFOID:0000000004649614

REMOVAL 1. 2. 3. 4.

5.

Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Drain engine coolant from cooling system. Refer to CO-7, "Draining". Remove cowl top cover. Refer to EXT-21, "Exploded View". Disconnect one-touch joint between low-pressure pipe 1 (1) and low-pressure pipe 2 (2) with disconnector (A) (SST: J-45815). CAUTION: Cap or wrap the joint of the A/C piping with suitable material such as vinyl tape to avoid the entry of air. Disconnect one-touch joint between high-pressure pipe 1 (3) and high-pressure pipe 2 (4) with disconnector (SST: J-45815). CAUTION: Cap or wrap the joint of the A/C piping with suitable material such as vinyl tape to avoid the entry of air. JSIIA0037ZZ

6.

Remove clamp (A), and then disconnect heater hoses (1).

7. 8. 9. 10. 11. 12.

Remove instrument panel assembly. Refer to IP-11, "Exploded View". Remove blower unit. Refer to VTL-16, "Exploded View". Remove clips of vehicle harness from steering member. Remove instrument stay. Remove drain hose. Remove mounting bolts (A) from heater & cooling unit assembly (1).

JSIIA0657ZZ

JSIIA0039ZZ

13. Remove front defroster nozzle, side defroster nozzles and ventilator duct. Refer to VTL-10, "Exploded View". Revision: 2009 October

HA-52

2009 G37 Coupe

HEATER & COOLING UNIT ASSEMBLY < REMOVAL AND INSTALLATION > 14. Remove steering column mounting bolts (A) and nuts (B). Refer to ST-18, "WITHOUT ELECTRIC MOTOR : Exploded View" (WITHOUT ELECTRIC MOTOR) or ST-21, "WITH ELECTRIC MOTOR : Exploded View" (WITH ELECTRIC MOTOR).

A

B

C

D

E

F

G

H JSIIA1411ZZ

HA

15. Remove steering member mounting bolts (C). 16. Remove steering member (1). 17. Remove heater & cooling unit assembly.

J

INSTALLATION Installation is basically the reverse order of removal. CAUTION: • Replace O-rings with new ones. Then apply compressor oil to them when installing. • Female-side piping connection is thin and easy to deform. Slowly insert the male-side piping straight in axial direction. • Insert piping securely until a clicks is heard. • After piping connection is completed, pull male-side piping by hand to make sure that connection does not come loose. • Check for leakages when recharging refrigerant. NOTE: • Perform 4WAS front actuator adjustment (WITH 4WAS). Refer to STC-28, "4WAS FRONT ACTUATOR NEUTRAL POSITION ADJUSTMENT : Description". • Refer to CO-8, "Refilling" when filling radiator with engine coolant. • Recharge the refrigerant.

K

L

M

N

HEATER CORE HEATER CORE : Removal and Installation

O INFOID:0000000004649615

REMOVAL 1.

P

Remove heater & cooling unit assembly. Refer to HA-50, "Exploded View".


HA-53

2009 G37 Coupe

HEATER & COOLING UNIT ASSEMBLY < REMOVAL AND INSTALLATION > 2. Remove mounting screws (A), and then remove heater pipe cover (1). 3. Remove mounting screws (B), and then remove foot duct (left) (2). 4. Slide heater core (3) to leftward (as shown in the figure).

JSIIA0017GB

INSTALLATION Installation is basically the reverse order of removal. NOTE: Refer to CO-8, "Refilling" when filling radiator with engine coolant.

EVAPORATOR EVAPORATOR : Removal and Installation

INFOID:0000000004649815

REMOVAL 1.

2. 3.

Remove low-pressure pipe 1 and high-pressure pipe 2. Refer to HA-41, "Exploded View". CAUTION: Cap or wrap the joint of the A/C piping and expansion valve with suitable material such as vinyl tape to avoid the entry of air. Slide evaporator (1) from heater & cooling unit assembly. Remove intake sensor (2) from evaporator, and then remove evaporator.

JSIIA0052ZZ

4.

Remove mounting bolts (A), and then remove expansion valve (1). CAUTION: Cap or wrap the joint of evaporator and expansion valve with suitable material such as vinyl tape to avoid the entry of air.

JSIIA0102ZZ

INSTALLATION Installation is basically the reverse order of removal. CAUTION: • Replace O-rings with new ones. Then apply compressor oil to them when installing. • Female-side piping connection is thin and easy to deform. Slowly insert the male-side piping straight in axial direction. • Insert piping securely until a click is heard. • After piping connection is completed, pull male-side piping by hand to check that connection does not come loose.


HA-54

2009 G37 Coupe

HEATER & COOLING UNIT ASSEMBLY < REMOVAL AND INSTALLATION > • O-rings differ from low-pressure flexible hose (high-pressure pipe 1) and low-pressure pipe 1 (highpressure pipe 2). • Mark the mounting position of intake sensor bracket prior to removal so that the reinstalled sensor can be located in the same position. • Check for leakages when recharging refrigerant.

EXPANSION VALVE EXPANSION VALVE : Removal and Installation

A

B

INFOID:0000000004649816

C

REMOVAL 1. 2.

Remove low-pressure pipe 1 and high-pressure pipe 2. Refer to HA-41, "Exploded View". Remove mounting bolts (A), and then remove expansion valve (1). CAUTION: Cap or wrap the joint of evaporator and expansion valve with suitable material such as vinyl tape to avoid the entry of air.

D

E

F

G JSIIA0102ZZ

INSTALLATION Installation is basically the reverse order of removal. H CAUTION: • Replace O-rings with new ones. Then apply compressor oil to them when installing. • O-rings are different from low-pressure pipe 1 (high-pressure pipe 1) and low-pressure pipe 2 (highHA pressure pipe 2). • Check for leakages when recharging refrigerant. J

K

L

M

N

O

P


HA-55

2009 G37 Coupe

SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Compressor

INFOID:0000000004655508

Model

CALSONIC KANSEI make CSE-617

Type

Variable displacement swash plate

Displacement cm3 (cu in)/rev

Max.

170 (10.4)

Number of cylinders

6

Cylinder bore × stroke (Max.) mm (in.)

34.8 (1.37) × 29.8 (1.17)

Direction of rotation

Clockwise (viewed from clutch)

Drive belt Disc to pulley clearance mm (in.)

Poly V Standard

0.3 – 0.6 (0.012 – 0.024)

Lubricant

INFOID:0000000004655509

Name Capacity m (US fl oz., lmp fl oz.)

NISSAN A/C System Oil Type S (DH-PS) Total in system

150 (5.07, 5.3)

Compressor (service part) charging amount

150 (5.07, 5.3)

Refrigerant

INFOID:0000000004655510

Type

HFC-134a (R-134a)

Capacity kg (lb)

0.55 (1.21)

Engine Idling Speed

INFOID:0000000004655511

Refer to EC-619, "Idle Speed".

Belt Tension

INFOID:0000000004655512

Refer to EM-148, "Drive Belt".


HA-56

2009 G37 Coupe


SECTION

HAC

HEATER & AIR CONDITIONING CONTROL SYSTEM

A

B

C

D

E

CONTENTS AUTOMATIC AIR CONDITIONER

System Diagram ......................................................36 System Description ..................................................36

BASIC INSPECTION .................................... 4 DIAGNOSIS AND REPAIR WORKFLOW .......... 4 Work Flow ................................................................. 4

INSPECTION AND ADJUSTMENT ..................... 5 Description & Inspection ........................................... 5 Temperature Setting Trimmer ................................... 7 Foot Position Setting Trimmer ................................... 9 Inlet Port Memory Function ..................................... 10

MAGNET CLUTCH CONTROL SYSTEM ......... 38 System Diagram ......................................................38 System Description ..................................................38

DIAGNOSIS SYSTEM (UNIFIED METER & A/ C AMP.) ............................................................. 40

DTC/CIRCUIT DIAGNOSIS ......................... 46 POWER SUPPLY AND GROUND CIRCUIT .... 46

COMPRESSOR CONTROL FUNCTION ............11

UNIFIED METER AND A/C AMP. ..............................46 UNIFIED METER AND A/C AMP. : Diagnosis Procedure ......................................................................46

AUTOMATIC AIR CONDITIONER SYSTEM ....16 System Diagram ...................................................... 16 System Description ................................................. 17 Component Part Location ....................................... 25 Component Description ........................................... 28

CAN COMMUNICATION SYSTEM ....................29 System Description ................................................. 29

MODE DOOR CONTROL SYSTEM ...................30 System Diagram ...................................................... 30 System Description ................................................. 30

AIR MIX DOOR CONTROL SYSTEM ................32 System Diagram ...................................................... 32 System Description ................................................. 32

INTAKE DOOR CONTROL SYSTEM ................34 System Diagram ...................................................... 34 System Description ................................................. 34

BLOWER MOTOR CONTROL SYSTEM ...........36 Revision: 2009 October

G

H

Diagnosis Description ..............................................40

SYSTEM DESCRIPTION ............................. 11 Description .............................................................. 11 Fail-safe .................................................................. 11 Component Part Location ....................................... 12 Component Description ........................................... 15

F

HAC

J

K

UNIFIED METER AND A/C AMP. ..................... 47 Description ...............................................................47 Component Function Check ....................................47 Diagnosis Procedure ...............................................47

MODE DOOR MOTOR ...................................... 48 Description ...............................................................48 Component Function Check ..................................48 Diagnosis Procedure ...............................................48

AIR MIX DOOR MOTOR ................................... 50 WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM ....50 WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Description .............................................50 WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Component Function Check .................50 WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure .............................50

HAC-1

2009 G37 Coupe

L

M

N

O

P

WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM ........... 51 WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Description ............................................................ 51 WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Component Function Check ............................... 52 WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure ............................................ 52

UNIFIED METER AND A/C AMP. ..................... 92

INTAKE DOOR MOTOR .................................... 54

Description ............................................................ 103 Inspection procedure ............................................ 103

Description .............................................................. 54 Component Function Check ................................. 54 Diagnosis Procedure .............................................. 54

BLOWER MOTOR ............................................. 56 Description .............................................................. 56 Component Function Check ................................. 56 Diagnosis Procedure .............................................. 57 Component Inspection ............................................ 59

MAGNET CLUTCH ............................................ 60 Description .............................................................. 60 Component Function Check ................................... 60 Diagnosis Procedure .............................................. 60

ECV (ELECTRICAL CONTROL VALVE) .......... 62 Description .............................................................. 62 Diagnosis Procedure .............................................. 62

AMBIENT SENSOR ........................................... 64 Description .............................................................. 64 Component Function Check ................................. 64 Diagnosis Procedure .............................................. 64 Component Inspection ............................................ 65

IN-VEHICLE SENSOR ....................................... 67 Description .............................................................. 67 Component Function Check ................................. 67 Diagnosis Procedure .............................................. 68 Component Inspection ............................................ 69

SUNLOAD SENSOR ......................................... 70 Description .............................................................. 70 Component Function Check ................................. 70 Diagnosis Procedure .............................................. 70 Component Inspection ............................................ 71

INTAKE SENSOR .............................................. 73 Description .............................................................. 73 Component Function Check ................................. 73 Diagnosis Procedure .............................................. 73 Component Inspection ............................................ 74

ECU DIAGNOSIS INFORMATION .............. 76 ECM ................................................................... 76 Reference Value ..................................................... 76

Reference Value ..................................................... 92 Wiring Diagram - AIR CONDITIONER CONTROL SYSTEM - ............................................................... 94 Fail-safe ................................................................ 100

SYMPTOM DIAGNOSIS ........................... 102 AIR CONDITIONER CONTROL ....................... 102 Diagnosis Chart By Symptom ............................... 102

INSUFFICIENT COOLING ................................ 103

INSUFFICIENT HEATING ................................ 105 Description ............................................................ 105 Inspection procedure ............................................ 105

NOISE ............................................................... 107 Description ............................................................ 107 Inspection procedure ............................................ 107

SELF-DIAGNOSIS CANNOT BE PERFORMED ........................................................... 109 Description ............................................................ 109 Inspection procedure ............................................ 109

MEMORY FUNCTION DOES NOT OPERATE.. 110 Description ............................................................ 110 Inspection procedure ............................................ 110

PRECAUTION ........................................... 111 PRECAUTIONS ................................................ 111 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ............................................................... 111 Precaution Necessary for Steering Wheel Rotation after Battery Disconnect ................................. 111 Precaution for Battery Service .............................. 112

REMOVAL AND INSTALLATION ............. 113 PRESET SWITCH ............................................. 113 Exploded View ...................................................... 113 Removal and Installation ....................................... 113

UNIFIED METER AND A/C AMP. .................... 114 Exploded View ...................................................... 114 Removal and Installation ....................................... 114

AMBIENT SENSOR .......................................... 115 Exploded View ...................................................... 115 Removal and Installation ....................................... 115

IN-VEHICLE SENSOR ...................................... 116 Exploded View ...................................................... 116 Removal and Installation ....................................... 116

SUNLOAD SENSOR ........................................ 117 Exploded View ...................................................... 117


HAC-2

2009 G37 Coupe

Removal and Installation ....................................... 117

INTAKE SENSOR ............................................ 118 Exploded View ...................................................... 118 Removal and Installation ....................................... 118

REFRIGERANT PRESSURE SENSOR ........... 119 Exploded View ...................................................... 119 Removal and Installation ....................................... 119

MODE DOOR MOTOR ............................................. 120 MODE DOOR MOTOR : Removal and Installation.. 120

A

AIR MIX DOOR MOTOR .......................................... 120 AIR MIX DOOR MOTOR : Removal and Installation ......................................................................... 121

B

INTAKE DOOR MOTOR .......................................... 121 INTAKE DOOR MOTOR : Removal and Installation ......................................................................... 121

C

DOOR MOTOR ................................................. 120 Exploded View ...................................................... 120

D

E

F

G

H

HAC

J

K

L

M

N

O

P


HAC-3

2009 G37 Coupe

DIAGNOSIS AND REPAIR WORKFLOW [AUTOMATIC AIR CONDITIONER]

< BASIC INSPECTION >

BASIC INSPECTION DIAGNOSIS AND REPAIR WORKFLOW Work Flow

INFOID:0000000004536434

DETAILED FLOW

1.LISTEN TO CUSTOMER COMPLAINT Listen to customer complaint. (Get detailed information about the conditions and environment when the symptom occurs.) >> GO TO 2.

2.VERIFY THE SYMPTOM WITH OPERATIONAL CHECK Verify the symptom with operational check. Refer to HAC-5, "Description & Inspection". >> GO TO 3.

3.GO TO APPROPRIATE TROUBLE DIAGNOSIS Go to appropriate trouble diagnosis. Refer to HAC-102, "Diagnosis Chart By Symptom". >> GO TO 4.

4.REPAIR OR REPLACE Repair or replace the specific parts. >> GO TO 5.

5.FINAL CHECK Final check. Is the inspection result normal? YES >> INSPECTION END NO >> GO TO 3.


HAC-4

2009 G37 Coupe

INSPECTION AND ADJUSTMENT [AUTOMATIC AIR CONDITIONER]

< BASIC INSPECTION >

INSPECTION AND ADJUSTMENT

A

Description & Inspection

INFOID:0000000004536435

DESCRIPTION

B

The purpose of the operational check is to check that the individual system operates normally. Conditions

: Engine running at normal operating temperature

C

INSPECTION PROCEDURE

1.CHECK MEMORY FUNCTION

D

1. Start the engine. 2. Turn temperature control dial (driver side) clockwise until 32.0°C (90°F) is displayed. 3. Press the OFF switch. 4. Turn the ignition switch OFF. 5. Turn the ignition switch ON. 6. Press the AUTO switch. 7. Check that the temperature setting before turning the ignition switch OFF is stored. Is the inspection result normal? YES >> GO TO 2 NO >> Memory function malfunction: HAC-110, "Inspection procedure".

E

F

G

2.CHECK BLOWER MOTOR SPEED 1. 2.

H Start the engine. *1 *2 Press fan (UP: +) switch (turn fan control dial clockwise ). Check that the fan speed is changed. Check the operation for all fan speeds. NOTE: HAC *1: With left and right ventilation temperature separately system. *2: Without left and right ventilation temperature separately system. 3. Set the fan speed to max speed. J Is the inspection result normal? YES >> GO TO 3 NO >> Blower motor system malfunction: HAC-57, "Diagnosis Procedure". K CHECK DISCHARGE AIR

3. 1. 2. 3.

Press the MODE switch and the DEF switch. Each position indicator should change shape. Confirm that discharge air comes out according to the air distribution table as follows:

L

Without left and right ventilation temperature separately control system

M

Discharge air flow Air outlet/distribution Mode position indication


FOOT

VENT

DEF

Front

Rear

100%

—

—

—

53%

29%

18%

—

11%

39%

24%

26%

9%

33%

21%

37%

16%

—

—

84%

HAC-5

2009 G37 Coupe

N

O

P


< BASIC INSPECTION > With left and right ventilation temperature separately control system


Condition

DUAL switch: OFF

VENT

FOOT

DEF

Front

Rear

100%

—

—

—

53%

29%

18%

—

11%

39%

24%

26%

9%

33%

21%

37%

16%

—

—

84%

NOTE: Confirm that the compressor clutch is engaged (sound or visual inspection) and the intake door position is at FRE when D/F or DEF is selected. Is the inspection result normal? YES >> GO TO 4 NO >> Mode door system malfunction: HAC-48, "Diagnosis Procedure".

4.CHECK INTAKE AIR 1. Press intake switch. REC indicator turns ON. 2. Press intake switch again. FRE indicator turns ON. 3. Listen for intake door position change. (Slight change of blower sound can be heard.) NOTE: Confirm that the compressor clutch is engaged (sound or visual inspection) and the intake door position is at FRE when D/F or DEF is selected. Is the inspection result normal? YES >> GO TO 5 NO >> Intake door system malfunction: HAC-54, "Diagnosis Procedure".

5.CHECK A/C SWITCH 1. 2.

Press the A/C switch. A/C switch indicator turns ON. Confirm that the compressor clutch engages (sound or visual inspection). Is the inspection result normal? YES >> GO TO 6 NO >> Magnet clutch system malfunction: HAC-60, "Diagnosis Procedure".

6.CHECK WITH TEMPERATURE SETTING LOWERED 1. Turn temperature control dial (driver side) counterclockwise until 18°C (64°F) is displayed. 2. Check that the cool air blows from the outlets. Is the inspection result normal? YES >> GO TO 7 NO >> Insufficient cooling: HAC-103, "Inspection procedure".

7.CHECK WITH TEMPERATURE SETTING RAISED 1. Turn temperature control dial (driver side) clockwise until 32°C (90°F) is displayed. 2. Check that the warm air blows from the outlets. Is the inspection result normal? YES-1 >> With left and right ventilation temperature separately system. GO TO 8 YES-2 >> Without left and right ventilation temperature separately system. GO TO 9 NO >> Insufficient heating: HAC-105, "Inspection procedure".

8.CHECK LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM FUNCTION 1. Press the DUAL switch, and then check that “DUAL” is shown on the display. Revision: 2009 October

HAC-6

2009 G37 Coupe

INSPECTION AND ADJUSTMENT [AUTOMATIC AIR CONDITIONER] < BASIC INSPECTION > 2. Operate temperature control dial (driver side). Check that the discharge air temperature (driver side) changes. 3. Operate the temperature control dial (passenger side). Check that the discharge air temperature (passenger side) changes. 4. Press the DUAL switch, and then check that the temperature setting (LH/RH) is unified to the driver side temperature setting. Is the inspection result normal? YES >> GO TO 9. NO >> Refer to HAC-102, "Diagnosis Chart By Symptom" and perform the appropriate diagnosis.

A

B

C

9.CHECK AUTO MODE Press the AUTO switch, and then check that “AUTO” is shown on the display. Check that the discharge air and fan speed depend on ambient temperature, in-vehicle temperature and temperature setting. Is the inspection result normal? YES >> INSPECTION END NO >> Refer to HAC-102, "Diagnosis Chart By Symptom" and perform the appropriate diagnosis.

D

Temperature Setting Trimmer

F

1. 2.

INFOID:0000000004536436

DESCRIPTION The trimmer compensates for differences in range of ±3°C (±6°F) between temperature setting (displayed digitally) and temperature felt by customer.

E

G

Operating procedures for this trimmer are as per the following:

1. 2.

3. 4.

H Begin self-diagnosis STEP-5 mode. Refer to HAC-40, "Diagnosis Description". Press fan (UP: +) switch*1 (turn fan control dial clockwise*2) to set system in auxiliary mode. NOTE: HAC *1: With left and right ventilation temperature separately system. *2: Without left and right ventilation temperature separately system. Display shows “61” in auxiliary mechanism. It takes approximately 3 seconds to enable setting operation. Turn temperature control dial (driver side) as desired. Temperature will change at a rate of 0.5°C (1.0°F) J each time a dial is turned. CAUTION: A decimal point is not indicated on the display. K

L

M

N

O

P


HAC-7

2009 G37 Coupe

INSPECTION AND ADJUSTMENT [AUTOMATIC AIR CONDITIONER] < BASIC INSPECTION > Without left and right ventilation temperrature separately system

JSIIA1056GB


HAC-8

2009 G37 Coupe

INSPECTION AND ADJUSTMENT [AUTOMATIC AIR CONDITIONER] < BASIC INSPECTION > With left and right ventilation temperature separately system A

B

C

D

E

F

G

H

HAC

J

K

L JSIIA1057GB

NOTE: When battery cable is disconnected or battery voltage is below 10 V, trimmer operation is canceled. Temperature set becomes that of initial condition, i.e. 0°C (0°F).

Foot Position Setting Trimmer

INFOID:0000000004536437

M

N

DESCRIPTION Wind distribution ratio in FOOT mode can be set.

O

Operating procedures for this trimmer are as per the following:

1. 2.

Begin self-diagnosis STEP-5 mode. Refer to HAC-40, "Diagnosis Description". Press fan (UP: +) switch*1 (turn fancontrol dial clockwise*2) to set system in auxiliary mode. NOTE: *1: With left and right ventilation temperature separately system. *2: Without left and right ventilation temperature separately system.


HAC-9

2009 G37 Coupe

P


< BASIC INSPECTION > 3. Press mode switch as desired.

JSIIA0864GB

NOTE: When battery cable is disconnected or battery voltage is below 10 V, trimmer operation is canceled. Air distribution ratio set becomes that of initial condition.

Inlet Port Memory Function

INFOID:0000000004536438

DESCRIPTION When ignition switch is turned from OFF to ON, inlet port can be set to AUTO or manual. Operating procedures for this trimmer are as per the following:

1. 2.

3.

Begin self-diagnosis STEP-5 mode. Refer to HAC-40, "Diagnosis Description". Press fan (UP: +) switch*1 (turn fan control dial clockwise*2) to set system in auxiliary mode. NOTE: *1: With left and right ventilation temperature separately system. *2: Without left and right ventilation temperature separately system. Press intake switch as desired.

FRE indicator

Setting status

REC indicator

FRE

REC

OFF

ON

AUTO control (Initial setting)

Manual REC status is memorized. (Initial setting)

ON

ON

Manual FRE status is memorized.

Manual REC status is memorized.

ON

OFF

Manual FRE status is memorized.

AUTO control

OFF

OFF

AUTO control

AUTO control

Setting changeover method

Intake switch: ON

NOTE: When battery cable is disconnected or battery voltage is below 10 V, memory function is canceled. Memory function set becomes that of initial condition.


HAC-10

2009 G37 Coupe

COMPRESSOR CONTROL FUNCTION [AUTOMATIC AIR CONDITIONER]

< SYSTEM DESCRIPTION >

SYSTEM DESCRIPTION

A

COMPRESSOR CONTROL FUNCTION Description

INFOID:0000000004536439

B

PRINCIPLE OF OPERATION Compressor is not activated.

C

Functional Circuit Diagram D

E

F

G

H

HAC

J

K

JSIIA0918GB

CAN(1) : A/C switch signal : Blower fan motor switch signal

CAN(2) : A/C compressor request signal

L

Functional Initial Inspection Chart ×: Applicable

Control unit Unified meter and A/C amp. ECM

IPDM E/R

Location

Diagnosis Item

A

B

C

D

×

–

–

–

Self-diagnosis (CAN system diagnosis)

–

–

×

–

Data monitor

×

×

×

–

Self-diagnosis (CAN system diagnosis)

–

–

–

×

Data monitor

–

–

×

–

–

–

–

×

Self-diagnosis function

“ENGINE”

“IPDM E/R” Auto active test

Fail-safe

INFOID:0000000004536440

FAIL-SAFE FUNCTION • If a communication error exists between the unified meter and A/C amp., and the AV control unit and preset switch for 30 seconds or longer, air conditioner is controlled under the following conditions: Revision: 2009 October

HAC-11

2009 G37 Coupe

M

N

O

P


< SYSTEM DESCRIPTION > Compressor Air outlet Air inlet Fan speed Set temperature

: ON : AUTO : FRE (Fresh) : AUTO : Setting before communication error occurs

Component Part Location

INFOID:0000000004536441

ENGINE COMPARTMENT


HAC-12

2009 G37 Coupe



A

B

C

D

E

F

G

H

HAC

J

K

L

M

N

O JSIIA0746ZZ

P 1.


4.

Compressor (ECV)

2.

Ambient sensor

3.

Compressor (magnet clutch)

PASSENGER COMPARTMENT


HAC-13

2009 G37 Coupe



JSIIA1415ZZ

1.

Intake door motor

2.

Mode door motor

3.

Air mix door motor (passenger side)

4.

Air mix door motor (driver side)*

5.

Sunload sensor

6.

In-vehicle sensor

7.

Unified meter and A/C amp.

8.

Intake sensor

9.

Blower motor

*: With left and right ventilation temperature separately control system.


HAC-14

2009 G37 Coupe




INFOID:0000000004536442

A Component

HAC-50, "WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Description"

Air mix door motor*1 Air mix door motor (driver side)*2 Air mix door motor (passenger

Reference

side)*2

HAC-51, "WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Description"

Ambient sensor

HAC-64, "Description"

Blower motor


Compressor


Intake door motor


Intake sensor


In-vehicle sensor


Mode door motor



EC-520, "Description"

Sunload sensor




B

C

D

E

F

G

*1: Without left and right ventilation temperature separately control system. *2: With left and right ventilation temperature separately control system.

H

HAC

J

K

L

M

N

O

P


HAC-15

2009 G37 Coupe

AUTOMATIC AIR CONDITIONER SYSTEM [AUTOMATIC AIR CONDITIONER]


AUTOMATIC AIR CONDITIONER SYSTEM System Diagram

INFOID:0000000004536443

CONTROL SYSTEM The control system consists of input sensors, switches, unified meter and A/C amp. (microcomputer) and outputs. The relationship of these components is as shown in the figure below:


JPIIA1458GB


HAC-16

2009 G37 Coupe

AUTOMATIC AIR CONDITIONER SYSTEM [AUTOMATIC AIR CONDITIONER] < SYSTEM DESCRIPTION > With left and right ventilation temperature separately control system A

B

C

D

E

F

G

H

HAC JPIIA1457GB

System Description

INFOID:0000000004536444

J

CONTROL OPERATION Display Screen The operation status of the system is displayed on the screen.

K

Without left and right ventilation temperature separately control system L

M

N JSIIA1047GB

O

With left and right ventilation temperature separately control system

P

JSIIA1049GB


HAC-17

2009 G37 Coupe


< SYSTEM DESCRIPTION > Preset Switch


JSIIA0767GB


JSIIA1070GB

MODE Switch The air discharge outlets is controlled with this switch. Temperature Control Dial (Potentio Temperature Control) (Driver Side) The set temperature is increased or decreased with this dial. Temperature Control Dial (Potentio Temperature Control) (Passenger Side)*1 • The set temperature is increased or decreased with this dial. • When the temperature control dial is turned, DUAL switch indicator turns ON. AUTO Switch • The compressor, intake doors, air mix doors, mode doors and fan speed are automatically controlled so that the in-vehicle temperature will reach, and be maintained at the set temperature selected by the operator. • When pressing AUTO switch, air inlet, air outlet, fan speed, and discharge air temperature are automatically controlled. Defroster (DEF) Switch Mode doors are set to the defrost position with this switch. Also, intake doors are set to the outside air position, and compressor turns ON. A/C Switch Compressor is ON or OFF with this switch.


HAC-18

2009 G37 Coupe

AUTOMATIC AIR CONDITIONER SYSTEM [AUTOMATIC AIR CONDITIONER] < SYSTEM DESCRIPTION > (Pressing the A/C switch when the A/C switch is ON turns OFF the A/C switch and compressor.) FAN Switches*1 The fan speed is manually controlled with this switch. Seven speeds are available for manual control (as shown on the display screen). FAN Control Dial*2 The fan speed is manually controlled with this switch. Seven speeds are available for manual control (as shown on the display screen).

A

B

C

OFF Switch Compressor and blower are OFF, air inlet is set to FRE, and mode position is set to foot position. D

Rear Window Defogger Switch When indicator is ON, rear window is defogged. Intake Switch • When intake switch is ON, FRE indicator turns ON, and air inlet is fixed to FRE. • When intake switch is pressed again, REC indicator turns ON, and air inlet is fixed to REC. • When intake switch is pressed for approximately 1.5 seconds or longer, FRE and REC indicators blink twice. Then, automatic control mode is entered. Inlet status is displayed by indicator even during automatic controlled. • When FRE indicator is turned ON, shifting mode position to D/F or DEF, or when compressor is turned from ON to OFF, intake switch is automatically turned OFF (fixed to FRE mode). REC mode can be re-entered by pressing intake switch again, and then compressor is turned ON. (Except D/F or DEF position)

E

F

G

DUAL Switch*1 • When the DUAL switch indicator is ON, the driver side and passenger side, temperature can each be set H independently. • When the DUAL switch indicator is OFF, the driver side outlet and setting temperature is applied to both sides. HAC NOTE: *1: With left and right ventilation temperature separately control system. *2: Without left and right ventilation temperature separately control system. J

K

L

M

N

O

P


HAC-19

2009 G37 Coupe


< SYSTEM DESCRIPTION > DISCHARGE AIR FLOW

JSIIA0661GB

SWITCHES AND THEIR CONTROL FUNCTION


HAC-20

2009 G37 Coupe


< SYSTEM DESCRIPTION > Without Left and right Ventilation Temperature Separately Control System

A

B

C

D

E

F

G

H JSIIA0662GB

HAC

J

K

L

M

JSIIA1104GB

N

O

P


HAC-21

2009 G37 Coupe


< SYSTEM DESCRIPTION > With Left and right Ventilation Temperature Separately Control System

JSIIA0664GB

JSIIA1105GB

AIR CONDITIONER LAN CONTROL SYSTEM The LAN (Local Area Network) system consists of unified meter and A/C amp., mode door motor, air mix door motors and intake door motor.


HAC-22

2009 G37 Coupe

AUTOMATIC AIR CONDITIONER SYSTEM < SYSTEM DESCRIPTION > A configuration of these components is as shown in the figure below.

[AUTOMATIC AIR CONDITIONER] A

B

C JSIIA0769GB

D

SYSTEM CONSTRUCTION A small network is constructed between the unified meter and A/C amp., mode door motor, air mix door motors and intake door motor. The unified meter and A/C amp. and motors are connected by data transmission lines and motor power supply lines. The LAN network is built through the ground circuits of each door motor. Addresses, motor opening angle signals, motor stop signals and error checking messages are all transmitted through the data transmission lines connecting the unified meter and A/C amp. and each door motor. The following functions are contained in LCUs built into the mode door motor, the air mix door motors and the intake door motor. • Address • Motor opening angle signals • Data transmission • Motor stop and drive decision • Opening angle sensor (PBR function) • Comparison • Decision (Unified meter and A/C amp. indicated value and motor opening angle comparison)


E

F

G

H

HAC

J

K

JSIIA0116GB

L

With left and right ventilation temperature separately control system M

N

O RJIA1747E

Operation The unified meter and A/C amp. receives data from each of the sensors. The unified meter and A/C amp. sends mode door, air mix door and intake door opening angle data to the mode door motor LCU, air mix door motor LCUs and intake door motor LCU. The mode door motor, air mix door motors and intake door motor read their respective signals according to the address signal. Opening angle indication signals received from the unified meter and A/C amp. and each of the motor position sensors is compared by the LCUs in each door motor with the existing decision and open-


HAC-23

2009 G37 Coupe

P

AUTOMATIC AIR CONDITIONER SYSTEM [AUTOMATIC AIR CONDITIONER] < SYSTEM DESCRIPTION > ing angles. Subsequently, HOT/COLD, DEF/VENT and FRE/REC operation is selected. The new selection data is returned to the unified meter and A/C amp. Without left and right ventilation temperature separately control system

JSIIA0117GB


RJIA1748E

Transmission Data and Transmission Order Unified meter and A/C amp. data is transmitted consecutively to each of the doors motor following the form as shown in the figure below. START:

• Initial compulsory signal is sent to each of the door motors. ADDRESS:

• Data sent from the unified meter and A/C amp. are selected according to data-based decisions made by the mode door motor, air mix door motors and intake door motor. • If the addresses are identical, the opening angle data and error check signals are received by the door motor LCUs. The LCUs then make the appropriate error decision. If the opening angle data have no error, door control begins. • If an error exists, the received data are rejected and corrected data received. Finally, door control is based upon the corrected opening angle data. OPENING ANGLE:

• Data that shows the indicated door opening angle of each door motor. ERROR CHECK:

• In this procedure, transmitted and received data is checked for errors. Error data are then compiled. The error check prevents corrupted data from being used by the mode door motor, the air mix door motors and the intake door motor. Error data can be related to the following symptoms. - Malfunction of electrical frequency - Poor electrical connections - Signal leakage from transmission lines - Signal level fluctuation STOP SIGNAL:

• At the end of each transmission, a stop operation, in-operation, or internal malfunction message is delivered to the unified meter and A/C amp. This completes one data transmission and control cycle.


HAC-24

2009 G37 Coupe

AUTOMATIC AIR CONDITIONER SYSTEM [AUTOMATIC AIR CONDITIONER] < SYSTEM DESCRIPTION > Without left and right ventilation temperature separately control system A

B

C

D

E

JSIIA0118GB

F

With left and right ventilation temperature separately control system G

H

HAC

J

K

RJIA1749E

Component Part Location

L

INFOID:0000000004578905

M

ENGINE COMPARTMENT

N

O

P


HAC-25

2009 G37 Coupe



JSIIA0746ZZ

1.


4.

Compressor (ECV)

2.

Ambient sensor

3.

Compressor (magnet clutch)

PASSENGER COMPARTMENT


HAC-26

2009 G37 Coupe



A

B

C

D

E

F

G

H

HAC

J

K

L

M

N

O JSIIA1415ZZ

P 1.

Intake door motor

2.

Mode door motor

3.

Air mix door motor (passenger side)

4.


5.

Sunload sensor

6.

In-vehicle sensor

7.


8.

Intake sensor

9.

Blower motor

*: With left and right ventilation temperature separately control system.


HAC-27

2009 G37 Coupe




INFOID:0000000004578906

Component

HAC-50, "WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Description"

Air mix door motor*1 Air mix door motor (driver side)*2 Air mix door motor (passenger

Reference

side)*2

HAC-51, "WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Description"

Ambient sensor


Blower motor


Compressor


Intake door motor


Intake sensor


In-vehicle sensor


Mode door motor



EC-520, "Description"

Sunload sensor






HAC-28

2009 G37 Coupe

CAN COMMUNICATION SYSTEM [AUTOMATIC AIR CONDITIONER]


CAN COMMUNICATION SYSTEM System Description

A INFOID:0000000004536447

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. For details, refer to LAN-27, "CAN System Specification Chart".

B

C

D

E

F

G

H

HAC

J

K

L

M

N

O

P


HAC-29

2009 G37 Coupe

MODE DOOR CONTROL SYSTEM [AUTOMATIC AIR CONDITIONER]


MODE DOOR CONTROL SYSTEM System Diagram

INFOID:0000000004536448

JPIIA1473GB

System Description

INFOID:0000000004536449

The mode door is automatically controlled by the temperature setting, ambient temperature, in-vehicle temperature, intake temperature and amount of sunload.

SYSTEM OPERATION • The unified meter and A/C amp. receives data from each of the sensors. • The unified meter and A/C amp. sends air mix door, mode door and intake door opening angle data to the air mix door motor LCUs, mode door motor LCU and intake door motor LCU. • The air mix door motors, mode door motor and intake door motor read their respective signals according to the address signal. Opening angle indication signals received from the unified meter and A/C amp. and each of the motor position sensors are compared by the LCUs in each door motor with the existing decision and opening angles. • Subsequently, HOT/COLD, DEF/VENT and FRE/REC operation is selected. The new selection data are returned to the unified meter and A/C amp. Door Motor Circuit


JSIIA0775GB


HAC-30

2009 G37 Coupe

MODE DOOR CONTROL SYSTEM [AUTOMATIC AIR CONDITIONER] < SYSTEM DESCRIPTION > With left and right ventilation temperature separately control system A

B

C

D

E

F

JSIIA0880GB

Mode Door Control Specification Mode position can be selected manually by pressing MODE switch or DEF switch of the preset switch. This enables to fix a mode position. Automatic control by unified meter and A/C amp. Pressing AUTO switch allows automatic control by unified meter and A/C amp. During the automatic control of mode position, a mode door position (VENT, B/L, FOOT, or D/F) is selected based on a target air mix door opening angle and sunload depending on a temperature calculated by unified meter and A/C amp. In addition, D/F is selected to prevent windshield fogging only when ambient temperature is extremely low with mode position FOOT.

G

H

HAC RJIA1778E

J

K

L

M

N

O

P


HAC-31

2009 G37 Coupe

AIR MIX DOOR CONTROL SYSTEM [AUTOMATIC AIR CONDITIONER]


AIR MIX DOOR CONTROL SYSTEM System Diagram

INFOID:0000000004536450

WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM

JPIIA1474GB

WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTORL SYSTEM

JPIIA1478GB

System Description

INFOID:0000000004536451

The air mix doors are automatically controlled so that in-vehicle temperature is maintained at a predetermined value by the temperature setting, ambient temperature, in-vehicle temperature and amount of sunload.

SYSTEM OPERATION • The unified meter and A/C amp. receives data from each of the sensors. The unified meter and A/C amp. sends air mix doors, mode door and intake door opening angle data to the air mix door motor LCUs, mode door motor LCU and intake door motor LCU. • The air mix door motors, mode door motor and intake door motor read their respective signals according to the address signal. Opening angle indication signals received from the unified meter and A/C amp. and each of the motor position sensors are compared by the LCUs in each door motor with the existing decision and opening angles. Subsequently, HOT/COLD, DEF/VENT and FRE/REC operation is selected. The new selection data are returned to the unified meter and A/C amp. Door Motor Circuit


HAC-32

2009 G37 Coupe

AIR MIX DOOR CONTROL SYSTEM [AUTOMATIC AIR CONDITIONER] < SYSTEM DESCRIPTION > Without left and right ventilation temperature separately control system A

B

C

D

E

F

JSIIA0775GB

With left and right ventilation temperature separately control system G

H

HAC

J

K

L

JSIIA0880GB

Air Mix Door Control Specification When ignition switch is ON, unified meter and A/C amp. continuously and automatically controls temperatures regardless of air conditioner operational condition. When setting a target temperature with temperature control dial, unified meter and A/C amp. corrects the set temperature and decides a target air mix door opening angle. Unified meter and A/C amp. controls air mix door according to the target air mix door opening angle and current air mix door opening angle for keeping an optimum air mix door opening angle. When a temperature is set at 18°C (64°F), air mix door is fixed at full cold, and when a temperature is set at 32°C (90°F), it is set at full hot.

M

N

O RJIA1782E

P


HAC-33

2009 G37 Coupe

INTAKE DOOR CONTROL SYSTEM [AUTOMATIC AIR CONDITIONER]


INTAKE DOOR CONTROL SYSTEM System Diagram

INFOID:0000000004536452

JPIIA1475GB

System Description

INFOID:0000000004536453

The intake door is automatically controlled by the temperature setting, ambient temperature, in-vehicle temperature, intake temperature, amount of sunload and ON/OFF operation of the compressor.

SYSTEM OPERATION The intake door control judges intake door position based on the ambient temperature, the intake air temperature and the in-vehicle temperature. When shifting mode position D/F, when the DEF or OFF switches are pressed, or when A/C switch is OFF, the unified meter and A/C amp. sets the intake door at the FRE position. Door Motor Circuit


JSIIA0775GB


HAC-34

2009 G37 Coupe

INTAKE DOOR CONTROL SYSTEM [AUTOMATIC AIR CONDITIONER] < SYSTEM DESCRIPTION > With left and right ventilation temperature separately control system A

B

C

D

E

F

JSIIA0880GB

Intake Door Control Specification • Intake door position is basically fixed at FRE when FRE indicator of intake switch is ON or DEF switch is ON. • Intake door position is basically fixed at REC when REC indicator of intake switch is ON. • Intake door automatic control selects FRE, 20 - 80% FRE, or REC depending on a target air mix door opening angle, based on invehicle temperature, ambient temperature, and sunload.

G

H

HAC RJIA4067E

J

K

L

M

N

O

P


HAC-35

2009 G37 Coupe

BLOWER MOTOR CONTROL SYSTEM [AUTOMATIC AIR CONDITIONER]


BLOWER MOTOR CONTROL SYSTEM System Diagram

INFOID:0000000004536454

JPIIA1477GB

System Description

INFOID:0000000004536455

Fan speed is automatically controlled by the temperature setting, ambient temperature, in-vehicle temperature, intake temperature, amount of sunload and air mix door position. With pressing AUTO switch, the blower motor starts to gradually increase air flow volume. When engine coolant temperature is low, the blower motor operation is delayed to prevent cool air from flowing.

SYSTEM OPERATION Automatic Mode In the automatic mode, the blower motor speed is calculated by the unified meter and A/C amp. based on the input from the PBR, in-vehicle sensor, sunload sensor, intake sensor and ambient sensor. When the air flow is increased, the duty ratio of the blower motor control signal is changed at 4%/sec. to prevent a sudden increase in air flow. In addition to manual air flow control and the usual automatic air flow control, starting air flow control, low water temperature starting control and high passenger compartment temperature starting control are available. Starting Fan Speed Control Start up from COLD SOAK Condition (Automatic mode) In a cold start up condition where the engine coolant temperature is below 56°C (133°F), the blower does not operate for a short period of time (up to 150 seconds). The exact start delay time varies depending on the ambient and engine coolant temperature. In the most extreme case (very low ambient) the blower start delay is 150 seconds as described above. After this delay, the blower will operate at low speed until the engine coolant temperature rises above 56°C (133°F), and then the fan speed increases to the objective speed. Start up from usual or HOT SOAK Condition (Automatic mode) The blower will begin operation momentarily after the AUTO switch is pressed. The fan speed rises gradually to the objective speed over a time period of 3 seconds or less (actual time depends on the objective fan speed). Fan speed Compensation Sunload When the in-vehicle temperature and the set temperature are very close, the blower operates at low speed. The low speed varies depending on the sunload. During conditions of low or no sunload, the fan speed is at duty ratio 25%. During high sunload conditions, the unified meter and A/C amp. raise the fan speed (duty ratio 49%).


HAC-36

2009 G37 Coupe

BLOWER MOTOR CONTROL SYSTEM [AUTOMATIC AIR CONDITIONER]

< SYSTEM DESCRIPTION > Fan Speed Control Specification

A

B

C JPIIA0635GB

D

E

F

G

H

HAC

J

K

L

M

N

O

P


HAC-37

2009 G37 Coupe

MAGNET CLUTCH CONTROL SYSTEM [AUTOMATIC AIR CONDITIONER]


MAGNET CLUTCH CONTROL SYSTEM System Diagram

INFOID:0000000004536456

JPIIA1476GB

System Description

INFOID:0000000004536457

Unified meter and A/C amp. controls compressor operation by ambient temperature, intake air temperature and signal from ECM.

SYSTEM OPERATION When A/C switch, AUTO switch, DEF switch is pressed or when shifting mode position D/F, unified meter and A/C amp. transmits A/C switch signal and blower fan motor switch signal to ECM, via CAN communication. ECM judges whether compressor can be turned ON, based on each sensor status (refrigerant-pressure sensor signal, throttle angle, etc.). If it judges compressor can be turned ON, it sends A/C compressor request signal to IPDM E/R, via CAN communication. Upon receipt of A/C compressor request signal from ECM, IPDM E/R turns A/C relay ON to operate compressor. When sending A/C compressor request signal to IPDM E/R via CAN communication line, ECM simultaneously sends A/C compressor feedback signal to unified meter and A/C amp. via CAN communication line. ECM sends A/C compressor feedback signal to unified meter and A/C amp., then, uses input A/C compressor feedback signal to control air inlet. Compressor Protection Control ECM makes the A/C relay go OFF and stops the compressor when pressure on the high-pressure side detected by refrigerant pressure sensor is over approximately 3,119 kPa (31.8 kg/cm2, 452 psi), or below approximately 118 kPa (1.2 kg/cm2, 17 psi). Low Temperature Protection Control Unified meter and A/C amp. turns compressor ON or OFF as judged by a signal detected by ambient sensor and intake sensor. When ambient temperature is higher than −2°C (28°F), the compressor turns ON. The compressor turns OFF when ambient temperature is lower than −5°C (23°F).

RHA094GB


HAC-38

2009 G37 Coupe

MAGNET CLUTCH CONTROL SYSTEM < SYSTEM DESCRIPTION > When intake air temperature is higher than 1°C (34°F), the compressor turns ON. The compressor turns OFF when intake air temperature is lower than −5°C (23°F).

[AUTOMATIC AIR CONDITIONER] A

B

C SJIA0267E

D

E

F

G

H

HAC

J

K

L

M

N

O

P


HAC-39

2009 G37 Coupe

DIAGNOSIS SYSTEM (UNIFIED METER & A/C AMP.) [AUTOMATIC AIR CONDITIONER]


DIAGNOSIS SYSTEM (UNIFIED METER & A/C AMP.) Diagnosis Description

INFOID:0000000004536458

SELF-DIAGNOSIS SYSTEM The self-diagnosis system is built into the unified meter and A/C amp. to quickly locate the cause of malfunctions. The self-diagnosis system diagnoses sensors, door motors, blower motor, etc. by system line. Refer to applicable sections (items) for details.

OPERATION PROCEDURE 1. 2. 3. 4.

Start the engine (turn ignition switch ON). NOTE: When checking the procedure except step-4, it is possible to perform in the state of ignition switch ON. Press the OFF switch at 5 seconds or more (within 10 seconds after ignition switch is turned ON). Unified meter and A/C amp. self diagnosis mode starts. “Test item” are changed by the following operation. Test item

Operation

STEP-1

Indicator and display screen are checked.

Former STEP-1 does not exist in this self-diagnosis function.

STEP-2

Input signals from each sensor are checked.

Turn temperature control dial (driver side) clockwise

⇒

STEP-3


⇒

STEP-4

Turn temperature control dial (driver side) counterclockwise

⇒

STEP-2


⇒

STEP-5 (1)


⇒

STEP-3


⇒

STEP-4

Press intake switch

⇒

STEP-5 (2)

⇒

AUXILIARY MECHANISM


⇒

STEP-4

Press intake switch

⇒

STEP-5 (1)

⇒

AUXILIARY MECHANISM

⇒

STEP-5 (1)

STEP-3

STEP-4*1

STEP-5 (1)

Mode and intake door motor positions are checked.

Motors are checked.

Temperature detected by each sensor is checked.

Press fan (UP:+) switch

*2

Turn fan control dial clockwise*3

STEP-5 (2)

Communication error.

Press fan (UP:+) switch

*2

Turn fan control dial clockwise*3 Temperature setting trimmer. AUXILIARY MECHANISM

Foot position setting trimmer.

Press fan (DOWN:−) switch*2 Turn fan control dial counterclockwise*3

Inlet port memory function. *1: Engine must be running for compressor to operate. *2: With left and right ventilation temperature separately control system. *3: Without left and right ventilation temperature separately control system.

5.

Self-diagnosis mode is canceled by either pressing AUTO switch or turning the ignition switch OFF.

CONFORMATION METHOD

1.SET IN SELF-DIAGNOSIS MODE 1. 2.

Turn ignition switch ON. Set in self-diagnosis mode as per the following. Press OFF switch for at least 5 seconds Within 10 seconds after starting engine (ignition switch is turned ON). NOTE:


HAC-40

2009 G37 Coupe

DIAGNOSIS SYSTEM (UNIFIED METER & A/C AMP.) [AUTOMATIC AIR CONDITIONER] < SYSTEM DESCRIPTION > • If battery voltage drops below 12 V during diagnosis STEP-3, door motor speed becomes slower and as a result, the system may generate an error even when operation is normal. Start engine before performing this diagnosis to avoid this. • Former STEP-1 (indicators and display screen are checked) does not exist in this self-diagnosis function. • OFF switch may not be recognized according to the timing of pressing it. Operate OFF switch after the intake switch indicators are turned ON. >> GO TO 2.

2.STEP-2: SENSOR AND DOOR MOTOR CIRCUITS ARE CHECKED FOR OPEN OR SHORT CIRCUIT

A

B

C

D

Does code No. 20 appear on the display? YES >> GO TO 3. NO >> GO TO 11.

E

F SJIA1778E

G

3.STEP-3: MODE DOOR AND INTAKE DOOR POSITIONS ARE CHECKED Turn temperature control dial (driver side) clockwise. Does code No. 30 appear on the display? YES >> GO TO 4. NO >> GO TO 12.

H

HAC

J SJIA1779E

4.STEP-4: OPERATION OF EACH DOOR MOTOR IS CHECKED 1. 2.

K

Turn temperature control dial (driver side) clockwise. Press DEF ( ) switch. Code No. of each door motor test is indicated on the display.

L

>> GO TO 5.

M

N SJIA1780E

5.CHECK MOTORS

O

Refer to the following chart and check discharge air flow, air temperature, blower motor duty ratio and compressor operation. P Code No. Mode door position

41

42

43

44

45

46

VENT

B/L 1

B/L 2

FOOT*

D/F

DEF

Intake door position

REC

REC

20% FRE

FRE

FRE

FRE

Air mix door position

FULL COLD

FULL COLD

FULL HOT

FULL HOT

FULL HOT

FULL HOT

37%

91%

65%

65%

65%

91%

Blower motor duty ratio


HAC-41

2009 G37 Coupe


< SYSTEM DESCRIPTION > Code No. Mode door position Compressor (Magnet clutch) Electronic control valve (ECV) duty ratio *:Mode

41

42

43

44

45

46

VENT

B/L 1

B/L 2

FOOT*

D/F

DEF

ON

ON

OFF

OFF

ON

ON

100%

100%

0%

0%

50%

100%

door position is in a condition of FOOT mode setting trimmer (automatic control).

Checks must be made visually, by listening the sound, or by touching air outlets with hand, etc. for improper operation. Without left and right ventilation temperature separately control system


FOOT

VENT

DEF

Front

Rear

100%

—

—

—

53%

29%

18%

—

11%

39%

24%

26%

9%

33%

21%

37%

16%

—

—

84%



Condition

DUAL switch: OFF

VENT

FOOT

DEF

Front

Rear

100%

—

—

—

53%

29%

18%

—

11%

39%

24%

26%

9%

33%

21%

37%

16%

—

—

84%

Is this inspection result normal? YES >> GO TO 6. NO-1 >> Air outlet does not change. Refer to HAC-48, "Diagnosis Procedure". NO-2 >> Intake door does not change. Refer to HAC-54, "Diagnosis Procedure". NO-3 >> • Discharge air temperature does not change.*1 Refer to HAC-50, "WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure". • Discharge air temperature (driver side) does not change.*2 Refer to HAC-52, "WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure". • Discharge air temperature (passenger side) does not change.*2 Refer to HAC-52, "WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure". NOTE: *1: Without left and right ventilation temperature separately control system. *2: With left and right ventilation temperature separately control system. NO-5 >> Blower motor operation is malfunctioning. Refer to HAC-57, "Diagnosis Procedure". NO-6 >> Magnet clutch does not engage. Refer to HAC-60, "Diagnosis Procedure".

6.STEP-5: TEMPERATURE OF EACH SENSOR IS CHECKED 1.

Turn temperature control dial (driver side) clockwise.


HAC-42

2009 G37 Coupe


< SYSTEM DESCRIPTION > 2. Code No. 51 appears on the display.

A

>> GO TO 7.

7.CHECK AMBIENT SENSOR

B

Press DEF ( ) switch one time. Temperature detected by ambient sensor is indicated on the display. NOTE: Check sensor circuit first if the temperature indicated on the display greatly differs from the actual temperature, and then check sensor. Is this inspection result normal? YES >> GO TO 8. NO >> Go to Ambient Sensor Circuit. Refer to HAC-64, "Diagnosis Procedure".

C

D

E PJIA0151E

8.CHECK IN-VEHICLE SENSOR F

Press DEF ( ) switch for the second time. Temperature detected by in-vehicle sensor is indicated on the display. NOTE: Check sensor circuit first if the temperature indicated on the display greatly differs from the actual temperature, and then check sensor. Is this inspection result normal? YES >> GO TO 9. NO >> Go to In-vehicle Sensor Circuit. Refer to HAC-68, "Diagnosis Procedure".

G

H

HAC PJIA0152E

9.CHECK INTAKE SENSOR J

Press DEF ( ) switch for the third time. Temperature detected by intake sensor is indicated on the display. NOTE: Check sensor circuit first if the temperature indicated on the display greatly differs from the actual temperature, and then check sensor. Is this inspection result normal? YES >> GO TO 10. NO >> Go to Intake Sensor Circuit. Refer to HAC-73, "Diagnosis Procedure".

K

L

PJIA0153E

M

10.CHECK CAN COMMUNICATION ERROR 1. 2.

Press intake switch. CAN communication error between each unit that uses the unified meter and A/C amp. can be detected as self-diagnosis results. (The display of each error will blink twice for 0.5 second intervals if plural errors occur.) Is the inspection result normal? YES >> INSPECTION END NO >> Go to CAN communication (Unified meter and A/C amp. AV control unit). Refer to MWI-41, "Diagnosis Procedure".

N

O

P

JPIIA1360GB

11.CHECK MALFUNCTIONING SENSOR AND DOOR MOTOR Refer to the following chart for malfunctioning code No. (Corresponding code Nos. indicates 1 second each if two or more sensors and door motors malfunction.) Revision: 2009 October

HAC-43

2009 G37 Coupe

DIAGNOSIS SYSTEM (UNIFIED METER & A/C AMP.) [AUTOMATIC AIR CONDITIONER] < SYSTEM DESCRIPTION > (Corresponding code Nos. indicates 0.5 second each if two door motors malfunction.) Code No.

Malfunctioning sensor and door motor (Including circuits)

Reference

21 / −21

Ambient sensor

HAC-64, "Diagnosis Procedure"

22 / −22

In-vehicle sensor


24 / −24

Intake sensor


25 / −25

Sunload sensor *1


Air mix door motor PBR*2

HAC-50, "WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure"

Air mix door motor PBR (driver side)*3

HAC-52, "WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure"

Air mix door motor PBR (passenger side)*3


26 / −26

27 / −27

*1: Perform self-diagnosis STEP-2 under sunshine. *2: Without left and right ventilation temperature separately control system. *3: With left and right ventilation temperature separately control system.

When performing indoors, aim a light (more than 60 W) at sunload sensor, otherwise code No. 25 indicates despite that sunload sensor is functioning normally.

SJIA1781E

>> INSPECTION END

12.CHECK MALFUNCTIONING DOOR MOTOR POSITION SWITCH Mode and/or intake door motor PBR (s) is/are malfunctioning. Code No. *1 *2

Mode or intake door position

31

VENT

32

DEF

37

FRE

38

20% FRE

39

REC

Reference

Mode door motor


Intake door motor


(Corresponding code Nos. indicates 1 second each if two or more mode or intake door motor malfunction.) *1: The following display pattern will appear if mode door motor harness connector is disconnected. 31→32→Return to 31 *2: The following display pattern will appear if intake door motor harness connector is disconnected.


HAC-44

2009 G37 Coupe


< SYSTEM DESCRIPTION > 37→38→39→Return to 37

A

B

C SJIA1782E

D

>> INSPECTION END E

F

G

H

HAC

J

K

L

M

N

O

P


HAC-45

2009 G37 Coupe

POWER SUPPLY AND GROUND CIRCUIT [AUTOMATIC AIR CONDITIONER]

< DTC/CIRCUIT DIAGNOSIS >

DTC/CIRCUIT DIAGNOSIS POWER SUPPLY AND GROUND CIRCUIT UNIFIED METER AND A/C AMP. UNIFIED METER AND A/C AMP. : Diagnosis Procedure

INFOID:0000000004536459

1.CHECK FUSE Check 10A fuses [Nos. 3, 11 and 19, located in the fuse block (J/B)]. NOTE: Refer to PG-94, "Fuse, Connector and Terminal Arrangement". Is the inspection result normal? YES >> GO TO 2. NO >> Check harness for short circuit and replace fuse.

2.CHECK POWER SUPPLY CIRCUIT FOR UNIFIED METER AND A/C AMP. 1. 2.

Disconnect unified meter and A/C amp. connector. Check voltage between unified meter and A/C amp. harness connector and ground. (+)

(−)

Unified meter and A/C amp. Connector

Terminal

M67

53

Voltage Ignition switch position

—

41 Ground

54

OFF

ACC

ON

Approx. 0 V

Battery voltage

Battery voltage

Approx. 0 V

Approx. 0 V

Battery voltage

Battery voltage

Battery voltage

Battery voltage

Is the inspection result normal? YES >> GO TO 3. NO >> Repair harness or connector.

3.CHECK GROUND CIRCUIT FOR UNIFIED METER AND A/C AMP. 1. 2.

Turn ignition switch OFF. Check continuity between unified meter and A/C amp. harness connector and ground. Unified meter and A/C amp. Connector M67

Terminal 55 71

—

Continuity

Ground

Existed

Is the inspection result normal? YES >> INSPECTION END NO >> Repair harness or connector.


HAC-46

2009 G37 Coupe

UNIFIED METER AND A/C AMP. [AUTOMATIC AIR CONDITIONER]


UNIFIED METER AND A/C AMP.

A

Description

INFOID:0000000004536460

COMPONENT DESCRIPTION

B

Unified Meter and A/C Amp. (Automatic Amplifier) The unified meter and A/C amp. (1) has a built-in microcomputer which processes information sent from various sensors needed for air conditioner operation. The air mix door motors, mode door motor, intake door motor, blower motor and compressor are then controlled. When the various switches and temperature control dial are operated, data is input to the unified meter and A/C amp. from the AV control unit using CAN communication. Self-diagnosis functions are also built into unified meter and A/C amp. to provide quick check of malfunctions in the auto air conditioner system.

C

D

E

JSIIA1072ZZ

Component Function Check

F

INFOID:0000000004536461

1.CONFIRM SYMPTOM BY PERFORMING THE FOLLOWING OPERATIONAL CHECK

G

1. 2.

Press AUTO switch. Display should indicate AUTO. Confirm that the compressor clutch engages (sound or visual inspection). (Discharge air and fan speed depend on ambient, in-vehicle and set temperatures.) H Does magnet clutch engaged? YES >> INSPECTION END NO >> Go to Diagnosis Procedure. Refer to HAC-47, "Diagnosis Procedure". HAC

Diagnosis Procedure

INFOID:0000000004536462

1.INSPECTION BY FAIL-SAFE FUNCTION

J

1. 2.

Turn the ignition switch ON. After approximately 30 seconds, check that the air conditioner is operated by the fail-safe function (the operation display of air conditioner is not performed). Refer to HAC-100, "Fail-safe". Is the fail-safe function operated? YES >> GO TO 3. NO >> GO TO 2.

K

L

2.CHECK UNIFIED METER AND A/C AMP. POWER SUPPLY CIRCUIT AND GROUND Check unified meter and A/C amp. power supply circuit and ground circuit. Refer to HAC-46, "UNIFIED METER AND A/C AMP. : Diagnosis Procedure". Is the inspection result normal? YES >> GO TO 3. NO >> Repair or replace parts according to the inspection results.

M

N

3.CHECK PRESET SWITCH Check preset switch. Refer to AV-104, "Symptom Table" (BASE AUDIO WITHOUT NAVIGATION), AV-339, "Symptom Table" (BOSE AUDIO WITHOUT NAVIGATION) or AV-603, "Symptom Table" (BOSE AUDIO WITH NAVIGATION). Is the inspection result normal? YES >> Replace unified meter and A/C amp. NO >> Repair or replace malfunctioning part.


HAC-47

2009 G37 Coupe

O

P

MODE DOOR MOTOR [AUTOMATIC AIR CONDITIONER]


MODE DOOR MOTOR Description

INFOID:0000000004536463

COMPONENT DESCRIPTION Mode Door Motor The mode door motor (1) is attached to the heater & cooling unit assembly. It rotates so that air is discharged from the outlet set by the unified meter and A/C amp. Motor rotation is conveyed to a link which activates the mode door. :

Vehicle front

JSIIA1389ZZ


INFOID:0000000004536464

1.CONFIRM SYMPTOM BY PERFORMING THE FOLLOWING OPERATIONAL CHECK 1. 2. 3.

Press MODE switch and DEF switch. Each position indicator should change shape. Confirm that discharge air comes out according to the air distribution table. Refer to VTL-5, "System Description". NOTE: Confirm that the compressor clutch is engaged (Sound or visual inspection) and intake door position is at FRE when D/F or DEF is selected. Is the inspection result normal? YES >> INSPECTION END NO >> Go to diagnosis procedure. Refer to HAC-48, "Diagnosis Procedure".

Diagnosis Procedure

INFOID:0000000004536465

1.PERFORM SELF-DIAGNOSIS Perform self-diagnosis function. Refer to HAC-40, "Diagnosis Description". Is the inspection result normal? YES >> GO TO 5. NO >> GO TO 2.

2.CHECK POWER SUPPLY FOR MODE DOOR MOTOR Check voltage between mode door motor harness connector and ground. (+)

(−)

Mode door motor Connector

Terminal

M253

1

—

Voltage (Approx.)

Ground

12 V


3.CHECK SIGNAL FOR MODE DOOR MOTOR Confirm A/C LAN signal between mode door motor harness connector and ground using an oscilloscope.


HAC-48

2009 G37 Coupe

MODE DOOR MOTOR [AUTOMATIC AIR CONDITIONER]

< DTC/CIRCUIT DIAGNOSIS > (+)

A

(−)

Mode door motor Connector

Terminal

M253

3

Voltage

—

B

C Ground

D SJIA1453J


E

4.CHECK MODE DOOR MOTOR GROUND CIRCUIT 1. 2. 3.

F

Turn ignition switch OFF. Disconnect mode door motor connector. Check continuity between mode door motor harness connector and ground.

G Mode door motor Connector

Terminal

M253

2

—

Continuity

Ground

Existed

H

Is the inspection result normal? YES >> Replace mode door motor. NO >> Repair harness or connector.

HAC

5.CHECK MODE DOOR CONTROL LINKAGE

J

Check mode door control linkage is properly installed. Refer to HAC-120, "Exploded View". Is it installed normally? YES >> INSPECTION END NO >> Repair or adjust control linkage.

K

L

M

N

O

P


HAC-49

2009 G37 Coupe

AIR MIX DOOR MOTOR [AUTOMATIC AIR CONDITIONER]


AIR MIX DOOR MOTOR WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Description

INFOID:0000000004560518

COMPONENT DESCRIPTION Air Mix Door Motor The air mix door motor (1) is attached to the heater & cooling unit assembly. It rotates so that the air mix door is opened or closed to a position set by the unified meter and A/C amp. Motor rotation is then conveyed through a shaft and the air mix door position feedback is then sent to the unified meter and A/C amp. by PBR built-in air mix door motors. :

Vehicle front

JSIIA1391ZZ

WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Component Function Check

INFOID:0000000004560519

1.CONFIRM SYMPTOM BY PERFORMING THE FOLLOWING OPERATIONAL CHECK 1. Turn temperature control dial clockwise until 32°C (90°F) is displayed. 2. Check for warm air at discharge air outlets. 3. Turn temperature control dial counterclockwise until 18°C (64°F) is displayed. 4. Check for cool air at discharge air outlets. Is the inspection result normal? YES >> INSPECTION END NO >> Go to diagnosis procedure. Refer to HAC-50, "WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure".

WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure

INFOID:0000000004560520


2.CHECK POWER SUPPLY FOR AIR MIX DOOR MOTOR Check voltage between air mix door motor harness connector and ground. (+)

(−)

Air mix door motor Connector

Terminal

M255

1

—

Voltage (Approx.)

Ground

12 V

Is the inspection result normal? YES >> GO TO 3. NO >> Repair harness or connector. Revision: 2009 October

HAC-50

2009 G37 Coupe



3.CHECK SIGNAL FOR AIR MIX DOOR MOTOR

A

Confirm A/C LAN signal between air mix door motor harness connector and ground using an oscilloscope. (+)

(−)


Terminal

B Voltage

—

C

M255

3

D

Ground

E SJIA1453J


F

4.CHECK AIR MIX DOOR MOTOR GROUND CIRCUIT 1. 2. 3.

G

Turn ignition switch OFF. Disconnect air mix door motor connector. Check continuity between air mix door motor harness connector and ground.

H Air mix door motor Connector

Terminal

M255

2

—

Continuity

Ground

Existed

HAC

Is the inspection result normal? YES >> Replace air mix door motor. NO >> Repair harness or connector.

J

5.CHECK INSTALLATION OF AIR MIX DOOR MOTOR K

Check air mix door motor is properly installed. Refer to HAC-120, "Exploded View". Is it installed normally? YES >> INSPECTION END NO >> Repair or replace air mix door motor.

L

WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM

M

WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Description

INFOID:0000000004536469

N

Air Mix Door Motor The air mix door motor (1) is attached to the heater & cooling unit assembly. It rotates so that the air mix door is opened or closed to a position set by the unified meter and A/C amp. Motor rotation is then conveyed through a shaft and the air mix door position feedback is then sent to the unified meter and A/C amp. by PBR built-in air mix door motors.

O


:

Vehicle front


HAC-51

2009 G37 Coupe

P


< DTC/CIRCUIT DIAGNOSIS > Driver side (LH)

JSIIA1390ZZ

Passenger side (RH)

JSIIA1391ZZ

WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Component Function Check

INFOID:0000000004536470

DRIVER SIDE

1.CONFIRM SYMPTOM BY PERFORMING THE FOLLOWING OPERATIONAL CHECK 1. Turn temperature control dial (driver side) clockwise until 32°C (90°F) is displayed. 2. Check for warm air at discharge air outlets. 3. Turn temperature control dial (driver side) counterclockwise until 18°C (64°F) is displayed. 4. Check for cool air at discharge air outlets. Is the inspection result normal? YES >> INSPECTION END NO >> Go to diagnosis procedure. Refer to HAC-52, "WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure".

PASSENGER SIDE

1.CONFIRM SYMPTOM BY PERFORMING THE FOLLOWING OPERATIONAL CHECK 1. Turn temperature control dial (passenger side) clockwise until 32°C (90°F) is displayed. 2. Check for warm air at discharge air outlets. 3. Turn temperature control dial (passenger side) counterclockwise until 18°C (64°F) is displayed. 4. Check for cool air at discharge air outlets. Is the inspection result normal? YES >> INSPECTION END NO >> Go to diagnosis procedure. Refer to HAC-52, "WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure".

WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure

INFOID:0000000004536471

1.PERFORM SELF-DIAGNOSIS Perform self-diagnosis function. Refer to HAC-40, "Diagnosis Description". Revision: 2009 October

HAC-52

2009 G37 Coupe


< DTC/CIRCUIT DIAGNOSIS > Is the inspection result normal? YES >> GO TO 5. NO >> GO TO 2.

A

2.CHECK POWER SUPPLY FOR AIR MIX DOOR MOTOR

B

Check voltage between air mix door motor harness connector and ground. (+)

(−)


Terminal

M255 (RH) M252 (LH)

1

—

Voltage (Approx.)

Ground

12 V

C

D


E

3.CHECK SIGNAL FOR AIR MIX DOOR MOTOR

F

Confirm A/C LAN signal between air mix door motor harness connector and ground using an oscilloscope. (+)

G

(−)


Terminal

M255 (RH) M252 (LH)

3

Voltage

—

H

HAC

Ground

J SJIA1453J


K

4.CHECK AIR MIX DOOR MOTOR GROUND CIRCUIT 1. 2. 3.

L

Turn ignition switch OFF. Disconnect air mix door motor connector. Check continuity between air mix door motor harness connector and ground.

M Air mix door motor Connector

Terminal

M255 (RH) M252 (LH)

2

—

Continuity

Ground

Existed

N

Is the inspection result normal? YES >> Replace air mix door motor. NO >> Repair harness or connector.

O

5.CHECK INSTALLATION OF AIR MIX DOOR MOTOR

P

Check air mix door motor is properly installed. Refer to HAC-120, "Exploded View". Is it installed normally? YES >> INSPECTION END NO >> Repair or replace air mix door motor.


HAC-53

2009 G37 Coupe

INTAKE DOOR MOTOR [AUTOMATIC AIR CONDITIONER]


INTAKE DOOR MOTOR Description

INFOID:0000000004536472

COMPONENT DESCRIPTION Intake Door Motor The intake door motor (1) is attached to the blower unit. It rotates so that air is drawn from inlets set by the unified meter and A/C amp. Motor rotation is conveyed to a lever which activates the intake door. :

Vehicle front

JSIIA1413ZZ


INFOID:0000000004536473

1.CONFIRM SYMPTOM BY PERFORMING THE FOLLOWING OPERATIONAL CHECK 1. Press intake switch. 2. REC indicator turns ON. 3. Listen for intake door position change (Slight change of blower sound can be heard.). 4. Press intake switch again. 5. FRE indicator turns ON. Is the inspection result normal? YES >> INSPECTION END NO >> Go to diagnosis procedure. Refer to HAC-54, "Diagnosis Procedure".

Diagnosis Procedure

INFOID:0000000004536474


2.CHECK POWER SUPPLY FOR INTAKE DOOR MOTOR Check voltage between intake door motor harness connector and ground. (+)

(−)

Intake door motor Connector

Terminal

M254

1

—

Voltage (Approx.)

Ground

12 V


3.CHECK SIGNAL FOR INTAKE DOOR MOTOR Confirm A/C LAN signal between intake door motor harness connector and ground using an oscilloscope.


HAC-54

2009 G37 Coupe

INTAKE DOOR MOTOR [AUTOMATIC AIR CONDITIONER]


A

(−)

Intake door motor Connector

Terminal

M254

3

Voltage

—

B

C Ground

D SJIA1453J


E

4.CHECK INTAKE DOOR MOTOR GROUND CIRCUIT 1. 2. 3.

F

Turn ignition switch OFF. Disconnect intake door motor connector. Check continuity between intake door motor harness connector and ground.

G Intake door motor Connector

Terminal

M254

2

—

Continuity

Ground

Existed

H

Is the inspection result normal? YES >> Replace intake door motor. NO >> Repair harness or connector.

HAC

5.CHECK INTAKE DOOR CONTROL LINKAGE

J

Check intake door control linkage is properly installed. Refer to HAC-120, "Exploded View". Is it installed normally? YES >> INSPECTION END NO >> Repair or adjust control linkage.

K

L

M

N

O

P


HAC-55

2009 G37 Coupe

BLOWER MOTOR [AUTOMATIC AIR CONDITIONER]


BLOWER MOTOR Description

INFOID:0000000004536475

COMPONENT DESCRIPTION Brush-less Motor The blower motor utilizes a brush-less motor with a rotating magnet. Quietness is improved over previous motors where the brush was the point of contact and the coil rotated.

RJIA2467J

ZHA152H

Blower Motor Circuit

RJIA4071E


INFOID:0000000004536476

1.CONFIRM SYMPTOM BY PERFORMING THE FOLLOWING OPERATIONAL CHECK Press fan (UP: +) switch*1 (turn fan control dial clockwise*2). Blower should operate on low speed. NOTE: *1: With left and right ventilation temperature separately control system. *2: Without left and right ventilation temperature separately control system. 2. Press fan (UP: +) switch*1 (turn control dial clockwise*2), and continue checking fan speed and fan symbol until all speeds checked. NOTE: *1: With left and right ventilation temperature separately control system. *2: Without left and right ventilation temperature separately control system. Is the inspection result normal? YES >> INSPECTION END NO >> Go to diagnosis procedure. Refer to HAC-57, "Diagnosis Procedure".

1.


HAC-56

2009 G37 Coupe



Diagnosis Procedure

INFOID:0000000004536477

A

1.PERFORM SELF-DIAGNOSIS STEP-4 Perform self-diagnosis STEP-4. Refer to HAC-40, "Diagnosis Description", see Nos. 1 to 5. Code No. Blower motor duty ratio

B

41

42

43

44

45

46

37%

91%

65%

65%

65%

91%

Does blower motor speed change according to each code No.? YES >> INSPECTION END NO >> GO TO 2.

C

D

2.CHECK POWER SUPPLY FOR BLOWER MOTOR 1. 2. 3.

Disconnect blower motor connector. Turn ignition switch ON. Check voltage between blower motor harness connector and ground. (+)

E

F

(−)

Blower motor Connector

Terminal

M109

1

Voltage

—

G Ground

Battery voltage

Is the inspection result normal? YES >> GO TO 3. NO >> GO TO 6.

H

3.CHECK BLOWER MOTOR GROUND CIRCUIT 1. 2.

HAC

Turn ignition switch OFF. Check continuity between blower motor harness connector and ground. J Blower motor Connector

Terminal

M109

3

—

Continuity

Ground

Existed

K


L

4.CHECK CIRCUIT CONTINUITY BETWEEN BLOWER MOTOR AND UNIFIED METER AND A/C AMP. 1. 2.

Disconnect unified meter and A/C amp. connector. Check continuity between blower motor harness connector and unified meter and A/C amp. harness connector.

M

N Blower motor

3.


Connector

Terminal

Connector

Terminal

M109

2

M66

38

Continuity

O

Existed

Check continuity between blower motor harness connector and ground. P

Blower motor Connector

Terminal

M109

2

—

Continuity

ground

Not existed

Is the inspection result normal? YES >> GO TO 5. NO >> Repair harness or connector. Revision: 2009 October

HAC-57

2009 G37 Coupe



5.CHECK UNIFIED METER AND A/C AMP. OUTPUT SIGNAL 1. 2. 3. 4.

Reconnect blower motor connector and unified meter and A/C amp. connector. Turn ignition switch ON. Set MODE switch to VENT position. Change fan speed from Lo to Hi, and check duty ratios between blower motor harness connector and ground by using an oscilloscope. NOTE: Calculate the drive signal duty ratio as shown in the figure. T2 = 1.6 ms Blower motor Connector

Condition

Terminal

• fan speed: manual • Vent mode

Duty ratio (Approx.)

1st

M109

2

25 %

2nd

33 %

3rd

41 %

4th

51 %

5th

61 %

6th

71 %

7th

83 %

JPLIA1210GB

Is the inspection result normal? YES >> Replace blower motor after confirming the fan air flow does not change. NO >> Replace unified meter and A/C amp.

6.CHECK POWER VOLTAGE OF BLOWER RELAY 1. 2. 3. 4.

Turn ignition switch OFF. Remove blower relay. Refer to PG-94, "Fuse, Connector and Terminal Arrangement". Turn ignition switch ON. Check the voltage between blower relay fuse block terminals and ground. Refer to PG-92, "Description" for relay terminal assignment. (+)

(−)

Blower relay

—

1 3

Voltage

Ground

Battery voltage

Is the inspection result normal? YES >> GO TO 7. NO >> Check ignition power supply circuit. Refer to PG-51, "Wiring Diagram - IGNITION POWER SUPPLY -".

7.CHECK BLOWER RELAY 1. Turn ignition switch OFF. 2. Install blower relay. Refer to PG-94, "Fuse, Connector and Terminal Arrangement". 3. Check operation sound of the blower relay after switching ignition switch ON. Is the inspection result normal? YES >> GO TO 8. NO >> Replace blower relay.

8.CHECK FUSE Check fuse 15A [Nos 21 and 22, located in the fuse block (J/B). Refer to PG-94, "Fuse, Connector and Terminal Arrangement". Is the inspection result normal? Revision: 2009 October

HAC-58

2009 G37 Coupe

BLOWER MOTOR [AUTOMATIC AIR CONDITIONER] < DTC/CIRCUIT DIAGNOSIS > YES >> Repair harness or connector. NO >> Be sure to eliminate cause of malfunction before installing new fuse.

Component Inspection

A

INFOID:0000000004536478

1.CHECK BLOWER MOTOR

B

1. Remove blower motor. Refer to VTL-16, "Exploded View". 2. Confirm smooth rotation of the blower motor. Is the inspection result normal? YES >> INSPECTION END NO >> Replace blower motor.

C

D

E

F

G

H

HAC

J

K

L

M

N

O

P


HAC-59

2009 G37 Coupe

MAGNET CLUTCH [AUTOMATIC AIR CONDITIONER]


MAGNET CLUTCH Description

INFOID:0000000004536479

Magnet clutch drives a compressor, by a signal of IPDM E/R.


INFOID:0000000004536480

1.CONFIRM SYMPTOM BY PERFORMING THE FOLLOWING OPERATIONAL CHECK 1. 2.

Press AUTO switch. Display should indicate AUTO. Confirm that the magnet clutch engages (sound or visual inspection). (Discharge air and fan speed depend on ambient, in-vehicle and set temperatures.) Does the magnet clutch operate? YES >> INSPECTION END NO >> Go to Diagnosis Procedure. Refer to HAC-60, "Diagnosis Procedure".

Diagnosis Procedure

INFOID:0000000004536481

1.PERFORM SELF-DIAGNOSIS Perform self-diagnosis function. Refer to HAC-40, "Diagnosis Description". Is the inspection result normal? YES >> INSPECTION END NO >> GO TO 2.

2.PERFORM IPDM E/R AUTO ACTIVE TEST Perform IPDM E/R auto active test. Refer to PCS-9, "Diagnosis Description". Does the magnet clutch operate? YES-1 >> WITH CONSULT-III: GO TO 6. YES-2 >> WITHOUT CONSULT-III: GO TO 5. NO >> Check 10A fuse (No. 49, located in IPDM E/R), and GO TO 3.

3.CHECK CIRCUIT CONTINUITY BETWEEN IPDM E/R AND COMPRESSOR 1. 2. 3.

Turn ignition switch OFF. Disconnect IPDM E/R connector and compressor connector. Check continuity between IPDM E/R harness connector and compressor harness connector. IPDM E/R

Compressor

Connector

Terminal

Connector

Terminal

E7

48

F43

1

Continuity Existed


4.CHECK MAGNET CLUTCH CIRCUIT Check for operation sound when applying battery voltage direct current to terminal. Is the inspection result normal? YES >> Replace IPDM E/R. NO >> Replace compressor.

5.CHECK REFRIGERANT PRESSURE SENSOR (WITHOUT CONSULT-III) 1. 2.

Start the engine. Check voltage between ECM harness connector and ground.


HAC-60

2009 G37 Coupe

MAGNET CLUTCH [AUTOMATIC AIR CONDITIONER]

< DTC/CIRCUIT DIAGNOSIS > (+) ECM connector M107

A

(−) Condition

—

Terminal

Voltage (Approx.)

B

105

A/C switch: ON (Blower motor operates.)

Ground

1.0 - 4.0 V

Is the inspection result normal? YES >> Repair harness or connector. NO >> Refer to EC-520, "Diagnosis Procedure".

C

6.CHECK ECM INPUT SIGNAL-1

D

Check A/C switch signal in “Data monitor”. Refer to EC-525, "Reference Value". Monitor item AIR COND SIG

Condition

E

Status

A/C switch: OFF

Off

A/C switch: ON

On

F


G

7.CHECK REFRIGERANT PRESSURE SENSOR (WITH CONSULT-III) 1. Start the engine. 2. Check voltage of refrigerant pressure sensor in “Data monitor”. Refer to EC-525, "Reference Value". Is the inspection result normal? YES >> GO TO 8. NO >> Refer to EC-520, "Diagnosis Procedure".

8.CHECK ECM INPUT SIGNAL-2

HEATER FAN SW

Condition

Status

Fan switch: OFF

Off

Fan switch: ON

On

HAC

J

Check blower fan motor switch signal in “Data monitor”. Refer to EC-525, "Reference Value". Monitor item

H

K

L


M

9.CHECK CAN COMMUNICATION Check CAN communication. Refer to LAN-18, "Trouble Diagnosis Flow Chart". • ECM – IPDM E/R • ECM – Unified meter and A/C amp. Is the inspection result normal? YES >> Replace ECM. NO >> Repair or replace malfunctioning part.

N

O

P


HAC-61

2009 G37 Coupe

ECV (ELECTRICAL CONTROL VALVE) [AUTOMATIC AIR CONDITIONER]


ECV (ELECTRICAL CONTROL VALVE) Description

INFOID:0000000004555201

The ECV (electrical control valve) is installed in the compressor and controls it for emitting appropriate amount of refrigerant when necessary.

Diagnosis Procedure

INFOID:0000000004555202

1.CHECK POWER SUPPLY FOR ECV (ELECTRIC CONTROL VALVE) 1. 2. 3.

Disconnect compressor (ECV) connector. Turn ignition switch ON. Check voltage between compressor (ECV) harness connector and ground. (+)

(−)

Compressor (ECV) Connector

Terminal

F44

2

Voltage

— Ground

Battery voltage

Is the inspection result normal? YES >> GO TO 3 NO >> GO TO 2

2.CHECK FUSE Check power supply circuit and 10A fuse [No. 3, located in the fuse block (J/B)]. Refer to PG-94, "Fuse, Connector and Terminal Arrangement". Is the inspection result normal? YES >> Check harness for open circuit. Repair or replace if necessary. NO >> Replace fuse and check harness for short circuit. Repair or replace if necessary.

3.CHECK ECV CONTROL SIGNAL 1. 2. 3. 4. 5.

Turn ignition switch OFF. Reconnect compressor (ECV) connector. Perform self-diagnosis. Refer to HAC-40, "Diagnosis Description". Set in self-diagnosis STEP-4 (Code No. 45). Confirm ECV control signal between unified meter and A/C amp harness connector M67 terminal 65 and ground using an oscilloscope. Is the inspection result normal? YES >> Replace compressor. NO >> GO TO 4

SJIA1765E

4.CHECK CIRCUIT CONTINUITY BETWEEN ECV AND UNIFIED METER AND A/C AMP. 1. 2. 3.

Turn ignition switch OFF. Disconnect compressor (ECV) connector and unified meter and A/C amp. connector. Check continuity between compressor (ECV) harness connector and unified meter and A/C amp harness connector. Compressor (ECV)


Connector

Terminal

Connector

Terminal

F44

3

M67

65

Continuity Existed

Is the inspection result normal? Revision: 2009 October

HAC-62

2009 G37 Coupe

ECV (ELECTRICAL CONTROL VALVE) [AUTOMATIC AIR CONDITIONER]

< DTC/CIRCUIT DIAGNOSIS > YES >> GO TO 5 NO >> Repair the harnesses or connectors.

A

5.CHECK ECV Check continuity between compressor (ECV) connector. Compressor (ECV) Connector

Terminal

Connector

Terminal

F44

2

F44

3

B Continuity

C Existed

Is the inspection result normal? YES >> Replace the unified meter and A/C amp. NO >> Replace the compressor.

D

E

F

G

H

HAC

J

K

L

M

N

O

P


HAC-63

2009 G37 Coupe

AMBIENT SENSOR [AUTOMATIC AIR CONDITIONER]


AMBIENT SENSOR Description

INFOID:0000000004536482

COMPONENT DESCRIPTION Ambient Sensor The ambient sensor (1) is attached on hood lock stay assembly. It detects ambient temperature and converts it into a resistance value which is then input into the unified meter and A/C amp.

JSIIA0658ZZ

Ambient Sensor Circuit

RJIA4088E

AMBIENT TEMPERATURE INPUT PROCESS The unified meter and A/C amp. equips a processing circuit for the ambient sensor input. However, when the temperature detected by the ambient sensor increases quickly, the processing circuit retards the unified meter and A/C amp. function. It only allows the unified meter and A/C amp. to recognize an ambient temperature increase of 0.33°C (0.6°F) per 100 seconds. As an example, consider stopping for a few minutes after high speed driving. Although the actual ambient temperature has not changed, the temperature detected by the ambient sensor increases. This is because the heat from the engine compartment can radiate to the front bumper area, location of the ambient sensor.


INFOID:0000000004536483

1.PERFORM SELF-DIAGNOSIS Perform self-diagnosis function STEP-2. Refer to HAC-40, "Diagnosis Description". 21 or −21 is displayed. YES >> Go to Diagnosis Procedure. Refer to HAC-64, "Diagnosis Procedure". NO >> INSPECTION END

Diagnosis Procedure

INFOID:0000000004536484

1.CHECK VOLTAGE BETWEEN AMBIENT SENSOR AND GROUND 1. 2. 3.

Disconnect ambient sensor connector. Turn ignition switch ON. Check voltage between ambient sensor harness connector and ground.


HAC-64

2009 G37 Coupe



A

(−)

Ambient sensor Connector

Terminal

E76

1

—

Voltage (Approx.)

Ground

5V

B


C

2.CHECK CIRCUIT CONTINUITY BETWEEN AMBIENT SENSOR AND UNIFIED METER AND A/C AMP. 1. 2. 3.

Turn ignition switch OFF. Disconnect unified meter and A/C amp. connector. Check continuity between ambient sensor harness connector and unified meter and A/C amp. harness connector. Ambient sensor


Connector

Terminal

Connector

Terminal

E76

2

M67

61

Continuity

D

E

F

Existed


G

3.CHECK AMBIENT SENSOR

H

Check ambient sensor. Refer to HAC-65, "Component Inspection". Is the inspection result normal? YES >> Replace unified meter and A/C amp. NO >> Replace ambient sensor.

HAC

4.CHECK CIRCUIT CONTINUITY BETWEEN AMBIENT SENSOR AND UNIFIED METER AND A/C AMP.

J

1. 2. 3.

K

Turn ignition switch OFF. Disconnect unified meter and A/C amp. connector. Check continuity between ambient sensor harness connector and unified meter and A/C amp. harness connector. Ambient sensor

4.


Connector

Terminal

Connector

Terminal

E76

1

M67

45

L

Continuity Existed

M

Check continuity between ambient sensor harness connector and ground. Ambient sensor Connector

Terminal

E76

1

—

Continuity

Ground

Not existed

N

O

Is the inspection result normal? YES >> Replace unified meter and A/C amp. NO >> Repair harness or connector.

P


INFOID:0000000004536485

1.CHECK AMBIENT SENSOR 1. 2. 3.

Turn ignition switch OFF. Disconnect ambient sensor connector. Refer to HAC-115, "Exploded View". Check resistance between ambient sensor terminals.


HAC-65

2009 G37 Coupe


< DTC/CIRCUIT DIAGNOSIS > Condition

Terminal

1

Temperature °C (°F)

2

Resistance kΩ

−15 (5)

12.73

−10 (14)

9.92

−5 (23)

7.80

0 (32)

6.19

5 (41)

4.95

10 (50)

3.99

15 (59)

3.24

20 (68)

2.65

25 (77)

2.19

30 (86)

1.81

35 (95)

1.51

40 (104)

1.27

45 (113)

1.07

Is the inspection result normal? YES >> INSPECTION END NO >> Replace ambient sensor.


HAC-66

2009 G37 Coupe

IN-VEHICLE SENSOR [AUTOMATIC AIR CONDITIONER]


IN-VEHICLE SENSOR

A

Description

INFOID:0000000004536486


B

In-vehicle Sensor The in-vehicle sensor (1) is located on instrument driver lower panel. It converts variations in compartment air temperature drawn from the aspirator into a resistance value. It is then input into the unified meter and A/C amp.

C

D

E

JSIIA0048ZZ

In-vehicle Sensor Circuit

F

G

H

HAC RJIA4094E

Aspirator The aspirator (1) is located on driver’s side of heater & cooling unit assembly. It produces vacuum pressure due to air discharged from the heater & cooling unit assembly, continuously taking compartment air in the aspirator. :

J

K

Vehicle front

L

M JSIIA1341ZZ

N

O

P RJIA1804E


INFOID:0000000004536487

1.PERFORM SELF-DIAGNOSIS Revision: 2009 October

HAC-67

2009 G37 Coupe

IN-VEHICLE SENSOR [AUTOMATIC AIR CONDITIONER] < DTC/CIRCUIT DIAGNOSIS > Perform self-diagnosis function STEP-2. Refer to HAC-40, "Diagnosis Description". 22 or –22 is displayed. YES >> Go to Diagnosis Procedure. Refer to HAC-68, "Diagnosis Procedure". NO >> INSPECTION END

Diagnosis Procedure

INFOID:0000000004536488

1.CHECK VOLTAGE BETWEEN IN-VEHICLE SENSOR AND GROUND 1. 2. 3.

Disconnect in-vehicle sensor connector. Turn ignition switch ON. Check voltage between in-vehicle sensor harness connector and ground. (+)

(−)

In-vehicle sensor Connector

Terminal

M61

1

—

Voltage (Approx.)

Ground

5V


2.CHECK CIRCUIT CONTINUITY BETWEEN IN-VEHICLE SENSOR AND UNIFIED METER AND A/C AMP. 1. 2. 3.

Turn ignition switch OFF. Disconnect unified meter and A/C amp. connector. Check continuity between in-vehicle sensor harness connector and unified meter and A/C amp. harness connector. In-vehicle sensor


Connector

Terminal

Connector

Terminal

M61

2

M67

60

Continuity Existed


3.CHECK IN-VEHICLE SENSOR Check in-vehicle sensor. Refer to HAC-69, "Component Inspection". Is the inspection result normal? YES >> Replace unified meter and A/C amp. NO >> Replace in-vehicle sensor.

4.CHECK CIRCUIT CONTINUITY BETWEEN IN-VEHICLE SENSOR AND UNIFIED METER AND A/C AMP. 1. 2. 3.

Turn ignition switch OFF. Disconnect unified meter and A/C amp. connector. Check continuity between in-vehicle sensor harness connector and unified meter and A/C amp. harness connector. In-vehicle sensor

4.


Connector

Terminal

Connector

Terminal

M61

1

M67

44

Continuity Existed

Check continuity between in-vehicle sensor harness connector and ground. In-vehicle sensor Connector

Terminal

M61

1


—

Continuity

Ground

Not existed

HAC-68

2009 G37 Coupe


< DTC/CIRCUIT DIAGNOSIS > Is the inspection result normal? YES >> Replace unified meter and A/C amp. NO >> Repair harness or connector.

A


INFOID:0000000004536489

B

1.CHECK IN-VEHICLE SENSOR 1. 2. 3.

Turn ignition switch OFF. Disconnect in-vehicle sensor connector. Refer to HAC-116, "Exploded View". Check resistance between in-vehicle sensor terminals. Condition

Terminal

1


2

C

D Resistance kΩ

−15 (5)

12.73

−10 (14)

9.92

−5 (23)

7.80

0 (32)

6.19

5 (41)

4.95

10 (50)

3.99

15 (59)

3.24

20 (68)

2.65

25 (77)

2.19

30 (86)

1.81

35 (95)

1.51

40 (104)

1.27

45 (113)

1.07

E

F

G

H

HAC

J

Is the inspection result normal? YES >> INSPECTION END NO >> Replace in-vehicle sensor.

K

L

M

N

O

P


HAC-69

2009 G37 Coupe

SUNLOAD SENSOR [AUTOMATIC AIR CONDITIONER]


SUNLOAD SENSOR Description

INFOID:0000000004536490

COMPONENT DESCRIPTION Sunload Sensor The sunload sensor (1) is located on the front defroster grille LH. It detects sunload entering through windshield by means of a photo diode. The sensor converts the sunload into a current value which is then input into the unified meter and A/C amp.

JSIIA1422ZZ

Sunload Sensor Circuit

RJIA4099E

SUNLOAD INPUT PROCESS The unified meter and A/C amp. also equips a processing circuit which averages the variations in detected sunload over a period of time. This prevents drastic swings in the air temperature control system operation due to small or quick variations in detected sunload. For example, consider driving along a road bordered by an occasional group of large trees. The sunload detected by the sunload sensor varies whenever the trees obstruct the sunlight. The processing circuit averages the detected sunload over a period of time, so that the (insignificant) effect of the trees momentarily obstructing the sunlight does not cause any change in the air temperature control system operation. On the other hand, shortly after entering a long tunnel, the system recognizes the change in sunload, and the system reacts accordingly.


INFOID:0000000004536491

1.PERFORM SELF-DIAGNOSIS Perform self-diagnosis function STEP-2. Refer to HAC-40, "Diagnosis Description". 25 or −25 is displayed. YES >> Go to Diagnosis Procedure. Refer to HAC-70, "Diagnosis Procedure". NO >> INSPECTION END

Diagnosis Procedure

INFOID:0000000004536492

1.CHECK VOLTAGE BETWEEN SUNLOAD SENSOR AND GROUND 1. 2. 3.

Disconnect sunload sensor connector. Turn ignition switch ON. Check voltage between sunload sensor harness connector and ground.


HAC-70

2009 G37 Coupe



A

(−)

Sunload sensor Connector

Terminal

M46

1

—

Voltage (Approx.)

Ground

5V

B


C

2.CHECK CIRCUIT CONTINUITY BETWEEN SUNLOAD SENSOR AND UNIFIED METER AND A/C AMP. 1. 2. 3.

Turn ignition switch OFF. Disconnect unified meter and A/C amp. connector. Check continuity between sunload sensor harness connector and unified meter and A/C amp. harness connector. Sunload sensor


Connector

Terminal

Connector

Terminal

M46

2

M67

62

Continuity

D

E

F

Existed


G

3.CHECK SUNLOAD SENSOR

H

1. Reconnect sunload sensor connector and unified meter and A/C amp. connector. 2. Check sunload sensor. Refer to HAC-71, "Component Inspection". Is the inspection result normal? YES >> Replace unified meter and A/C amp. NO >> Replace sunload sensor.

HAC

4.CHECK CIRCUIT CONTINUITY BETWEEN SUNLOAD SENSOR AND UNIFIED METER AND A/C AMP. 1. 2. 3.

Turn ignition switch OFF. Disconnect unified meter and A/C amp. connector. Check continuity between sunload sensor harness connector and unified meter and A/C amp. harness connector.

J

K

L Sunload sensor

4.


Connector

Terminal

Connector

Terminal

M46

1

M67

46

Continuity

M

Existed

Check continuity between sunload sensor harness connector and ground. N

Sunload sensor Connector

Terminal

M46

1

—

Continuity

Ground

Not existed

O


P


INFOID:0000000004536493

1.CHECK SUNLOAD SENSOR 1. 2.

Turn ignition switch ON. Check voltage between unified meter and A/C amp. harness connector and ground.


HAC-71

2009 G37 Coupe



(−)

Unified meter and A/C amp. Connector

Terminal

M67

46

— Ground

SHA930E

NOTE: Select a place where sunshine directly on it when checking sunload sensor. Is the inspection result normal? YES >> INSPECTION END NO >> Replace sunload sensor.


HAC-72

2009 G37 Coupe

INTAKE SENSOR [AUTOMATIC AIR CONDITIONER]


INTAKE SENSOR

A

Description

INFOID:0000000004536494


B

Intake Sensor The intake sensor (1) is located on the evaporator. It converts air temperature after it passes through the evaporator (2) into a resistance value which is then input to the unified meter and A/C amp.

C

D

E

JSIIA1423ZZ

F

Intake Sensor Circuit G

H

HAC RJIA4104E

J


INFOID:0000000004536495

1.PERFORM SELF-DIAGNOSIS

K

Perform self-diagnosis function STEP-2. Refer to HAC-40, "Diagnosis Description". 24 or −24 is displayed. YES >> Go to Diagnosis Procedure. Refer to HAC-73, "Diagnosis Procedure". NO >> INSPECTION END

Diagnosis Procedure

L

INFOID:0000000004536496

M

1.CHECK VOLTAGE BETWEEN INTAKE SENSOR AND GROUND 1. 2. 3.

Disconnect intake sensor connector. Turn ignition switch ON. Check voltage between intake sensor harness connector and ground.

N

O (+)

(−)

Intake sensor Connector

Terminal

M77

1

—

Voltage (Approx.)

Ground

5V

P


2.CHECK CIRCUIT CONTINUITY BETWEEN INTAKE SENSOR AND UNIFIED METER AND A/C AMP. Revision: 2009 October

HAC-73

2009 G37 Coupe

INTAKE SENSOR [AUTOMATIC AIR CONDITIONER] < DTC/CIRCUIT DIAGNOSIS > 1. Turn ignition switch OFF. 2. Disconnect unified meter and A/C amp. connector. 3. Check continuity between intake sensor harness connector and unified meter and A/C amp. harness connector. Intake sensor


Connector

Terminal

Connector

Terminal

M77

2

M67

59

Continuity Existed


3.CHECK INTAKE SENSOR Check intake sensor. Refer to HAC-74, "Component Inspection". Is the inspection result normal? YES >> Replace unified meter and A/C amp. NO >> Replace intake sensor.

4.CHECK CIRCUIT CONTINUITY BETWEEN INTAKE SENSOR AND UNIFIED METER AND A/C AMP. 1. 2. 3.

Turn ignition switch OFF. Disconnect unified meter and A/C amp. connector. Check continuity between intake sensor harness connector and unified meter and A/C amp. harness connector. Intake sensor

4.


Connector

Terminal

Connector

Terminal

M77

1

M67

43

Continuity Existed

Check continuity between intake sensor harness connector and ground. Intake sensor Connector

Terminal

M77

1

—

Continuity

Ground

Not existed



INFOID:0000000004536497

1.CHECK INTAKE SENSOR 1. 2. 3.

Turn ignition switch OFF. Disconnect intake sensor connector. Check resistance between intake sensor terminals.


HAC-74

2009 G37 Coupe


< DTC/CIRCUIT DIAGNOSIS > Condition

Terminal

1


2

A Resistance kΩ

−15 (5)

12.28

−10 (14)

9.58

−5 (23)

7.55

0 (32)

6.00

5 (41)

4.81

10 (50)

3.88

15 (59)

3.16

20 (68)

2.59

25 (77)

2.14

30 (86)

1.77

35 (95)

1.48

40 (104)

1.24

45 (113)

1.05

B

C

D

E

F

Is the inspection result normal? YES >> INSPECTION END NO >> Replace intake sensor.

G

H

HAC

J

K

L

M

N

O

P


HAC-75

2009 G37 Coupe

ECM [AUTOMATIC AIR CONDITIONER]

< ECU DIAGNOSIS INFORMATION >

ECU DIAGNOSIS INFORMATION ECM Reference Value

INFOID:0000000004554978

VALUES ON THE DIAGNOSIS TOOL NOTE: • Specification data are reference values. • Specification data are output/input values which are detected or supplied by the ECM at the connector. * Specification data may not be directly related to their components signals/values/operations. i.e. Adjust ignition timing with a timing light before monitoring IGN TIMING, because the monitor may show the specification data in spite of the ignition timing not being adjusted to the specification data. This IGN TIMING monitors the data calculated by the ECM according to the signals input from the camshaft position sensor and other ignition timing related sensors. CONSULT-III MONITOR ITEM

Monitor Item

Condition

Values/Status Almost the same speed as the tachometer indication

ENG SPEED

• Run engine and compare CONSULT-III value with the tachometer indication.

MAS A/F SE-B1

See EC-137, "Description".

MAS A/F SE-B2


B/FUEL SCHDL


A/F ALPHA-B1


A/F ALPHA-B2


COOLAN TEMP/S

• Ignition switch: ON

A/F SEN1 (B1)

• Engine: After warming up

Maintaining engine speed at 2,000 rpm

Fluctuates around 2.2 V

A/F SEN1 (B2)


Maintaining engine speed at 2,000 rpm

Fluctuates around 2.2 V

HO2S2 (B1)

• Revving engine from idle up to 3,000 rpm quickly after the following conditions are met. - Engine: After warming up - After keeping engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load

0 - 0.3 V ←→ Approx. 0.6 1.0 V

HO2S2 (B2)


0 - 0.3 V ←→ Approx. 0.6 1.0 V

HO2S2 MNTR (B1)


LEAN ←→ RICH

HO2S2 MNTR (B2)


LEAN ←→ RICH

VHCL SPEED SE

• Turn drive wheels and compare CONSULT-III value with the speedometer indication.

Almost the same speed as speedometer indication

BATTERY VOLT

• Ignition switch: ON (Engine stopped)

11 - 14 V

ACCEL SEN 1


Accelerator pedal: Fully released

0.45 - 1.00 V

Accelerator pedal: Fully depressed

4.4 - 4.8 V

ACCEL SEN 2*1



0.45 - 1.00 V


4.3 - 4.8 V


Indicates engine coolant temperature

HAC-76

2009 G37 Coupe


< ECU DIAGNOSIS INFORMATION > Monitor Item TP SEN 1-B1

TP SEN

2-B1*1

Condition

Values/Status

• Ignition switch: ON (Engine stopped) • Selector lever: D (A/T) or 1st (M/T)


More than 0.36 V


Less than 4.75 V



More than 0.36 V


Less than 4.75 V

FUEL T/TMP SE


Indicates fuel tank temperature

INT/A TEMP SE


Indicates intake air temperature

EVAP SYS PRES


Approx. 1.8 - 4.8 V

FUEL LEVEL SE


Depending on fuel level of fuel tank

START SIGNAL

• Ignition switch: ON → START → ON

CLSD THL POS


AIR COND SIG

• Engine: After warming up, idle the engine

P/N POSI SW


PW/ST SIGNAL

LOAD SIGNAL

IGNITION SW



B

C

D

E

OFF → ON → OFF Accelerator pedal: Fully released

ON

Accelerator pedal: Slightly depressed

OFF

Air conditioner switch: OFF

OFF

Air conditioner switch: ON (Compressor operates.)

ON

Selector lever: P or N (A/T), Neutral (M/T)

ON

Selector lever: Except above

OFF

Steering wheel: Not being turned

OFF

Steering wheel: Being turned

ON

F

G

H

HAC

Rear window defogger switch: ON and/or Lighting switch: 2nd position

ON

Rear window defogger switch and lighting switch: OFF

OFF

• Ignition switch: ON → OFF → ON

J

ON → OFF → ON Heater fan switch: ON

ON

Heater fan switch: OFF

OFF

Brake pedal: Fully released

OFF

Brake pedal: Slightly depressed

ON

K

HEATER FAN SW


BRAKE SW


Idle

2.0 - 3.0 msec

INJ PULSE-B1

• Engine: After warming up • Selector lever: P or N (A/T), Neutral (M/T) • Air conditioner switch: OFF • No load

2,000 rpm

1.9 - 2.9 msec

Idle

2.0 - 3.0 msec

INJ PULSE-B2


2,000 rpm

1.9 - 2.9 msec

Idle

7° BTDC

IGN TIMING


2,000 rpm

25° - 45° BTDC

Idle

5% - 35%

CAL/LD VALUE


2,500 rpm

5% - 35%


A

L

M

N

O

P

HAC-77

2009 G37 Coupe


< ECU DIAGNOSIS INFORMATION > Monitor Item

Condition

Values/Status

Idle

2.0 - 6.0 g·m/s

MASS AIRFLOW


2,500 rpm

7.0 - 20.0 g·m/s

Idle (Accelerator pedal: Not depressed even slightly, after engine starting.)

0%

PURG VOL C/V


2,000 rpm

—

Idle

− 5 - 5°CA

INT/V TIM (B1)


2,000 rpm

Approx. 0 - 30°CA

Idle

− 5 - 5°CA

INT/V TIM (B2)


2,000 rpm

Approx. 0 - 30°CA

Idle

0 - 2%

INT/V SOL (B1)


2,000 rpm

Approx. 0 - 50%

Idle

0 - 2%

INT/V SOL (B2)


2,000 rpm

Approx. 0 - 50%



More than 0.36 V

TP SEN 1-B2


Less than 4.75 V



More than 0.36 V

TP SEN 2-B2*1


Less than 4.75 V

Air conditioner switch: OFF

OFF

AIR COND RLY


Air conditioner switch: ON (Compressor operates)

ON

• For 1 second after turning ignition switch: ON • Engine running or cranking

ON

• Except above

OFF

VENT CONT/V


OFF

THRTL RELAY


ON

• Engine speed: Below 3,600 rpm after the following conditions are met. - Engine: After warming up - Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load

ON

• Engine speed: Above 3,600 rpm

OFF

• Engine speed: Below 3,600 rpm after the following conditions are met. - Engine: After warming up - Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load

ON

• Engine speed: Above 3,600 rpm

OFF

• Vehicle speed: More than 20 km/h (12 MPH)

Almost the same speed as the tachometer indication

FUEL PUMP RLY

HO2S2 HTR (B1)

HO2S2 HTR (B2)

I/P PULLY SPD


HAC-78

2009 G37 Coupe


< ECU DIAGNOSIS INFORMATION > Monitor Item VEHICLE SPEED

IDL A/V LEARN

Condition

Values/Status


Almost the same speed as the speedometer indication

• Engine: Running

SNOW MODE SW


ENG OIL TEMP


Idle air volume learning has not been performed yet.

YET

Idle air volume learning has already been performed successfully.

CMPLT

Snow mode switch: Pressed

ON

Snow mode switch: Released

OFF

B

C

More than 70°C (158°F) Vehicle has traveled after MIL has illuminated.


A/F S1 HTR (B1)

• Engine: After warming up, idle the engine (More than 140 seconds after starting engine)

4 - 100%

A/F S1 HTR (B2)

• Engine: After warming up, idle the engine (More than 140 seconds after starting engine)

4 - 100%

AC PRESS SEN

• Engine: Idle • Both A/C switch and blower fan switch: ON (Compressor operates)

1.0 - 4.0 V

VHCL SPEED SE


Almost the same speed as the speedometer indication

SET VHCL SPD

• Engine: Running

ASCD: Operating

The preset vehicle speed is displayed

MAIN switch: Pressed

ON

MAIN switch: Released

OFF

CANCEL switch: Pressed

ON

CANCEL switch: Released

OFF

RESUME/ACCELERATE switch: Pressed

ON

RESUME/ACCELERATE switch: Released

OFF

SET/COAST switch: Pressed

ON

SET/COAST switch: Released

OFF


ON


OFF


OFF


ON

DISTANCE switch: Pressed

ON

DISTANCE switch: Released

OFF

MAIN switch: Pressed at the 1st time → at the 2nd time

ON → OFF


CANCEL SW


RESUME/ACC SW


SET SW


BRAKE SW1 (ICC/ASCD brake switch)


BRAKE SW2 (Stop lamp switch)


DIST SW


CRUISE LAMP


BAT CUR SEN

G

H

HAC

J

K

L

M

N

O

Battery: Fully charged*2 Selector lever: P or N (A/T), Neutral (M/T) Air conditioner switch: OFF No load

ALT DUTY

• Engine: Idle

ATOM PRES SEN

• This item is displayed but is not applicable to this model.

BRAKE BST PRES SE

• This item is displayed but is not applicable to this model.


E

F

• Engine speed: Idle • • • •

D

0 - 65,535 km (0 - 40,723 miles)

TRVL AFTER MIL

MAIN SW

A

Approx. 2,600 - 3,500 mV

P 0 - 80%

HAC-79

2009 G37 Coupe


< ECU DIAGNOSIS INFORMATION > Monitor Item

Condition

Values/Status

Idle

Approx. 0.25 - 1.40 V

VVEL POSITION SEN-B1


When revving engine up to 2,000 rpm quickly

Approx. 0.25 - 4.75 V

Idle

Approx. 0.25 - 1.40 V

VVEL POSITION SEN-B2



Approx. 0.25 - 4.75 V

Idle

Approx. 0 - 20 deg

VVEL TIM-B1



Approx. 0 - 90 deg

Idle

Approx. 0 - 20 deg

VVEL TIM-B2



Approx. 0 - 90 deg

VVEL learning has not been performed yet.

YET

VVEL learning has already been performed successfully.

DONE

VVEL LEARN

• Ignition switch: OFF → ON (After warming up)

VVEL SEN LEARNB1

• VVEL learning has already been performed successfully

Approx. 0.30 - 0.80 V

VVEL SEN LEARNB2

• VVEL learning has already been performed successfully

Approx. 0.30 - 0.80 V

A/F ADJ-B1

• Engine: Running

−0.330 - 0.330

A/F ADJ-B2

• Engine: Running

−0.330 - 0.330

FAN DUTY

• Engine: Running

0 - 100%

• Power generation voltage variable control: Operating

ON

• Power generation voltage variable control: Not operating

OFF

ALT DUTY SIG

*1: Accelerator pedal position sensor 2 signal and throttle position sensor 2 signal are converted by ECM internally. Thus, they differ from ECM terminals voltage signal. *2: Before measuring the terminal voltage, confirm that the battery is fully charged. Refer to PG-3, "How to Handle Battery".

TERMINAL LAYOUT

JMBIA0070ZZ

PHYSICAL VALUES NOTE: • ECM is located behind the instrument assist lower panel. For this inspection, remove passenger side instrument lower panel. • Specification data are reference values and are measured between each terminal and ground. • Pulse signal is measured by CONSULT-III.


HAC-80

2009 G37 Coupe


< ECU DIAGNOSIS INFORMATION > Terminal No. (Wire color) +

-–

A

Description Signal name

Value (Approx.)

Condition

Input/ Output

B 2.9 - 8.8 V

1 (W)

128 (B)

A/F sensor 1 heater (bank 1)

Output

[Engine is running] • Warm-up condition • Idle speed (More than 140 seconds after starting engine)

C

D JMBIA0030GB

0 - 14 V

E

[Ignition switch: ON] • Engine stopped • Selector lever: D (A/T) or 1st (M/T) • Accelerator pedal: Fully depressed 2 (G)

128 (B)

Throttle control motor (Open) (bank 1)

F

JMBIA0031GB

G

Output 0 - 14 V [Ignition switch: ON] • Engine stopped • Selector lever: D (A/T) or 1st (M/T) • Accelerator pedal: Fully released

H

HAC JMBIA0032GB

3 (R)

128 (B)

Throttle control motor power supply (bank 1)

Input

[Ignition switch: ON]

BATTERY VOLTAGE (11 - 14 V)

J

0 - 14 V

4 (BR)

128 (B)

Throttle control motor (Close) (bank 1)

Output

[Ignition switch: ON] • Engine stopped • Selector lever: D (A/T) or 1st (M/T) • Accelerator pedal: In the middle of releasing operation

K

L JMBIA0033GB

2.9 - 8.8 V

5 (GR)

128 (B)

A/F sensor 1 heater (bank 2)

Output

M

[Engine is running] • Warm-up condition • Idle speed (More than 140 seconds after starting engine)

N

JMBIA0030GB

8 (B)

—

ECM ground

—

—

O

—

P


HAC-81

2009 G37 Coupe



-–


11 (GR)

Ignition signal No. 4

12 (L)


15 (V)


16 (G)

128 (B)

Input/ Output

Value (Approx.)

Condition

0 - 0.2 V [Engine is running] • Warm-up condition • Idle speed NOTE: The pulse cycle changes depending on rpm at idle JMBIA0035GB

Output 0.1 - 0.4 V


19 (SB)


20 (Y)


[Engine is running] • Warm-up condition • Engine speed: 2,000 rpm

JMBIA0036GB

17 (P)

128 (B)

Heated oxygen sensor 2 heater (bank 1)

Output

[Engine is running] • Engine speed: Below 3,600 rpm after the following conditions are met - Engine: after warming up - Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load

10 V

JMBIA0037GB

[Ignition switch: ON] • Engine stopped [Engine is running] • Engine speed: Above 3,600 rpm


[Engine is running] • Warm-up condition • Idle speed

BATTERY VOLTAGE (11 - 14 V) 7 - 12 V

18 (W)

128 (B)

Intake valve timing control solenoid valve (bank 1)

Output

[Engine is running] • Warm-up condition • Engine speed: 2,000rpm

JMBIA0038GB


HAC-82

2009 G37 Coupe



-–


Input/ Output

Value (Approx.)

A

BATTERY VOLTAGE

B

Condition

(11 - 14 V) [Engine is running] • Idle speed • Accelerator pedal: Not depressed even slightly, after engine starting

C

D 21 (GR)

128 (B)

EVAP canister purge volume control solenoid valve

JMBIA0039GB

Output

BATTERY VOLTAGE

E

(11 - 14 V) [Engine is running] • Engine speed: About 2,000 rpm (More than 100 seconds after starting engine)

F

JMBIA0040GB

22 (R)

24 (P)

25 (O)

28 (BR)

128 (B)

128 (B)

128 (B)

128 (B)

Fuel pump relay

ECM relay (Self shut-off)

Throttle control motor relay

VVEL actuator motor relay abort signal [VVEL control module]

Output

Output

Output

Output

G

[Ignition switch: ON] • For 1 second after turning ignition switch ON [Engine is running]

0 - 1.5 V

[Ignition switch: ON] • More than 1 second after turning ignition switch ON


[Engine is running] [Ignition switch: OFF] • A few seconds after turning ignition switch OFF

0 - 1.5 V

J

[Ignition switch: OFF] • More than a few seconds after turning ignition switch OFF


K

[Ignition switch: ON → OFF]

0 - 1.0 V ↓ BATTERY VOLTAGE (11 - 14 V) ↓ 0V

H

HAC

L

M


0 - 1.0 V


0V

N



O

7 - 12 V 29 (G)

128 (B)

Intake valve timing control solenoid valve (bank 2)

P Output

[Engine is running] • Warm-up condition • Engine speed: 2,000rpm

JMBIA0038GB


HAC-83

2009 G37 Coupe



30 (Y)

31 (R)

33 (SB)

-–

40 (R)

48 (B)

128 (B)


Throttle position sensor 1 (bank 1)


Heated oxygen sensor 2 heater (bank 2)

Input/ Output

Input

Input

Output

Value (Approx.)

Condition

[Ignition switch: ON] • Engine stopped • Selector lever: D (A/T) or 1st (M/T) • Accelerator pedal: Fully released

More than 0.36 V

[Ignition switch: ON] • Engine stopped • Selector lever: D (A/T) or 1st (M/T) • Accelerator pedal: Fully depressed

Less than 4.75 V


More than 0.36 V


Less than 4.75 V

[Engine is running] • Engine speed: Below 3,600 rpm after the following conditions are met - Engine: after warming up - Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load

10 V

JMBIA0037GB

34 (B)

35 (W)

36 (O)

40 (R)

48 (B)

—



Sensor ground [Brake booster pressure sensor]


Input

Input

—

[Ignition switch: ON] • Engine stopped [Engine is running] • Engine speed: Above 3,600 rpm



Less than 4.75 V


More than 0.36 V


Less than 4.75 V


More than 0.36 V

—

—

HAC-84

2009 G37 Coupe



-–


Input/ Output

A

Value (Approx.)

Condition

B

4.0 - 5.0 V [Engine is running] • Warm-up condition • Idle speed NOTE: The pulse cycle changes depending on rpm at idle 37 (W)

128 (B)

Crankshaft position sensor (POS)

C

JMBIA0041GB

D

Input 4.0 - 5.0 V

E [Engine is running] • Engine speed: 2,000 rpm

F JMBIA0042GB

38 (O)

39 (P)

96 (P)

36 (O)

Manifold absolute pressure (MAP) sensor

Brake booster pressure sensor

Input

Input


1.2 V


1.5 V

[Engine is running] • Warm-up condition • Idle speed • Brake pedal: Fully released

1.2 V

G

H

HAC

J

[Engine is running] • Warm-up condition • Idle speed • Brake pedal: Fully depressed

3.0 V

K

—

Sensor ground [Throttle position sensor (bank 1)]

—

—

—

43 (G)

48 (B)

Sensor power supply [Throttle position sensor (bank 2)]

—


5V

44 (L)

40 (R)

Sensor power supply [Throttle position sensor (bank 1)]

—


5V

45 (LG)

36 (O)

Sensor power supply [Brake booster pressure sensor]

—


5V

46 (R)

128 (B)

Sensor power supply [Crankshaft position sensor (POS)]

—


5V

O

47 (Y)

—

Sensor ground [Crankshaft position sensor (POS)]

—

—

—

P

48 (B)

—

Sensor ground [Throttle position sensor (bank 2)]

—

—

—

40 (R)


L

M

HAC-85

N

2009 G37 Coupe



-–


Value (Approx.)

Condition

Input/ Output

0 - 14 V

49 (GR)

128 (B)

Throttle control motor (Close) (bank 2)

Output

[Ignition switch: ON] • Engine stopped • Selector lever: D (A/T) or 1st (M/T) • Accelerator pedal: In the middle of releasing operation JMBIA0033GB

0 - 14 V [Ignition switch: ON] • Engine stopped • Selector lever: D (A/T) or 1st (M/T) • Accelerator pedal: Fully depressed 50 (V)

128 (B)

Throttle control motor (Open) (bank 2)

JMBIA0031GB

Output 0 - 14 V [Ignition switch: ON] • Engine stopped • Selector lever: D (A/T) or 1st (M/T) • Accelerator pedal: Fully released JMBIA0032GB

52 (R)

128 (B)

Throttle control motor power supply (bank 2)

Input



53 (W)

128 (B)

Ignition switch

Input

[Ignition switch: OFF]

0V



54 (Y)

—

CAN communication line [VVEL control module]

Input/ output

—

—

55 (LG)

—

CAN communication line [VVEL control module]

Input/ output

—

—

57 (L)

128 (B)

A/F sensor 1 (bank 1)

Input


2.2 V 3.0 - 5.0 V

[Engine is running] • Warm-up condition • Idle speed NOTE: The pulse cycle changes depending on rpm at idle 59 (O)

128 (B)

Camshaft position sensor (PHASE) (bank 1)

JMBIA0045GB

Input 3.0 - 5.0 V

[Engine is running] • Engine speed: 2,000 rpm

JMBIA0046GB


HAC-86

2009 G37 Coupe



Description

-–

Signal name

60 (G)

128 (B)

Sensor power supply [Camshaft position sensor (PHASE) (bank 1), Manifold absolute pressure (MAP) sensor, Power steering pressure sensor]

61 (R)

128 (B)


Input/ Output

A

Value (Approx.)

Condition

B

—

Input


5V


1.8 V Output voltage varies with air fuel ratio.

D

3.0 - 5.0 V

E

C

[Engine is running] • Warm-up condition • Idle speed NOTE: The pulse cycle changes depending on rpm at idle 63 (L)

128 (B)

Camshaft position sensor (PHASE) (bank 2)

F

JMBIA0045GB

G

Input 3.0 - 5.0 V

H [Engine is running] • Engine speed: 2,000 rpm

HAC JMBIA0046GB

64 (SB)

128 (B)

Sensor power supply [Camshaft position sensor (PHASE) (bank 2), Battery current sensor]

65 (LG)

128 (B)

66 (V) 67 (P)

68 (LG) 69 (W) 71 (Y)

J —


5V


Input


2.2 V

128 (B)


Input


1.8 V Output voltage varies with air fuel ratio.

L

128 (B)

Intake air temperature sensor

Input

[Engine is running]

0 - 4.8 V Output voltage varies with intake air temperature.

M

—

—

N

[Engine is running] • Idle speed

2.5 V*1

[Engine is running]

0 - 4.8 V Output voltage varies with engine coolant temperature.

—

Sensor ground [Mass air flow sensor (bank 1), Intake air temperature sensor]

—

128 (B)

Knock sensor (bank 2)

Input

128 (B)

72 (—)

—

73 (W)

128 (B)

Engine coolant temperature sensor Sensor ground (Knock sensor) Knock sensor (bank 1)


Input

— Input

—

—

[Engine is running] • Idle speed

2.5 V*1

HAC-87

K

O

2009 G37 Coupe

P



76 (W)

77 (SB)

78 (G)

79 (BR)

80 (O)

-–

128 (B)

68 (LG)

84 (B)

94 (Y)

128 (B)

81 (R)


Heated oxygen sensor 2 (bank 1)

Mass air flow sensor (bank 1)

Engine oil temperature sensor



Input

Input

Input

Input

[Engine is running] • Revving engine from idle to 3,000 rpm quickly after the following conditions are met - Engine: after warming up - Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load

0 - 1.0 V


0.7 - 1.2 V


1.3 - 1.7 V

[Engine is running]

0 - 4.8 V Output voltage varies with engine oil temperature.


0.7 - 1.2 V


1.3 - 1.7 V

[Engine is running] • Revving engine from idle to 3,000 rpm quickly after the following conditions are met - Engine: after warming up - Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load

0 - 1.0 V

BATTERY VOLTAGE

Fuel injector No. 3

82 (V)

Fuel injector No. 6

85 (BR)

Fuel injector No. 2

86 (W)

Input/ Output

Input

128 (B)

Value (Approx.)

Condition

[Engine is running] • Warm-up condition • Idle speed NOTE: The pulse cycle changes depending on rpm at idle

(11 - 14 V)

JMBIA0047GB

Output

BATTERY VOLTAGE

Fuel injector No. 5

(11 - 14 V)

89 (GR)

Fuel injector No. 1

90 (O)

Fuel injector No. 4


JMBIA0048GB

84 (B)

—

Sensor ground (Heated oxygen sensor 2, Engine coolant temperature sensor, Engine oil temperature sensor)


—

—

—

HAC-88

2009 G37 Coupe



87 (Y)

-–

96 (P)


Power steering pressure sensor

Input/ Output

Output

95 (G)

Battery current sensor

92 (G)

—

Sensor ground [Camshaft position sensor (PHASE) (bank 2)]

93 (P)

128 (B)

Power supply for ECM (Back-up)

Input

94 (Y)

—

Sensor ground [Mass air flow sensor (bank 2)]

95 (G)

—

—

97 (R)

98 (P)

100 (W)

104 (GR)

[Engine is running] • Steering wheel: Being turned

0.5 - 4.5 V

[Engine is running] • Steering wheel: Not being turned

0.4 - 0.8 V

A

B

C

[Engine is running]

91 (SB)

96 (P)

Value (Approx.)

Condition

• Battery: Fully charged*2 • Idle speed

2.6 - 3.5 V

—

—

[Ignition switch: OFF]


—

—

—

Sensor ground (Battery current sensor)

—

—

—

Sensor ground [Camshaft position sensor (PHASE) (bank 1),Manifold absolute pressure (MAP) sensor, Power steering pressure sensor]

—

—

—

Accelerator pedal position sensor 1

Accelerator pedal position sensor 2

Input

—

D

E

F

G

H

HAC

Input

Input

[Ignition switch: ON] • Engine stopped • Accelerator pedal: Fully released

0.45 - 1.00 V

[Ignition switch: ON] • Engine stopped • Accelerator pedal: Fully depressed

4.2 - 4.8 V

[Ignition switch: ON] • Engine stopped • Accelerator pedal: Fully released

0.22 - 0.50 V

[Ignition switch: ON] • Engine stopped • Accelerator pedal: Fully depressed

2.1 - 2.5 V

J

K

L

M

99 (L)

100 (W)

Sensor power supply (Accelerator pedal position sensor 1)

—


5V

100 (W)

—

Sensor ground (Accelerator pedal position sensor 1)

—

—

—

N

O

P


HAC-89

2009 G37 Coupe



101 (SB)

101 (SB)

-–

108 (Y)

108 (Y)


ICC steering switch (models with ICC system)

ASCD steering switch (models with ASCD system)

Value (Approx.)

Condition

Input/ Output

[Ignition switch: ON] • ICC steering switch: OFF

4.3 V

[Ignition switch: ON] • MAIN switch: Pressed

0V

[Ignition switch: ON] • CANCEL switch: Pressed

1.3 V

[Ignition switch: ON] • RESUME/ACCELERATE switch: Pressed

3.7 V

[Ignition switch: ON] • SET/COAST switch: Pressed

3V

[Ignition switch: ON] • DISTANCE switch: Pressed

2.2 V

[Ignition switch: ON] • ASCD steering switch: OFF

4V

[Ignition switch: ON] • MAIN switch: Pressed

0V

[Ignition switch: ON] • CANCEL switch: Pressed

1V

[Ignition switch: ON] • RESUME/ACCELERATE switch: Pressed

3V

[Ignition switch: ON] • SET/COAST switch: Pressed

2V

Input


1.8 - 4.8 V

Input

Input

102 (GR)

112 (SB)

EVAP control system pressure sensor

103 (G)

104 (GR)

Sensor power supply (Accelerator pedal position sensor 2)

—


5V

104 (GR)

—

Sensor ground (Accelerator pedal position sensor 2)

—

—

—

105 (L)

116 (P)


Input

[Engine is running] • Warm-up condition • Both A/C switch and blower fan motor switch: ON (Compressor operates)

1.0 - 4.0 V

106 (W)

128 (B)

Fuel tank temperature sensor

Input

[Engine is running]

0 - 4.8 V Output voltage varies with fuel tank temperature.

107 (BR)

112 (SB)

Sensor power supply (EVAP control system pressure sensor,Refrigerant pressure sensor)

—


5V

108 (Y)

—

Sensor ground (ASCD/ICC steering switch)

—

—

—

[Ignition switch: ON] • Selector lever: P or N (A/T), Neutral (M/ T)


[Ignition switch: ON] • Selector lever: Except above

0V

109 (G)

128 (B)

PNP signal


Input

HAC-90

2009 G37 Coupe



-–


Input/ Output

A

Value (Approx.)

Condition

B

1V [Engine is running] • Warm-up condition • Idle speed NOTE: The pulse cycle changes depending on rpm at idle 110 (R)

128 (B)

Engine speed output signal

C

JMBIA0076GB

D

Output 1V

E [Engine is running] • Engine speed is 2,000 rpm

F JMBIA0077GB

—

Sensor ground (EVAP control system pressure sensor, Refrigerant pressure sensor)

—

—

—

113 (P)

—

CAN communication line

Input/ Output

—

—

114 (L)

—

CAN communication line

Input/ Output

—

—

117 (V)

128 (B)

Data link connector

Input/ Output

—

—

121 (LG)

128 (B)

EVAP canister vent control valve

Output



122 (P)

128 (B)

[Ignition switch: OFF] • Brake pedal: Fully released

0V

[Ignition switch: OFF] • Brake pedal: Slightly depressed


112 (SB)

Stop lamp switch

—

125 (R)

128 (B)

Power supply for ECM

128 (B)

ICC brake switch (models with ICC system) ASCD brake switch (models with ASCD system)

127 (B) 128 (B)

Input

H

HAC

J

K

L

123 (B) 124 (B)

126 (BR)

G

ECM ground

—

—

—



[Ignition switch: ON] • Brake pedal: Slightly depressed

0V

[Ignition switch: ON] • Brake pedal: Fully released


—

—

M

—

ECM ground

Input

Input

—

N

P

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) *1: This may vary depending on internal resistance of the tester. **2: Before measuring the terminal voltage, confirm that the battery is fully charged. Refer to PG-3, "How to Handle Battery".


O

HAC-91

2009 G37 Coupe



UNIFIED METER AND A/C AMP. Reference Value

INFOID:0000000004536499

TERMINAL LAYOUT

JSIIA0097ZZ

PHYSICAL VALUES Terminal No. (Wire color) +

−

38 (P)

Ground


Blower motor control signal

Condition

Input/ Output

Output

Value (Approx.)

• Ignition switch ON • Fan speed: 1st speed (manual)

JSIIA0096ZZ

41 (L)

Ground

ACC power supply

—

43 (R)

Ground

Intake sensor signal

Input

Ignition switch ON

0 – 4.8 V Output voltage varies with intake temperature.

44 (LG)

Ground

In-vehicle sensor signal

Input

Ignition switch ON


45 (V)

Ground

Ambient sensor signal

Input

Ignition switch ON


46 (O)

Ground

Sunload sensor signal

Input

Ignition switch ON


53 (W)

Ground

Ignition power supply

—

Ignition switch ON

Battery voltage

54 (Y)

Ground

Battery power supply

—

Ignition switch OFF

Battery voltage

55 (B)

Ground

Ground

—

Ignition switch ON

0V

56 (L)

Ground

CAN-H

—

—

—

59 (Y)

Ground

Intake sensor ground

—

—

0V

60 (L)

Ground

In-vehicle sensor ground

—


Ignition switch ACC

Ignition switch ON

HAC-92

Battery voltage

0V

2009 G37 Coupe


< ECU DIAGNOSIS INFORMATION > Terminal No. (Wire color)

Description Condition

Input/ Output

+

−

61 (R)

Ground

Ambient sensor ground

—

Ignition switch ON

0V

62 (SB)

Ground

Sunload sensor ground

—

Ignition switch ON

0V

Ground

ECV (Electrical Control Valve) signal

65 (O)

Signal name

Output

A

Value (Approx.)

B

C

D

• Ignition switch ON • Self-diagnosis. STEP-4 (Code No. 45)

E SJIA1607E

F 69 (L)

Ground

A/C LAN signal

Input/ Output

Ignition switch ON

G SJIA1453J

70 (R)

Ground

Each door motor power supply

71 (GR)

Ground

72 (P)

Ground

H Output

Ignition switch ON

12 V

Ground

—

Ignition switch ON

0V

CAN-L

—

—

HAC

—

J

K

L

M

N

O

P


HAC-93

2009 G37 Coupe



Wiring Diagram - AIR CONDITIONER CONTROL SYSTEM -

INFOID:0000000004536500

JCIWM0351GB


HAC-94

2009 G37 Coupe



A

B

C

D

E

F

G

H

HAC

J

K

L

M

N

O JCIWM0352GB

P


HAC-95

2009 G37 Coupe



JCIWM0353GB


HAC-96

2009 G37 Coupe



A

B

C

D

E

F

G

H

HAC

J

K

L

M

N

O JCIWM0354GB

P


HAC-97

2009 G37 Coupe



JCIWM0355GB


HAC-98

2009 G37 Coupe



A

B

C

D

E

F

G

H

HAC

J

K

L

M

N

O JCIWM0356GB

P


HAC-99

2009 G37 Coupe



JCIWM0357GB

Fail-safe

INFOID:0000000004536501

FAIL-SAFE FUNCTION • If a communication error exists between the unified meter and A/C amp., and the AV control unit and preset switch for 30 seconds or longer, air conditioner is controlled under the following conditions:


HAC-100

2009 G37 Coupe


< ECU DIAGNOSIS INFORMATION > Compressor Air outlet Air inlet Fan speed Set temperature

: ON : AUTO : FRE (Fresh) : AUTO : Setting before communication error occurs

A

B

C

D

E

F

G

H

HAC

J

K

L

M

N

O

P


HAC-101

2009 G37 Coupe

AIR CONDITIONER CONTROL [AUTOMATIC AIR CONDITIONER]

< SYMPTOM DIAGNOSIS >

SYMPTOM DIAGNOSIS AIR CONDITIONER CONTROL Diagnosis Chart By Symptom

INFOID:0000000004536502

Symptom A/C system does not activate.

A/C system cannot be controlled.

Air outlet does not change. Mode door motor does not operate normally.

Reference Go to Trouble Diagnosis Procedure for A/C System.

Go to Preset Switch System.

Air mix door motor does not operate

AV-104, "Symptom Table" (BASE AUDIO WITHOUT NAVIGATION), AV-339, "Symptom Table" (BOSE AUDIO WITHOUT NAVIGATION) or AV-603, "Symptom Table" (BOSE AUDIO WITH NAVIGATION)

Go to Trouble Diagnosis Procedure for Mode Door Motor. (LAN)


Go to Trouble Diagnosis Procedure for Air Mix Door Motor. (LAN)

HAC-50, "WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Diagnosis Procedure"

Discharge air temperature does not change.*1


normally.*1 Discharge air temperature (driver side) does not change.*2 Air mix door motor (driver side)

Go to Trouble Diagnosis Procedure for Air Mix Door Motor (driver side). (LAN)

does not operate normally.*2 Discharge air temperature (passenger side) does not change.*2 Air mix door motor (passenger side)

Go to Trouble Diagnosis Procedure for Air Mix Door Motor (passenger side). (LAN)


does not operate normally.*2 Intake door does not change.

Go to Trouble Diagnosis Procedure for Intake Door Motor. (LAN)


Blower motor operation is malfunctioning.

Go to Trouble Diagnosis Procedure for Blower Motor.


Magnet clutch does not engage.

Go to Trouble Diagnosis Procedure for Magnet Clutch.


Intake door motor does not operate normally.

Insufficient cooling Go to Trouble Diagnosis Procedure for Insufficient Cooling.

HAC-103, "Inspection procedure"

No warm air comes out. (Air flow volume is normal.)

Go to Trouble Diagnosis Procedure for Insufficient Heating.


Noise

Go to Trouble Diagnosis Procedure for Noise.


Self-diagnosis function cannot be performed normally.

Go to Trouble Diagnosis Procedure for Self-diagnosis.


Memory function does not operate normally.

Go to Trouble Diagnosis Procedure for Memory Function.


No cool air comes out. (Air flow volume is normal.) Insufficient heating



HAC-102

2009 G37 Coupe

INSUFFICIENT COOLING [AUTOMATIC AIR CONDITIONER]


INSUFFICIENT COOLING

A

Description

INFOID:0000000004536503

B

Symptom

• Insufficient cooling • No cool air comes out. (Air flow volume is normal.) C

Inspection procedure

INFOID:0000000004536504

1.CHECK WITH A GAUGE OF RECOVERY/RECYCLING RECHARGING EQUIPMENT Connect the recovery/recycling recharging equipment to the vehicle and perform the pressure inspection with the gauge. Is there refrigerant? YES >> GO TO 2. NO-1 >> Check for refrigerant leakages with the refrigerant leakage detecting fluorescent leak detector. Refer to HA-35, "Inspection". NO-2 >> GO TO 2 after repairing or replacing the parts according to the inspection results.

D

E

F

2.CHECK CHARGED REFRIGERANT AMOUNT 1.

Connect recovery/recycling recharging equipment to the vehicle and discharge the refrigerant. Refer to G HA-26, "Collection and Charge". 2. Recharge with the proper amount of refrigerant. Refer to HA-26, "Collection and Charge". 3. Perform the inspection with the refrigerant leakage detecting fluorescent leak detector. Refer to HA-35, H "Inspection". Is the inspection result normal? YES >> GO TO 3. HAC NO >> Refill the refrigerant and repair or replace the parts according to the inspection results.

3.PERFORM THE PERFORMANCE TEST Connect recovery/recycling recharging equipment to the vehicle and perform the performance test. Refer to HA-33, "Performance Chart". Is the inspection result normal? YES >> GO TO 4. NO >> Perform the diagnosis with the gauge pressure. Refer to HA-7, "Trouble Diagnosis For Unusual Pressure".

4.CHECK SETTING OF TEMPERATURE SETTING TRIMMER

J

K

L

Check the setting of temperature setting trimmer. Refer to HAC-7, "Temperature Setting Trimmer". 1. Check that the temperature setting trimmer is set to “+ direction”. NOTE: The control temperature can be set with the setting of temperature setting trimmer. 2. Set temperature control dial to “0”. Are the symptoms solved? YES >> INSPECTION END NO >> GO TO 5.

M

N


O

Perform self-diagnosis function. Refer to HAC-40, "Diagnosis Description". Is the inspection result normal? YES >> GO TO 6. NO >> Repair or replace parts according to the inspection results.

P

6.CHECK DRIVE BELT Check tension of the drive belt. Refer to EM-13, "Checking". Is the inspection result normal? YES >> GO TO 7. Revision: 2009 October

HAC-103

2009 G37 Coupe

INSUFFICIENT COOLING [AUTOMATIC AIR CONDITIONER]

< SYMPTOM DIAGNOSIS > NO >> Adjust or replace drive belt.

7.CHECK AIR LEAKAGE FROM DUCT Check duct and nozzle, etc. of A/C system for air leakage. Is the inspection result normal? YES >> GO TO 8. NO >> Repair or replace parts according to the inspection results.

8.CHECK ECV Perform the ECV diagnosis procedure. Refer to HAC-62, "Diagnosis Procedure". Is the inspection result normal? YES >> Replace the unified meter and A/C amp. NO >> Replace the compressor.


HAC-104

2009 G37 Coupe

INSUFFICIENT HEATING [AUTOMATIC AIR CONDITIONER]


INSUFFICIENT HEATING

A

Description

INFOID:0000000004536505

B

Symptom

• Insufficient heating • No warm air comes out. (Air flow volume is normal.) C


INFOID:0000000004536506

1.CHECK COOLING SYSTEM 1. Check engine coolant level and check for leakage. Refer to CO-7, "Inspection". 2. Check radiator cap. Refer to CO-11, "RADIATOR CAP : Inspection". 3. Check water flow sounds of engine coolant. Refer to CO-8, "Refilling". Is the inspection result normal? YES >> GO TO 2. NO >> Refill the engine coolant and repair or replace the parts according to the inspection results.

2.CHECK SETTING OF TEMPERATURE SETTING TRIMMER 1. 2.

Check the setting of temperature setting trimmer. Refer to HAC-7, "Temperature Setting Trimmer". Check that the temperature setting trimmer is set to “− direction”. NOTE: The control temperature can be set with the setting of temperature setting trimmer. 3. Set temperature control dial to “0”. Are the symptoms solved? YES >> INSPECTION END NO >> GO TO 3.

3.CHECK OPERATION Turn temperature dial (driver side) and raise temperature setting to 32°C (90°F) after warming up the engine. 2. Check that warm air blows from outlets. Is the inspection result normal? YES >> INSPECTION END NO >> GO TO 4.

D

E

F

G

H

HAC

1.


J

K

L

Perform self-diagnosis function. Refer to HAC-40, "Diagnosis Description". Is the inspection result normal? YES >> GO TO 5. NO >> Repair or replace parts according to the inspection results.

M

5.CHECK AIR LEAKAGE FROM DUCT N

Check duct and nozzle, etc. of A/C system for air leakage. Is the inspection result normal? YES >> GO TO 6. NO >> Repair or replace parts according to the inspection results.

O

6.CHECK HEATER HOSE INSTALLATION CONDITION Check the heater hose installation condition visually (for twist, crush, etc.). Is the inspection result normal? YES >> GO TO 7. NO >> Repair or replace parts according to the inspection results.

P

7.CHECK TEMPERATURE OF HEATER HOSE 1.

Check the temperature of inlet hose and outlet hose of heater core.


HAC-105

2009 G37 Coupe

INSUFFICIENT HEATING [AUTOMATIC AIR CONDITIONER] < SYMPTOM DIAGNOSIS > 2. Check that the inlet side of heater core is hot and the outlet side is slightly lower than/almost equal to the inlet side. CAUTION: The temperature inspection should be performed in a short time because the engine coolant temperature is too hot. Is the inspection result normal? YES >> GO TO 8. NO >> Replace the heater core after performing the procedures after the cooling system inspection again. GO TO 1.

8.REPLACE HEATER CORE Replace the heater core. Refer to heater core. Refer to HA-50, "Exploded View". Are the symptoms solved? YES >> INSPECTION END NO >> Perform the procedures after the cooling system inspection again. GO TO 1.


HAC-106

2009 G37 Coupe

NOISE [AUTOMATIC AIR CONDITIONER]


NOISE

A

Description

INFOID:0000000004536507

B

Symptom

• Noise • Noise is heard when the A/C system operates. C


INFOID:0000000004536508

1.CHECK OPERATION 1. Operate the A/C system and check the operation. Refer to HAC-5, "Description & Inspection". 2. Check the parts where noise is occurring. Can the parts where noise is occurring be checked? YES-1 >> Noise from blower motor: GO TO 2. YES-2 >> Noise from compressor: GO TO 3. YES-3 >> Noise from expansion valve: GO TO 4. YES-4 >> Noise from A/C piping (pipe, flexible hose): GO TO 6. YES-5 >> Noise from drive belt: GO TO 7. NO >> INSPECTION END

2.CHECK BLOWER MOTOR

E

F

G

1. Remove blower motor. 2. Remove in-cabin microfilter. 3. Remove foreign materials that are in the blower unit. 4. Check the noise from blower motor again. Is the inspection result normal? YES >> INSPECTION END NO >> Replace blower motor.

H

HAC

3.REPLACE COMPRESSOR

J

1. Correct the refrigerant with recovery/recycling recharging equipment. 2. Recharge with the proper amount of the collected refrigerant after recycling or new refrigerant. 3. Check for the noise from compressor again. Is the inspection result normal? YES >> INSPECTION END NO >> Replace compressor.

4.CHECK WITH GAUGE PRESSURE Perform the diagnosis with the gauge pressure. Refer to HA-7, "Trouble Diagnosis For Unusual Pressure". Is the inspection result normal? YES >> GO TO 5. NO >> Repair or replace malfunctioning part.

5.REPLACE EXPANSION VALVE 1. Correct the refrigerant with recovery/recycling recharging equipment. 2. Recharge with the proper amount of the collected refrigerant after recycling or new refrigerant. 3. Check for the noise from expansion valve again. Are the symptoms solved? YES >> INSPECTION END NO >> Replace expansion valve.

6.CHECK A/C PIPING (PIPE, FLEXIBLE HOSE) 1. Check A/C piping (pipe, flexible hose) (for deformation and damage, etc.). 2. Check the installation condition of clips and brackets, etc. of A/C piping (pipe, flexible hose). Is the inspection result normal? YES >> Fix the line with rubber or come vibration absorbing material. Revision: 2009 October

D

HAC-107

2009 G37 Coupe

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L

M

N

O

P

NOISE [AUTOMATIC AIR CONDITIONER] < SYMPTOM DIAGNOSIS > NO >> Repair or replace parts according to the inspection results.

7.CHECK DRIVE BELT Check tension of the drive belt. Refer to EM-13, "Checking". Is the inspection result normal? YES >> Check the noise from compressor: GO TO 3. NO >> Adjust or replace drive belt according to the inspection results.


HAC-108

2009 G37 Coupe

SELF-DIAGNOSIS CANNOT BE PERFORMED [AUTOMATIC AIR CONDITIONER]


SELF-DIAGNOSIS CANNOT BE PERFORMED Description

A INFOID:0000000004536509

Symptom: Self-diagnosis function does not operate normally.


B INFOID:0000000004536510

1.CHECK SELF-DIAGNOSIS FUNCTION

C

1. 2.

Turn ignition switch ON. Set in self-diagnosis mode as per the following. Within 10 seconds after starting engine (ignition switch is turned ON.), press OFF switch for at least 5 seconds. NOTE: • If battery voltage drops below 12 V during diagnosis STEP-3, door motor speed becomes slower and as a result, the system may generate an error even when operation is normal. Start engine before performing this diagnosis to avoid this. • Former STEP-1 (indicators and display screen are checked) does not exist in this self-diagnosis function. • OFF switch may not be recognized according to the timing of pressing it. Operate OFF switch after the intake switch indicators are turned ON. Does self-diagnosis function operate? YES >> INSPECTION END NO >> GO TO 2.

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E

F

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2.CHECK POWER SUPPLY AND GROUND CIRCUIT OF UNIFIED METER AND A/C AMP. Check power supply and ground circuit of unified meter and A/C amp. Refer to HAC-46, "UNIFIED METER H AND A/C AMP. : Diagnosis Procedure". Is the inspection result normal? YES >> Replace unified meter and A/C amp. HAC NO >> Repair or replace malfunctioning part. J

K

L

M

N

O

P


HAC-109

2009 G37 Coupe

MEMORY FUNCTION DOES NOT OPERATE [AUTOMATIC AIR CONDITIONER]


MEMORY FUNCTION DOES NOT OPERATE Description

INFOID:0000000004536511

Symptom

• Memory function does not operate normally. • The setting is not maintained. (It returns to the initial condition.)


INFOID:0000000004536512

1.CHECK OPERATION 1. Set temperature control dial to 32°C (90°F). 2. Press OFF switch. 3. Turn ignition switch OFF. 4. Turn ignition switch ON. 5. Press AUTO switch. 6. Check that the set temperature is maintained. Is the inspection result normal? YES >> INSPECTION END NO >> GO TO 2.

2.CHECK POWER SUPPLY AND GROUND CIRCUIT OF UNIFIED METER AND A/C AMP Check power supply and ground circuit of unified meter and A/C amp. Refer to HAC-46, "UNIFIED METER AND A/C AMP. : Diagnosis Procedure". Is the inspection result normal? YES >> Replace unified meter and A/C amp. NO >> Repair or replace malfunctioning part.


HAC-110

2009 G37 Coupe

PRECAUTIONS [AUTOMATIC AIR CONDITIONER]

< PRECAUTION >

PRECAUTION

A


B

INFOID:0000000004732336



C

D

E

F

G

H

WARNING: • When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) HAC with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing serious injury. • When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the J battery, and wait at least 3 minutes before performing any service.




2. 3. 4.



HAC-111

2009 G37 Coupe

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L

M

N

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PRECAUTIONS [AUTOMATIC AIR CONDITIONER] < PRECAUTION > 5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock when the push-button ignition switch is turned to LOCK position.) 6. Perform self-diagnosis check of all control units using CONSULT-III.


INFOID:0000000004536515



HAC-112

2009 G37 Coupe

PRESET SWITCH [AUTOMATIC AIR CONDITIONER]

< REMOVAL AND INSTALLATION >


A

PRESET SWITCH Exploded View

INFOID:0000000004536529

B

C

D

E

F

G JSNIA0107ZZ

H 1.

Clock

2.

Cluster lid C


3.

Preset switch INFOID:0000000004536530

HAC

REMOVAL Refer to AV-120, "Exploded View" (BASE AUDIO WITHOUT NAVIGATION), AV-362, "Exploded View" (BOSE AUDIO WITHOUT NAVIGATION) or AV-629, "Exploded View" (BOSE AUDIO WITH NAVIGATION).

J

INSTALLATION Installation is basically the reverse order of removal.

K

L

M

N

O

P


HAC-113

2009 G37 Coupe



UNIFIED METER AND A/C AMP. Exploded View

INFOID:0000000004536531

JSNIA0105ZZ

1.


4.

Bracket (RH)

2.

Bracket (LH)


3.

Audio unit

INFOID:0000000004536532

REMOVAL 1.

2.

Remove audio unit. Refer to AV-111, "Exploded View" (BASE AUDIO WITHOUT NAVIGATION), AV-348, "Exploded View" (BOSE AUDIO WITHOUT NAVIGATION) or AV-616, "Exploded View" (BOSE AUDIO WITH NAVIGATION). Remove mounting screws, and then remove unified meter and A/C amp.

INSTALLATION Installation is basically the reverse order of removal. CAUTION: Since unified meter and A/C amp. connector and AV control unit connector have the same form, be careful not to insert them wrongly.


HAC-114

2009 G37 Coupe



AMBIENT SENSOR

A

Exploded View

INFOID:0000000004536533

B 1.

Ambient sensor

C

D

JPIIA1479ZZ


INFOID:0000000004536534

F

REMOVAL 1. 2.

E

Remove front grille. Refer to EXT-19, "Exploded View". Disconnect ambient sensor connector, and then remove ambient sensor.

G

INSTALLATION Installation is basically the reverse order of removal. H

HAC

J

K

L

M

N

O

P


HAC-115

2009 G37 Coupe



IN-VEHICLE SENSOR Exploded View

INFOID:0000000004536535

JPIIA0645ZZ

1.

Instrument lower panel LH

2.

In-vehicle sensor


INFOID:0000000004536536

REMOVAL 1. 2.

Remove instrument lower panel LH. Refer to IP-11, "Exploded View". Remove mounting screw, and then remove in-vehicle sensor.



HAC-116

2009 G37 Coupe



SUNLOAD SENSOR

A

Exploded View

INFOID:0000000004536537

B 1.

Front defroster grille LH

2.

Sunload sensor

C

D

JPIIA0648ZZ


INFOID:0000000004536538

F

REMOVAL 1. 2.

E

Remove front defroster grille LH. Refer to VTL-10, "Exploded View". Disconnect sunload sensor connector, and then remove sunload sensor.

G

INSTALLATION Installation is basically the reverse order of removal. H

HAC

J

K

L

M

N

O

P


HAC-117

2009 G37 Coupe



INTAKE SENSOR Exploded View

INFOID:0000000004536539

JSIIA1424ZZ

1.


2.

Intake sensor bracket

4.

Evaporator assembly

5.

Evaporator cover


3.

Intake sensor

INFOID:0000000004536540

REMOVAL 1.

2.

Remove low-pressure pipe 1 and high-pressure pipe 2. Refer to HA-41, "Exploded View". CAUTION: Cap or wrap the joint of the A/C piping with suitable material such as vinyl tape to avoid the entry of air. Slide evaporator to passenger side, and then remove intake sensor.

INSTALLATION Installation is basically the reverse order of removal. CAUTION: • Replace O-rings with new ones. Then apply compressor oil to them when installing. • Mark the mounting position of intake sensor bracket prior to removal so that the reinstalled sensor can be located in the same position. • Female-side piping connection is thin and easy to deform. Slowly insert the male-side piping straight in axial direction. • Insert piping securely until a click is heard. • After piping connection is completed, pull male-side piping by hand to make sure that connection does not come loose. • Check for leakages when recharging refrigerant.


HAC-118

2009 G37 Coupe

REFRIGERANT PRESSURE SENSOR [AUTOMATIC AIR CONDITIONER]


REFRIGERANT PRESSURE SENSOR

A

Exploded View

INFOID:0000000004536541

B

C

D

E

F

G JSIIA0012GB

1.


2.

O-ring

3.

Liquid tank bracket

4.

Liquid tank

5.

Bracket

6.

Condenser pipe assembly

7.


H


HAC


INFOID:0000000004536542

REMOVAL 1. 2.

J

Remove liquid tank. Refer to HA-47, "Exploded View". Fix the liquid tank (1) with a vise (A). Remove the refrigerant pressure sensor (2) with a wrench (B). CAUTION: Be careful not to damage liquid tank.

K

L

M

JSIIA0075ZZ

INSTALLATION Installation is basically the reverse order of removal. CAUTION: • Replace O-ring with new one. Then apply compressor oil to them when installing. • Check for leakages when recharging refrigerant.

N

O

P


HAC-119

2009 G37 Coupe

DOOR MOTOR [AUTOMATIC AIR CONDITIONER]


DOOR MOTOR Exploded View

INFOID:0000000004536543

JSIIA1425ZZ

1.


2.

Air mix door motor adapter

3.

4.

Ventilator door lever

5.

Foot door lever

6.

7.

Air mix door motor adapter

8.

Air mix door motor (passenger side) 9.

11.

Intake door lever 2

10. Blower unit

Heater & cooling unit assembly Foot door link Ventilator door link

12. Intake door motor

13. Intake door link

14.

Intake door lever 1

15. Mode door motor

16. Mode door motor bracket

17.

Main link

18. Main link sub

19. Max.cool door link

20.

Defroster door link

21. Max.cool door lever

22. Defroster door lever *: With left and right ventilation temperature separately control system.

MODE DOOR MOTOR MODE DOOR MOTOR : Removal and Installation

INFOID:0000000004536545

REMOVAL 1. 2. 3.

Remove blower unit. Refer to VTL-16, "Exploded View". Remove mounting screws, and then remove mode door motor. Disconnect mode door motor connector.

INSTALLATION installation is basically the reverse order of removal.

AIR MIX DOOR MOTOR Revision: 2009 October

HAC-120

2009 G37 Coupe

DOOR MOTOR [AUTOMATIC AIR CONDITIONER]


AIR MIX DOOR MOTOR : Removal and Installation

INFOID:0000000004536547

A

REMOVAL Without left and right ventilation temperature separately control system

1.

2. 3. 4. 5.

B

Set the temperature at 18°C (64°F). CAUTION: The angle may be out, when installing the air mix door motor to the air mix door, unless the above procedure is performed. Disconnect the battery cable from the negative terminal. Remove blower unit. Refer to VTL-16, "Exploded View". Remove mounting screws, and then remove air mix door motor. Disconnect air mix door motor connector.

With left and right ventilation temperature separately control system Driver side 1. Set the temperature (driver side) at 18°C (64°F). CAUTION: The angle may be out, when installing the air mix door motor to the air mix door, unless the above procedure is performed. 2. Disconnect the battery cable from the negative terminal. 3. Remove Instrument driver lower panel. Refer to IP-11, "Exploded View". 4. Remove Accelerator pedal bracket and lever assembly. Refer to ACC-3, "Exploded View". 5. Remove mounting screws, and then remove air mix door motor (driver side). 6. Disconnect air mix door motor connector.

Passenger side 1. Set the temperature (passenger side) at 18°C (64°F). CAUTION: The angle may be out, when installing the air mix door motor to the air mix door, unless the above procedure is performed. 2. Disconnect the battery cable from the negative terminal. 3. Remove blower unit. Refer to VTL-16, "Exploded View". 4. Remove mounting screws, and then remove air mix door motor (passenger side). 5. Disconnect air mix door motor connector.

C

D

E

F

G

H

HAC

J

K

L


INTAKE DOOR MOTOR

M

INTAKE DOOR MOTOR : Removal and Installation

INFOID:0000000004536549

N

REMOVAL 1. 2. 3.

Remove ECM and power steering control unit with bracket attached. Refer to VTL-17, "BLOWER UNIT : Removal and Installation". Remove mounting screws, and then remove intake door motor from blower unit. Disconnect intake door motor connector.

P



O

HAC-121

2009 G37 Coupe

DRIVER CONTROLS

SECTION

HRN

HORN

A

B

C

D

E

CONTENTS DTC/CIRCUIT DIAGNOSIS .......................... 2 Wiring Diagram - HORN - ......................................... 2

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" .................................................................. 5 Precaution for Battery Service .................................. 5

PRECAUTION ............................................... 5

REMOVAL AND INSTALLATION ................ 6

PRECAUTIONS ................................................... 5

HORN ................................................................. 6

HORN .................................................................. 2

F

G

H

Exploded View .......................................................... 6 Removal and Installation .......................................... 6 I

J

K

HRN

M

N

O

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HRN-1

2009 G37 Coupe

HORN < DTC/CIRCUIT DIAGNOSIS >

DTC/CIRCUIT DIAGNOSIS HORN Wiring Diagram - HORN -

INFOID:0000000004249148

JCLWM2731GB


HRN-2

2009 G37 Coupe

HORN < DTC/CIRCUIT DIAGNOSIS > A

B

C

D

E

F

G

H

I

J

K

HRN

M

N

O JCLWM2732GB

P


HRN-3

2009 G37 Coupe

HORN < DTC/CIRCUIT DIAGNOSIS >

JCLWM2733GB


HRN-4

2009 G37 Coupe


PRECAUTION

A


B

INFOID:0000000004249149




C

D

E

F

G

H

I

J

INFOID:0000000004249150

K Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interference between the window edge and the vehicle when the door is opened/closed. During normal operation, the window slightly raises and lowers automatically to prevent any window to vehicle interference. The automatic HRN window function will not work with the battery disconnected.

M

N

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P


HRN-5

2009 G37 Coupe

HORN < REMOVAL AND INSTALLATION >

REMOVAL AND INSTALLATION HORN Exploded View

INFOID:0000000004249151

JPLIA0569ZZ

1.

Horn (LOW)

2.

Horn (HIGH)


INFOID:0000000004249152

REMOVAL Horn (LOW)

1. 2. 3.

Remove radiator core support ornament. Refer to DLK-212, "Exploded View". Disconnect the horn (LOW) connector. Remove the horn mounting nut, and remove the horn (LOW) from the vehicle.

Horn (HIGH)

1. 2. 3.

Remove fender protector (LH). Refer to EXT-24, "FENDER PROTECTOR : Exploded View". Disconnect the horn (HIGH) connector. Remove the horn mounting bolt, and remove the horn (HIGH) from the vehicle.



HRN-6

2009 G37 Coupe

ENGINE

SECTION

EM

ENGINE MECHANICAL

A

EM

C

D

E


AIR CLEANER FILTER ..................................... 15

F

Removal and Installation .........................................15

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ............................. 3

SPARK PLUG ................................................... 16

NVH Troubleshooting - Engine Noise .................... 3 Use the Chart Below to Help You Find the C ause of the Symptom .............................................. 3


PRECAUTION ............................................... 5

CAMSHAFT VALVE CLEARANCE .................. 18

G

H

Inspection and Adjustment ......................................18

PRECAUTIONS ................................................... 5 Precaution for Procedure without Cowl Top Cover...... 5 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ................................................................... 5 Precaution Necessary for Steering Wheel Rotation after Battery Disconnect ..................................... 5 Precaution for Battery Service .................................. 6 Draining Engine Coolant .......................................... 6 Disconnecting Fuel Piping ....................................... 6 Removal and Disassembly ...................................... 6 Inspection, Repair and Replacement ...................... 6 Assembly and Installation ........................................ 6 Parts Requiring Angle Tightening ........................... 7 Liquid Gasket ........................................................... 7 Definitions of Bank Names ........................................ 8

COMPRESSION PRESSURE ........................... 23 Inspection ................................................................23

REMOVAL AND INSTALLATION ............... 25 Exploded View .........................................................25 Removal and Installation .........................................25

DRIVE BELT AUTO TENSIONER AND IDLER PULLEY ............................................................. 26

K

L

Exploded View .........................................................26 Removal and Installation .........................................26

AIR CLEANER AND AIR DUCT ....................... 27

PREPARATION ............................................ 9 PREPARATION ................................................... 9

INTAKE MANIFOLD COLLECTOR .................. 29

Special Service Tools .............................................. 9 Commercial Service Tools ..................................... 10


PERIODIC MAINTENANCE ......................... 13

INTAKE MANIFOLD ......................................... 32

DRIVE BELT .......................................................13



J

ENGINE COVER ............................................... 25


Exploded View ........................................................ 13 Checking ................................................................. 13 Tension Adjustment ................................................ 13 Removal and Installation ......................................... 13 Inspection ................................................................ 14

I

EXHAUST MANIFOLD ...................................... 34

EM-1


2009 G37 Coupe

M

N

O

P

FUEL INJECTOR AND FUEL TUBE ................. 37 Exploded View ........................................................ 37 Removal and Installation ........................................ 37 Inspection ............................................................... 42

OIL PAN (LOWER) ............................................ 43 Exploded View (2WD) ............................................ 43 Exploded View (AWD) ............................................ 44 Removal and Installation ........................................ 44 Inspection ............................................................... 46

2WD ........................................................................... 82 2WD : Exploded View ............................................. 82 2WD : Disassembly and Assembly ......................... 82 2WD : Inspection ..................................................... 84 AWD .......................................................................... 84 AWD : Exploded View ............................................. 85 AWD : Disassembly and Assembly ......................... 85 AWD : Inspection .................................................... 88

REAR TIMING CHAIN CASE ............................ 89

IGNITION COIL, SPARK PLUG AND ROCKER COVER ......................................................... 47

Exploded View ........................................................ 89 Disassembly and Assembly .................................... 90

Exploded View ........................................................ 47 Removal and Installation ........................................ 47

CAMSHAFT ....................................................... 94

TIMING CHAIN .................................................. 50 Exploded View ........................................................ 50 Removal and Installation ........................................ 51 Inspection ............................................................... 65

Exploded View ........................................................ 94 Disassembly and Assembly .................................... 95 Inspection .............................................................. 104

CYLINDER HEAD ............................................. 111

OIL SEAL ........................................................... 67

Exploded View ...................................................... 111 Disassembly and Assembly .................................. 112 Inspection .............................................................. 117

FRONT OIL SEAL ..................................................... 67 FRONT OIL SEAL : Removal and Installation ........ 67

CYLINDER BLOCK .......................................... 121

REAR OIL SEAL ....................................................... 67 REAR OIL SEAL : Removal and Installation .......... 67

Exploded View ...................................................... 121 Disassembly and Assembly .................................. 122 Inspection .............................................................. 131

UNIT REMOVAL AND INSTALLATION ..... 69

HOW TO SELECT PISTON AND BEARING .. 142

ENGINE ASSEMBLY ......................................... 69 2WD ........................................................................... 69 2WD : Exploded View ............................................. 69 2WD : Removal and Installation ............................. 69 2WD : Inspection .................................................... 72 AWD .......................................................................... 73 AWD : Exploded View ............................................ 73 AWD : Removal and Installation ............................. 74 AWD : Inspection .................................................... 77

UNIT DISASSEMBLY AND ASSEMBLY ... 79 ENGINE STAND SETTING ................................ 79 Setting .................................................................... 79

ENGINE UNIT .................................................... 81 Disassembly ........................................................... 81 Assembly ................................................................ 81

Description ............................................................ 142 Piston .................................................................... 142 Connecting Rod Bearing ..................................... 143 Main Bearing ........................................................ 146

SERVICE DATA AND SPECIFICATIONS (SDS) ......................................................... 148 SERVICE DATA AND SPECIFICATIONS (SDS) ................................................................ 148 General Specification ........................................... 148 Drive Belt .............................................................. 148 Spark Plug ............................................................ 148 Intake Manifold ...................................................... 149 Exhaust Manifold .................................................. 149 Camshaft ............................................................... 149 Cylinder Head ...................................................... 151 Cylinder Block ...................................................... 153 Main Bearing ........................................................ 157 Connecting Rod Bearing ..................................... 158

OIL PAN (UPPER) AND OIL STRAINER .......... 82


EM-2

2009 G37 Coupe

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING < SYMPTOM DIAGNOSIS >

SYMPTOM DIAGNOSIS

A

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting - Engine Noise

INFOID:0000000004250451

EM

C

D

E

F

G

H

I

J

K

L

M

N

O

P

JPBIA1048GB

Use the Chart Below to Help You Find the Cause of the Symptom 1.

INFOID:0000000004250452

Locate the area where noise occurs.


EM-3

2009 G37 Coupe

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING < SYMPTOM DIAGNOSIS > 2. Confirm the type of noise. 3. Specify the operating condition of the engine. 4. Check specified noise source. If necessary, repair or replace these parts. Operating condition of engine Location of noise

Type of noise

Top of engine Rocker cover Cylinder head

When starting

When idling

When racing

While driving

Ticking or clicking

C

A

—

A

B

—

Tappet noise

Valve clearance

EM-18

Rattle

C

A

—

A

B

C

Camshaft bearing noise

Camshaft runout Camshaft journal oil clearance

EM-149

—

Piston pin noise

Piston to piston pin oil clearance Connecting rod bushing oil clearance

EM-153

A

Piston slap noise

Piston to cylinder bore clearance Piston ring side clearance Piston ring end gap Connecting rod bend and torsion

EM-153

B

Connecting rod bearing noise

Connecting rod bushing oil clearance Connecting rod bearing oil clearance

Slap or rap

Knock

Knock

Front of engine Timing chain case

Front of engine

Reference page

After warmup

Slap or knock

Crankshaft pulley Cylinder block (Side of engine) Oil pan

Source of noise

Before warmup

Tapping or ticking

—

A

A

A

A

A

—

B

B

A

—

—

C

—

—

B

B

B

A

B

B

B

B

B

B

Check item

C

Main bearing oil clearMain bearance ing noise Crankshaft runout

B

Timing chain and timing chain tensioner noise

Timing chain cracks and wear Timing chain tensioner operation

Drive belt (Sticking or slipping)

Drive belt deflection

Squeaking or fizzing

A

Creaking

A

B

A

B

A

B

Drive belt (Slipping)

Idler pulley bearing operation

Squall Creak

A

B

—

B

A

B

Water pump noise

Water pump operation

B

—

A: Closely related B: Related C: Sometimes related


B

—

C

EM-153 EM-158 EM-157 EM-153

EM-65 EM-51

EM-13

CO-18, "Exploded View"

—: Not related

EM-4

2009 G37 Coupe


PRECAUTION

A

PRECAUTIONS Precaution for Procedure without Cowl Top Cover

INFOID:0000000004685367


EM

C

D

E PIIB3706J

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"

F


G


L

INFOID:0000000004685366

WARNING: • When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing serious injury. • When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the battery, and wait at least 3 minutes before performing any service.


NOTE: • Before removing and installing any control units, first turn the push-button ignition switch to the LOCK position, then disconnect both battery cables. • After finishing work, confirm that all control unit connectors are connected properly, then re-connect both battery cables. • Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results. For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and cannot be turned.


EM-5

2009 G37 Coupe

H

I

J

K

M

N

O

P

PRECAUTIONS < PRECAUTION > If turning the steering wheel is required with the battery disconnected or discharged, follow the operation procedure below before starting the repair operation.


2. 3. 4. 5.

6.

Connect both battery cables. NOTE: Supply power using jumper cables if battery is discharged. Turn the push-button ignition switch to ACC position. (At this time, the steering lock will be released.) Disconnect both battery cables. The steering lock will remain released with both battery cables disconnected and the steering wheel can be turned. Perform the necessary repair operation. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock when the push-button ignition switch is turned to LOCK position.) Perform self-diagnosis check of all control units using CONSULT-III.


INFOID:0000000004704593


Draining Engine Coolant

INFOID:0000000004250455

Drain engine coolant and engine oil when the engine is cooled.

Disconnecting Fuel Piping

INFOID:0000000004250456

• Before starting work, make sure that no fire or spark producing items are in the work area. • Release fuel pressure before disconnecting and disassembly. • After disconnecting pipes, plug openings to stop fuel leakage.

Removal and Disassembly

INFOID:0000000004250457

• When instructed to use SST, use the specified tools. Always be careful to work safely, and avoid forceful or uninstructed operations. • Exercise maximum care to avoid damage to mating or sliding surfaces. • Dowel pins are used for the alignment of several parts. When replacing and reassembling parts with dowel pins, make sure that dowel pins are installed in the original position. • Cover openings of engine system with tape or equivalent, if necessary, to seal out foreign materials. • Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly. • When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used in the step.

Inspection, Repair and Replacement

INFOID:0000000004250458

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and replace if necessary.

Assembly and Installation

INFOID:0000000004250459

• Use torque wrench to tighten bolts or nuts to specification. • When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified. • Replace with new gasket, packing, oil seal or O-ring. • Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for any restriction and blockage.


EM-6

2009 G37 Coupe

PRECAUTIONS < PRECAUTION > • Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well. • Release air within route when refilling after draining engine coolant. • After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and exhaust gases for leakage.

Parts Requiring Angle Tightening • • • •

Liquid Gasket

INFOID:0000000004250461

REMOVAL OF LIQUID GASKET SEALING • After removing mounting nuts and bolts, separate the mating surface using the seal cutter [SST: KV10111100 (J-37228)] (A) and remove old liquid gasket sealing. CAUTION: Be careful not to damage the mating surfaces. • Tap the seal cutter [SST: KV10111100 (J-37228)] to insert it (B), and then slide it (C) by tapping on the side as shown in the figure. • In areas where the seal cutter [SST: KV10111100 (J-37228)] is difficult to use, lightly tap the parts using a plastic hammer to remove it. CAUTION: If for some unavoidable reason a tool such as a screwdriver is used, be careful not to damage the mating surfaces.

C

D

E

F

G

H

I JPBIA0052ZZ

J

LIQUID GASKET APPLICATION PROCEDURE

2.

EM

INFOID:0000000004250460

Use the angle wrench [SST: KV10112100 (BT8653-A)] for the final tightening of the following engine parts: Cylinder head bolts Lower cylinder block bolts Connecting rod cap bolts Do not use a torque value for final tightening. The torque value for these parts are for a preliminary step. Ensure thread and seat surfaces are clean and coated with engine oil.

1.

A

Using a scraper (A), remove old liquid gasket adhering to the liquid gasket application surface and the mating surface. • Remove liquid gasket completely from the groove of the liquid gasket application surface, mounting bolts and bolt holes. Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove adhering moisture, grease and foreign materials.

K

L

M JPBIA0053ZZ

3.

4.

N

Attach liquid gasket tube to the tube presser (commercial service tool). Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-17, "Recommended Chemical Products and Sealants". Apply liquid gasket without gaps to the specified location according to the specified dimensions. • If there is a groove for liquid gasket application, apply liquid gasket to the groove.

O

P

EMA0622D


EM-7

2009 G37 Coupe

PRECAUTIONS < PRECAUTION > • As for bolt holes (B), normally apply liquid gasket inside the holes. Occasionally, it should be applied outside the holes. Make sure to read the text of this manual. A

: Groove : Inside

• Within five minutes of liquid gasket application, install the mating component. • If liquid gasket protrudes, wipe it off immediately. • Do not retighten mounting bolts or nuts after the installation. • After 30 minutes or more have passed from the installation, fill engine oil and engine coolant. CAUTION: If there are specific instructions in this manual, observe them.

Definitions of Bank Names

JPBIA0010ZZ

INFOID:0000000004250462

• In this manual, each bank name is defined as follows: A

: Bank 1 (The conventional right bank)

B

: Bank 2 (The conventional left bank) : Engine front

• For cylinder numbers and bank layout, refer to the illustration. Bank 1 Bank 2

: The bank side including cylinder No. 1 (odd-numbered cylinder side) : The other bank side of the above (even-numbered cylinder side)


EM-8

JPBIA1135ZZ

2009 G37 Coupe


PREPARATION

A

PREPARATION Special Service Tools

INFOID:0000000004250463

EM

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number (Kent-Moore No.) Tool name KV10116200 (J-26336-A) Valve spring compressor 1. KV10115900 (J-26336-20) Attachment 2.KV10109220 ( — ) Adapter

Description

C

Disassembling valve mechanism Part (1) is a component of KV10116200 (J26336-A), but Part (2) is not so.

D

E

PBIC1650E

F Replacing valve oil seal

KV10107902 (J-38959) Valve oil seal puller

G

H NT011

Installing valve oil seal Use side A (G). a: 20 (0.79) dia. d: 8 (0.31) dia. b: 13 (0.51) dia. e: 10.7 (0.421) c: 10.3 (0.406) dia. f: 5 (0.20) H: side B Unit: mm (in)

KV10115600 (J-38958) Valve oil seal drift

I

J

JPBIA0396ZZ

Installing piston assembly into cylinder bore

EM03470000 (J-8037) Piston ring compressor

K

L

M

NT044

Removing pilot converter

ST16610001 (J-23907) Pilot bushing puller

N

O NT045

Removing oil pan (lower and upper), front and rear timing chain case, etc.

KV10111100 (J-37228) Seal cutter

NT046


EM-9

2009 G37 Coupe

P


Description Tightening bolts for connecting rod bearing cap, cylinder head, etc. at an angle

KV10112100 (BT8653-A) Angle wrench

NT014

Loosening or tightening air fuel ratio sensor 1 a: 22 mm (0.87 in)

KV10114400 (J-38365) Heated oxygen sensor wrench

JPBIA0397ZZ

Removing and installing crankshaft pulley

KV10118600 (J-48641) Ring gear stopper

JPBIA0409ZZ


INFOID:0000000004250464

(Kent-Moore No.) Tool name

Description

( — ) Tube presser

Pressing the tube of liquid gasket

NT052

( — ) Power tool

Loosening nuts and bolts

PBIC0190E

( — ) TORX socket

Removing and installing drive plate

PBIC1113E


EM-10

2009 G37 Coupe

PREPARATION < PREPARATION > (Kent-Moore No.) Tool name

Description

( — ) Manual lift table caddy

A

Removing and installing engine

EM

C ZZA1210D

(J-24239-01) Cylinder head bolt wrench

Loosening and tightening cylinder head bolt, and used with the angle wrench [SST: KV10112100 (BT8653-A)] a: 13 (0.51) dia. b: 12 (0.47) c: 10 (0.39) Unit: mm (in)

D

E

JPBIA0398ZZ

Checking compression pressure

( — ) 1.Compression gauge 2.Adapter

F

G

H ZZA0008D

( — ) Spark plug wrench

Removing and installing spark plug a: 14 mm (0.55 in)

I

J JPBIA0399ZZ

( — ) Valve seat cutter set

Finishing valve seat (EXH) dimensions

K

L

M

NT048

( — ) Piston ring expander

Removing and installing piston ring

N

O NT030

( — ) Valve guide drift

Removing and installing valve guide (EXH) Exhaust: a: 9.5 mm (0.374 in) dia. b: 5.5 mm (0.217 in) dia.

JPBIA0400ZZ


EM-11

2009 G37 Coupe

P

PREPARATION < PREPARATION > (Kent-Moore No.) Tool name

Description

( — ) Valve guide reamer

A: Reaming valve guide (EXH) inner hole B: Reaming hole for oversize valve guide (EXH) Exhaust: c: 6.0 mm (0.236 in) dia. d: 10.2 mm (0.402 in) dia.

JPBIA0401ZZ

(J-43897-18) (J-43897-12) Oxygen sensor thread cleaner

JPBIA0238ZZ

Reconditioning the exhaust system threads before installing a new air fuel ratio sensor and heated oxygen sensor (Use with anti-seize lubricant shown below.) A: J-43897-18 [18 mm (0.71 in) dia.] for zirconia heated oxygen sensor and air fuel ratio sensor B: J-43897-12 [12 mm (0.47 in) dia.] for titania heated oxygen sensor C: Mating surface shave cylinder D: Flutes Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads

( — ) Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907)

AEM489

( — ) Feeler gauge

Inspection valve clearance (Use a curved-tip gauge)

JPBIA1362ZZ


EM-12

2009 G37 Coupe

DRIVE BELT < PERIODIC MAINTENANCE >

PERIODIC MAINTENANCE

A

DRIVE BELT Exploded View

INFOID:0000000004250465

EM

C

D

E

F

G JPBIA1060ZZ

H 1.

Power steering oil pump

2.

Alternator

3.

Drive belt auto-tensioner

4.

Idler pulley

5.

Crankshaft pulley

6.

A/C compressor

7.

Idler pulley

8.

Drive belt

9.

Idler pulley

A.

Possible use range

B.

Range when new drive belt is installed

C.

Indicator

D.

View D

I

J

Checking

INFOID:0000000004250466

WARNING: Be sure to perform the this step when engine is stopped. • Check that the indicator (C) (notch on fixed side) of drive belt auto-tensioner is within the possible use range (A). NOTE: • Check the drive belt auto-tensioner indication when the engine is cold. • When new drive belt is installed, the indicator (notch on fixed side) should be within the range (B) in the figure. • Visually check the entire drive belt for wear, damage or crack. • If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.

Tension Adjustment

K

L

M

INFOID:0000000004250467

N

INFOID:0000000004250468

O

Refer to EM-148, "Drive Belt".

Removal and Installation REMOVAL 1.

P

Remove engine undercover with power tool.


EM-13

2009 G37 Coupe

DRIVE BELT < PERIODIC MAINTENANCE > 2. While securely holding the square hole (A) in pulley center of auto tensioner (1) with a spinner handle, move spinner handle in the direction of arrow (loosening direction of drive belt). CAUTION: Never place hand in a location where pinching may occur if the holding tool accidentally comes off. : Loosening direction of drive belt

3.

4.

Under the above condition, insert a metallic bar of approximately 6 mm (0.24 in) in diameter [hexagonal wrench (C) shown as example in the figure] through the holding boss (B) to lock autotensioner pulley arm.

JPBIA0003ZZ

Remove drive belt.

INSTALLATION Note the following, and install in the reverse order of removal. CAUTION: • Check drive belt is securely installed around all pulleys. • Check drive belt is correctly engaged with the pulley groove. • Check for engine oil and engine coolant are not adhered drive belt and pulley groove.

Inspection

INFOID:0000000004250469

INSPECTION AFTER INSTALLATION • Turn crankshaft pulley clockwise several times to equalize tension between each pulley, and then confirm tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to EM-13, "Exploded View".


EM-14

2009 G37 Coupe

AIR CLEANER FILTER < PERIODIC MAINTENANCE >

AIR CLEANER FILTER

A


INFOID:0000000004250470

REMOVAL 1.

EM

Unhook clips (A). 1

: Holder

2

: Air cleaner case

C

D

E JPBIA1597ZZ

2.

Remove holder (3) from air cleaner case (2), and then remove air cleaner filter (1) from holder.

F

G

H

JPBIA1598ZZ

I

INSTALLATION Note the following, and install in the reverse order of removal. • Install the air cleaner filter by aligning the seal with the notch of air cleaner case.

J

K

L

M

N

O

P


EM-15

2009 G37 Coupe

SPARK PLUG < PERIODIC MAINTENANCE >

SPARK PLUG Exploded View

INFOID:0000000004250471

JPBIA2803GB

1.

PCV hose

2.

Clamp

3.

PCV valve

4.

O-ring

5.

Clamp

6.

PCV hose

7.

Ignition coil

8.

Spark plug

9.

Rocker cover (bank 1)

10.

Oil filler cap

11.

Rocker cover gasket (bank 1)

12. Clamp

13.

PCV hose

14. PCV hose

15. Rocker cover gasket (bank 2)

16.

Rocker cover (bank 2) B.

C.

A.

To intake manifold collector

D.

Refer to EM-47

To air duct

VVEL ladder assembly side



INFOID:0000000004250472

REMOVAL 1. 2. 3. 4.

Remove engine cover with power tool. Refer to EM-25, "Exploded View". Remove air cleaner case and air duct (RH and LH). Refer to EM-27, "Exploded View". Remove electric throttle control actuator. Refer to EM-29, "Exploded View". Remove ignition coil. Refer to EM-47, "Removal and Installation".


EM-16

2009 G37 Coupe

SPARK PLUG < PERIODIC MAINTENANCE > 5. Remove spark plug with a spark plug wrench (commercial service tool). a

A

: 14 mm (0.55 in)

EM

C JPBIA0030ZZ

D

INSTALLATION Installation is the reverse order of removal.

Inspection

INFOID:0000000004250473

E

INSPECTION AFTER REMOVAL F

Use the standard type spark plug for normal condition. Spark plug (Standard type) : Refer to EM-148, "Spark Plug".

G

CAUTION: • Never drop or shock spark plug. • Never use a wire brush for cleaning. • If plug tip is covered with carbon, use spark plug cleaner to clean.

H

Cleaner air pressure

I 2

: Less than 588 kPa (6 kg/cm , 85 psi) Cleaning time : Less than 20 seconds

J SMA773C

K

• Check and adjustment of plug gap is not required between change intervals.

L

M

JPBIA0031ZZ

N

O

P


EM-17

2009 G37 Coupe

CAMSHAFT VALVE CLEARANCE < PERIODIC MAINTENANCE >

CAMSHAFT VALVE CLEARANCE Inspection and Adjustment

INFOID:0000000004250474

INSPECTION Check valve clearance if applicable to the following cases: Intake side:

• At the removal and installation of VVEL ladder assembly or valve-related parts, or at the occurrence of malfunction (poor starting, idle malfunction, unusual noise) due to aged deterioration in valve clearance. CAUTION: Valve clearance check on the intake side is not required after replacing the VVEL ladder assembly and cylinder head assembly with a new one. (Install new VVEL ladder assembly and cylinder head assembly in factory-shipped condition because it is factory-adjusted and inspected.) NOTE: VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinder head assembly. Exhaust side:

• At the removal, installation, and replacement of camshaft (EXH) or valve-related parts, or at the occurrence of malfunction (poor starting, idle malfunction, unusual noise) due to aged deterioration in valve clearance. 1. 2.

Remove rocker covers (bank 1 and bank 2). Refer to EM-47, "Removal and Installation". Measure the valve clearance as follows: • Use the feeler gauge (commercial service tool) of curved-tip. This allows the feeler gauge to access the clearance between camshaft and valve lifter with ease. Valve clearance

: Refer to EM-149, "Camshaft".

NOTE: Be sure to note the following points when measuring valve clearance on the intake side. • Before measuring, check that the position of drive shaft nose is within the angle shown in the figure. A

: Bank 1

B

: Feeler gauge (commercial service tool)

D

: View D

c

: 45 degrees (drive shaft nose angle) : Insertion direction of feeler gauge on the bank 1 : Insertion direction of feeler gauge on the bank 2

• Refer to the illustration for the insertion direction of the feeler gauge since the direction depends on the bank.

JPBIA1118ZZ

a.

Set No. 1 cylinder at TDC of its compression stroke.


EM-18

2009 G37 Coupe

CAMSHAFT VALVE CLEARANCE < PERIODIC MAINTENANCE > • Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator.

A

: Timing mark (grooved line without color)

EM

C JPBIA0043ZZ

D

• Check that exhaust cam nose on No. 1 cylinder (engine front side of bank 1) is located as shown in the figure. 1

E

: Camshaft (EXH) (bank 1) : Engine front

F

• If not, turn crankshaft one revolution (360 degrees) and align as shown in the figure.

G JPBIA1127ZZ

H

• By referring to the figure, measure the valve clearances at locations marked “×” as shown in the table below (locations indicated in the figure).

I : Engine front

• No. 1 cylinder at compression TDC J Measuring position [bank 1 (A)] No. 1 cylinder at compression TDC

INT

No. 3 CYL.

No. 5 CYL.

× (C)

EXH

Measuring position [bank 2 (B)] No. 1 cylinder at compression TDC

No. 1 CYL.

K

× (D) No. 2 CYL.

No. 4 CYL.

No. 6 CYL. × (E)

INT EXH

L

× (F)

M

N JPBIA1334ZZ

b.

Rotate crankshaft 240 degrees clockwise (when viewed from engine front) to align No. 3 cylinder at TDC its compression stroke. NOTE:

O

P


EM-19

2009 G37 Coupe

CAMSHAFT VALVE CLEARANCE < PERIODIC MAINTENANCE > Mark a position 240 degrees (b) from a corner of the hexagonal part of crankshaft pulley mounting bolt as shown in the figure. Use the hexagonal part as a guide. 1

: Crankshaft pulley

A

: Paint mark

JPBIA0166ZZ

• By referring to the figure, measure the valve clearances at locations marked “×” as shown in the table below (locations indicated in the figure). : Engine front

• No. 3 cylinder at compression TDC Measuring position [bank 1 (A)] No. 3 cylinder at compression TDC

No. 3 CYL.

No. 5 CYL. × (C)

EXH × (D)

INT


No. 1 CYL.

INT EXH

No. 2 CYL.

No. 4 CYL.

No. 6 CYL.

× (E) × (F)

JPBIA1335ZZ

c.

Rotate crankshaft 240 degrees clockwise (when viewed from engine front) to align No. 5 cylinder at TDC of compression stroke. NOTE: Mark a position 240 degrees (b) from a corner of the hexagonal part of crankshaft pulley mounting bolt as shown in the figure. Use the hexagonal part as a guide. 1

: Crankshaft pulley

A

: Paint mark

JPBIA0166ZZ


EM-20

2009 G37 Coupe

CAMSHAFT VALVE CLEARANCE < PERIODIC MAINTENANCE > • By referring to the figure, measure the valve clearances at locations marked “×” as shown in the table below (locations indicated in the figure).

A

: Engine front

EM

• No. 5 cylinder at compression TDC Measuring position [bank 1 (A)] No. 5 cylinder at compression TDC

EXH

No. 3 CYL.

INT EXH

C

No. 5 CYL.

× (C) × (D)

INT


No. 1 CYL.

No. 2 CYL.

No. 4 CYL.

D

No. 6 CYL.

× (E) × (F)

E

F

G JPBIA1336ZZ

3.

Perform adjustment or replacement if the measured value is out of the standard. • If a valve clearance on the exhaust side is out of specification, adjust the valve clearance. • If a valve clearance on the intake side is out of specification, replace VVEL ladder assembly and cylinder head assembly. Refer to EM-94, "Exploded View". CAUTION: Never adjust valve clearance on the intake side. NOTE: Since the valve lifter (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head assembly replacement are required.

H

I

J

CAMSHAFT (EXH) VALVE CLEARANCE ADJUSTMENT • Perform adjustment depending on selected head thickness of valve lifter (EXH). 1. Measure the valve clearance. Refer to “INSPECTION”. 2. Remove VVEL ladder assembly and camshaft (EXH). Refer to EM-95, "Disassembly and Assembly". CAUTION: Never loosen adjusting bolts and mounting bolts (black color) of VVEL ladder assembly. 3. Remove valve lifter (EXH) at the locations that are out of the standard. 4. Measure the center thickness of the removed valve lifters (EXH) with a micrometer (A).

K

L

M

N

O

JPBIA0169ZZ

5.

Use the equation below to calculate valve lifter (EXH) thickness for replacement. Valve lifter (EXH) thickness calculation: t = t1 + (C1 – C2) t = Valve lifter (EXH) thickness to be replaced = Removed valve lifter (EXH) thickness t1


EM-21

2009 G37 Coupe

P

CAMSHAFT VALVE CLEARANCE < PERIODIC MAINTENANCE > C1 C2

= Measured valve clearance = Standard valve clearance: Exhaust : 0.33 mm (0.013 in)

• Thickness of new valve lifter (EXH) can be identified by stamp marks on the reverse side (inside the cylinder). Stamp mark 788 indicates 7.88 mm (0.3102 in) in thickness. A

: Stamp

B

: Thickness of valve lifter (EXH)

JPBIA0170ZZ

Available thickness of valve lifter (EXH): 27 sizes with range 7.88 to 8.40 mm (0.3102 to 0.3307 in) in steps of 0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-149, "Camshaft". 6. Install selected valve lifter (EXH). 7. Install VVEL ladder assembly and camshaft (EXH). Refer to EM-95, "Disassembly and Assembly". 8. Manually turn crankshaft pulley a few turns. 9. Check that the valve clearances for cold engine are within the specifications by referring to the specified values. Refer to EM-18, "Inspection and Adjustment". 10. Install all removed parts in the reverse order of removal. 11. Warm up the engine, and check for unusual noise and vibration.


EM-22

2009 G37 Coupe

COMPRESSION PRESSURE < PERIODIC MAINTENANCE >

COMPRESSION PRESSURE

A

Inspection 1. 2. 3.

INFOID:0000000004250475

Warm up engine thoroughly. Then, stop it. Release fuel pressure. Refer to EC-614, "Inspection". Disconnect fuel pump fuse (1) from IPDM E/R (2) to avoid fuel injection during measurement.

EM

C

D

E JMBIA0021ZZ

F

4. 5. 6. 7.

Remove engine cover with power tool. Refer to EM-25, "Exploded View". Remove ignition coil and spark plug from each cylinder. Refer to EM-47, "Exploded View". Connect engine tachometer (not required in use of CONSULT-III). Install compression gauge with an adapter (commercial service tool) onto spark plug hole.

G

H

I

J PBIC0900E

K

• Use the adapter whose picking up end inserted to spark plug hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it may be caught by cylinder head during removal.

L a

: 20 mm (0.79 in)

M

N JPBIA0171ZZ

8.

With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each cylinder. Compression pressure

: Refer to EM-148, "General Specification".

P

CAUTION: • Measure a six-cylinder under the same conditions since a measurement depends on measurement conditions (engine water temperature, etc.). • Always use a fully changed battery to obtain the specified engine speed. • If the engine speed is out of the specified range, check battery liquid for proper gravity. Check the engine speed again with normal battery gravity.


EM-23

O

2009 G37 Coupe

COMPRESSION PRESSURE < PERIODIC MAINTENANCE > • If compression pressure is below the minimum value, check valve clearances and parts associated with combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head gasket). After checking, measure compression pressure again. • If a cylinder has low compression pressure, pour a small amount of engine oil into the spark plug hole of the cylinder to recheck it for compression. - If the added engine oil improves the compression, piston rings may be worn out or damaged. Check piston rings and replace if necessary. - If the compression pressure remains at low level despite the addition of engine oil, valves may be malfunctioning. Check valves for damage. Replace valve or valve seat accordingly. • If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil, cylinder head gaskets are leaking. In such a case, replace cylinder head gaskets. 9. After inspection is completed, install removed parts. 10. Start the engine, and check that the engine runs smoothly. 11. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-137, "Description".


EM-24

2009 G37 Coupe

ENGINE COVER < REMOVAL AND INSTALLATION >


A

ENGINE COVER Exploded View

1

INFOID:0000000004250476

EM

C

: Engine cover


D

E

F

G

H

JPBIA1049GB


I

INFOID:0000000004496176

J

REMOVAL Loosen mounting bolts and nuts in the reverse order as shown in the figure, and then remove engine cover. CAUTION: Never damage or scratch engine cover when installing or removing.

K

L

M JPBIA1785ZZ

INSTALLATION

N

Install engine cover, and then tighten mounting bolts and nuts in numerical order as shown in the figure. CAUTION: Never damage or scratch engine cover when installing or removing.

O

P

JPBIA1785ZZ


EM-25

2009 G37 Coupe

DRIVE BELT AUTO TENSIONER AND IDLER PULLEY < REMOVAL AND INSTALLATION >

DRIVE BELT AUTO TENSIONER AND IDLER PULLEY Exploded View

INFOID:0000000004250478

JPBIA1059GB

1.

Front timing chain case

2.

Idler pulley

4.

Idler pulley

5.

Idler pulley

3.

Drive belt auto-tensioner



INFOID:0000000004250479

REMOVAL 1. 2.

Remove drive belt. Refer to EM-13, "Exploded View". • Keep auto-tensioner pulley arm locked after drive belt is removed. Remove auto-tensioner and idler pulley. • Keep auto-tensioner pulley arm locked to install or remove auto-tensioner.

INSTALLATION Installation is the reverse order of removal. CAUTION: If there is damage greater than peeled paint, replace drive belt auto-tensioner.


EM-26

2009 G37 Coupe

AIR CLEANER AND AIR DUCT < REMOVAL AND INSTALLATION >

AIR CLEANER AND AIR DUCT

A

Exploded View

INFOID:0000000004250480

EM

C

D

E

F

G

H

I JPBIA1977GB

1.


2.

Air cleaner filter

3.

Holder

4.

Bracket

5.

Air dust side duct (bank 1)

6.

Resonator (RH)

7.

Bracket

8.

Grommet

9.

Clamp

J

10. PCV hose

11. Grommet

12. Air cleaner case (RH)

13. Clamp

14. Air duct (RH)

15. Air duct (LH)

16. Clamp

17. PCV hose

18. Air cleaner case (LH)

19. Air dust side duct (bank 2)

20. Bracket

21. Resonator (LH)

22. Bracket

23. Mass air flow sensor (bank 2)

A.

B.

To electric throttle control actuator

To rocker cover (bank 1)

C.

K

L

To rocker cover (bank 2)

M



INFOID:0000000004250481

N

REMOVAL NOTE: Mass air flow sensor is removable under the car-mounted condition. 1. Disconnect mass air flow sensor harness connector. 2. Disconnect PCV hose. 3. Remove air cleaner case & mass air flow sensor assembly and air duct & air hose by disconnecting their joints. • Add marks if necessary for easier installation. 4. Remove mass air flow sensor from air cleaner case, if necessary. CAUTION: Handle mass air flow sensor according to the following instructions. • Never shock the mass air flow sensor. • Never disassemble the mass air flow sensor. Revision: 2009 October

EM-27

2009 G37 Coupe

O

P

AIR CLEANER AND AIR DUCT < REMOVAL AND INSTALLATION > • Never touch the sensor of the mass air flow sensor.

INSTALLATION Note the following, and install in the reverse order of removal. • Align marks. Attach each joint. Screw clamps firmly.

Inspection

INFOID:0000000004250482

INSPECTION AFTER REMOVAL Inspect air duct and resonator assembly for crack or tear. • If anything is found, replace air duct and resonator assembly


EM-28

2009 G37 Coupe

INTAKE MANIFOLD COLLECTOR < REMOVAL AND INSTALLATION >

INTAKE MANIFOLD COLLECTOR

A

Exploded View

INFOID:0000000004250483

EM

C

D

E

F

G

H

I

J JPBIA1356GB

1.

EVAP canister purge control solenoid valve

2.

Clamp

3.

EVAP hose

4.

EVAP hose

5.

Clamp

6.

Water hose

7.

Water hose

8.

Electric throttle control actuator (bank 1) 9.

K

L

Gasket

10. PCV hose

11. Clamp

12. PCV hose

13. Intake manifold collector

14. Gasket

15. Water hose

16. Water hose

17. Electric throttle control actuator (bank 2) 18. EVAP hose

Manifold absolute Pressure (MAP) sen19. sor

20. EVAP tube assembly

21. EVAP hose

A.

To vacuum pipe

B.

To brake booster

C.

D.

To PCV valve

E.

To heater pipe

M

To water outlet (rear)

N



INFOID:0000000004250484

REMOVAL WARNING: Never drain engine coolant when the engine is hot to avoid the danger of being scalded. 1. Remove engine cover with power tool. Refer to EM-25, "Exploded View". 2. Remove air cleaner case and air duct (RH and LH). Refer to EM-27, "Exploded View". 3. Remove electric throttle control actuator as follows: a. Drain engine coolant. When water hoses are disconnected, attach plug to prevent engine coolant leakage. Revision: 2009 October

EM-29

2009 G37 Coupe

O

P

INTAKE MANIFOLD COLLECTOR < REMOVAL AND INSTALLATION > CAUTION: • Perform this step when engine is cold. • Never spill engine coolant on drive belt. b. Disconnect water hoses from electric throttle control actuator. When engine coolant is not drained from radiator, attach plug to water hoses to prevent engine coolant leakage. c. Disconnect harness connector. d. Loosen mounting bolts in reverse order as shown in the figure. NOTE: • When removing only intake manifold collector, move electric throttle control actuator without disconnecting the water hose. • The figure shows the electric throttle control actuator (bank 1) viewed from the air duct side. • Viewed from the air duct side, the order of loosening mounting bolts of electric throttle control actuator (bank 2) is the same as that of the electric throttle control actuator (bank 1). CAUTION: Handle carefully to avoid any shock to electric throttle conJPBIA0011ZZ trol actuator. 4. 5. 6.

Disconnect vacuum hose, PCV hose and EVAP hose from intake manifold collector. Remove EVAP canister purge volume control solenoid valve and EVAP tube assembly from intake manifold collector. Loosen mounting bolts and nuts with power tool in the reverse order as shown in the figure to remove intake manifold collector. : Engine front

JPBIA1353ZZ

INSTALLATION Note the following, and install in the reverse order of removal. INTAKE MANIFOLD COLLECTOR

• If stud bolts were removed, install them and tighten to the torque specified below. : 10.8 N·m (1.1 kg-m, 8 ft-lb) • Tighten mounting bolts and nuts in numerical order as shown in the figure. : Engine front

JPBIA1353ZZ

WATER HOSE

• Insert hose by 27 to 32 mm (1.06 to 1.26 in) from connector end. • Clamp hose at location of 3 to 7 mm (0.12 to 0.28 in) from hose end. ELECTRIC THROTTLE CONTROL ACTUATOR (BANK 1 AND BANK 2)


EM-30

2009 G37 Coupe

INTAKE MANIFOLD COLLECTOR < REMOVAL AND INSTALLATION > • Tighten in numerical order as shown in the figure. NOTE: A • The figure shows the electric throttle control actuator (bank 1) viewed from the air duct side. • Viewed from the air duct side, the order of tightening mounting EM bolts of electric throttle control actuator (bank 2) is the same as that of the electric throttle control actuator (bank 1). • Perform the “Throttle Valve Closed Position Learning” when harness connector of electric throttle control actuator is disconnected. C Refer to EC-18, "THROTTLE VALVE CLOSED POSITION LEARNING : Description". JPBIA0011ZZ • Perform the “Idle Air Volume Learning” and “Throttle Valve Closed D Position Learning” when electric throttle control actuator is replaced. Refer to EC-19, "IDLE AIR VOLUME LEARNING : Description" and EC-18, "THROTTLE VALVE CLOSED POSITION LEARNING : Description". E

F

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M

N

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P


EM-31

2009 G37 Coupe

INTAKE MANIFOLD < REMOVAL AND INSTALLATION >

INTAKE MANIFOLD Exploded View

INFOID:0000000004250485

JPBIA1350GB

1.

Intake manifold

A.

Refer to EM-32

2.

Gasket



INFOID:0000000004250486

REMOVAL 1. 2. 3. 4.

Release fuel pressure. Refer to EC-614, "Inspection". Remove intake manifold collector. Refer to EM-29, "Exploded View". Remove fuel tube and fuel injector assembly. Refer to EM-37, "Exploded View". Loosen mounting bolts in reverse order as shown in the figure to remove intake manifold with power tool. : Engine front

CAUTION: • Cover engine openings to avoid entry of foreign materials. • Put a mark on the intake manifold and the cylinder head with paint before removal because they need to be installed in the specified direction. JPBIA1352ZZ

5.

Remove gaskets.

INSTALLATION Note the following, and install in the reverse order of removal. INTAKE MANIFOLD

• If stud bolts were removed, install them and tighten to the torque specified below. : 10.8 N·m (1.1 kg-m, 8 ft-lb)


EM-32

2009 G37 Coupe

INTAKE MANIFOLD < REMOVAL AND INSTALLATION > • Tighten all mounting bolts to the specified torque in two or more steps in numerical order as shown in the figure.

A

: Engine front

EM

CAUTION: • Install intake manifold with the marks (put on the intake manifold and the cylinder head before removal) aligned.

C

1st step: : 7.4 N·m (0.75 kg-m, 5 ft-lb)

JPBIA1352ZZ

D

2nd step and after: : 25.5 N·m (2.6 kg-m, 19 ft-lb)

E

Inspection

INFOID:0000000004250487

INSPECTION AFTER REMOVAL

F

Surface Distortion • Check the surface distortion of the intake manifold mating surface with a straightedge (A) and a feeler gauge (B).

G

Limit

: Refer to EM-149, "Intake Manifold". H

• If it exceeds the limit, replace intake manifold.

I JPBIA1348ZZ

J

K

L

M

N

O

P


EM-33

2009 G37 Coupe

EXHAUST MANIFOLD < REMOVAL AND INSTALLATION >

EXHAUST MANIFOLD Exploded View

INFOID:0000000004250488

JPBIA2812GB

1.


2.

Air fuel ratio sensor 1 (bank 1)

3.

Exhaust manifold cover (upper)

4.

Exhaust manifold (bank 1)

5.

Exhaust manifold cover (lower)

6.

Gasket

7.

Ring gasket

8.

Three way catalyst (bank 1)

9.

Gasket

11. Gasket

12.

Three way catalyst (bank 2)

13. Ring gasket

14. Exhaust manifold (bank 2)

15.

Exhaust manifold cover (lower)

16. Gasket

17. Air fuel ratio sensor 1 (bank 2)

18.

Exhaust manifold cover (upper)

10. Heated oxygen sensor 2 (bank 2)



INFOID:0000000004250489

REMOVAL WARNING: Perform the work when the exhaust and cooling system have completely cooled down. NOTE: When removing bank 1 side parts only, steps 1, 4 and 7 are unnecessary. 1. Drain engine coolant. Refer to CO-7, "Draining". 2. Remove engine cover with power tool. Refer to EM-25, "Exploded View". 3. Remove air cleaner case and air duct (RH and LH). Refer to EM-27, "Exploded View". 4. Remove water pipe and water hose. Refer to CO-23, "Exploded View". 5. Remove engine undercover with power tool. 6. Remove exhaust front tube and three way catalysts (bank 1 and bank 2). Refer to EX-5, "Exploded View". 7. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Revision: 2009 October

EM-34

2009 G37 Coupe

EXHAUST MANIFOLD < REMOVAL AND INSTALLATION > 8. Disconnect air fuel ratio sensor 1 (bank 1 and bank 2) harness connectors and remove harness clip. 9. Using the heated oxygen sensor wrench [SST: KV10114400 (J38365)] (C), remove air fuel ratio sensor 1 (bank 1 and bank 2). A

: Bank 1

B

: Bank 2

EM

CAUTION: • Be careful not to damage air fuel ratio sensor 1. • Discard any air fuel ratio sensor 1 that has been dropped onto a hard surface such as a concrete floor. Replace with a new sensor.

C

JPBIA2176ZZ

10. Remove exhaust manifold cover (upper) (bank 1 and bank 2). 11. Loosen mounting nuts in the reverse order as shown in the figure to remove exhaust manifold. A

: Bank 1

B

: Bank 2

A

D

E

F

: Engine front

G

NOTE: Disregard the numerical order No. 7 and 8 in removal.

H

I

J

K JPBIA0017ZZ

L

12. Remove gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

M

INSTALLATION Note the following, and install in the reverse order of removal.

N

EXHAUST MANIFOLD GASKET

• Install exhaust manifold gasket in direction shown in the figure. (Follow the same procedure for both banks.) O A

: Bank 1

B

: Triangle press

C

: Bank 2

P

: Engine front

JPBIA0019ZZ

EXHAUST MANIFOLD

• If stud bolts were removed, install them and tighten to the torque specified below. Revision: 2009 October

EM-35

2009 G37 Coupe

EXHAUST MANIFOLD < REMOVAL AND INSTALLATION > Tightening torque

: Refer to EM-34, "Exploded View".

• Install exhaust manifold and tighten mounting bolts in numerical order as shown in the figure. A

: Bank 1

B

: Bank 2 : Engine front

NOTE: Tighten nuts the No. 1 and 2 in two steps. The numerical order No. 7 and 8 shows the second step.

JPBIA0017ZZ

AIR FUEL RATIO SENSOR 1 CAUTION: • Before installing a new air fuel ratio sensor 1, clean exhaust system threads using heated oxygen sensor thread cleaner tool (Commercial Service Tool: J-43897-18 or J-43897-12) and apply anti-seize lubricant. • Never apply excessive torque to air fuel ratio sensor 1. Doing so may cause damage to air fuel ratio sensor 1, resulting in the “MIL” illuminating.

Inspection

INFOID:0000000004250490

INSPECTION AFTER REMOVAL Surface Distortion • Check the surface distortion of the exhaust manifold mating surface with a straightedge (A) and a feeler gauge (B).

Limit

: Refer to EM-149, "Exhaust Manifold".

• If it exceeds the limit, replace exhaust manifold.

JPBIA0018ZZ


EM-36

2009 G37 Coupe

FUEL INJECTOR AND FUEL TUBE < REMOVAL AND INSTALLATION >

FUEL INJECTOR AND FUEL TUBE

A

Exploded View

INFOID:0000000004250491

EM

C

D

E

F

G

H

I JPBIA1169GB

1.

Quick connector cap

2.

Fuel feed hose (with damper)

3.

O-ring

4.

Fuel sub tube

5.

O-ring

6.

Clip

7.

Fuel damper

8.

O-ring

9.

Fuel tube

10. O-ring (black)

11. Fuel injector

J

12. Clip

K

13. O-ring (green) A.

Refer to EM-37

L


CAUTION: Never remove or disassemble parts unless instructed as shown in the figure. M


INFOID:0000000004250492

REMOVAL

N

WARNING: • Put a “CAUTION: FLAMMABLE” sign in the workshop. • Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher. • Never smoke while servicing fuel system. Keep open flames and sparks away from the work area. • Never drain engine coolant when the engine is hot to avoid the danger of being scalded. 1. Release fuel pressure. Refer to EC-614, "Inspection". 2. Disconnect battery cable from the negative terminal. Refer to PG-99, "Exploded View". 3. Remove engine cover with power tool. Refer to EM-25, "Exploded View". 4. Remove air cleaner case and air duct (RH and LH). Refer to EM-27, "Exploded View". 5. Remove intake manifold collector. Refer to EM-29, "Exploded View".


EM-37

2009 G37 Coupe

O

P

FUEL INJECTOR AND FUEL TUBE < REMOVAL AND INSTALLATION > 6. Remove fuel feed hose (with damper) (1) from fuel sub-tube (2) and remove harness bracket (3). : Engine front

NOTE: There is no fuel return route. CAUTION: • While hoses are disconnected, plug them to prevent fuel from draining. • Never separate damper and hose. JPBIA0032ZZ

7. a. b.

When separating fuel feed hose (with damper) and centralized under-floor piping connection, disconnect quick connector as follows: Remove quick connector cap (2) from quick connector connection on right member side. Disconnect fuel feed hose (with damper) (1) from bracket hose clamp.

JPBIA0254ZZ

c. d.

Push in retainer tabs (2). Draw and pull out quick connector (1) straight from centralized under-floor piping (3). CAUTION: • Pull quick connector holding (A) position as shown in the figure. • Never pull with lateral force applied. O-ring inside quick connector may be damaged. • Prepare container and cloth beforehand because fuel will leak out. • Avoid fire and sparks. JPBIA1854ZZ • Keep parts away from heat source. Especially, be careful when welding is performed around them. • Never expose parts to battery electrolyte or other acids. • Never bend or twist connection between quick connector and fuel feed hose (with damper) during installation/removal. • To keep the connecting portion clean and to avoid damage and foreign materials, cover them completely with plastic bags, etc. (A) or a similar item.

JPBIA0035ZZ

8. 9.

Remove fuel sub tube mounting bolt. Disconnect harness connector from fuel injector.


EM-38

2009 G37 Coupe

FUEL INJECTOR AND FUEL TUBE < REMOVAL AND INSTALLATION > 10. Loosen mounting bolts in reverse order as shown in the figure, and remove fuel tube and fuel injector assembly.

A

: Engine front

EM

CAUTION: Never tilt it, or remaining fuel in pipes may flow out from pipes.

C JPBIA1170ZZ

D

11. Remove fuel injector (2) from fuel tube (4) as follows:

a. b.

3

: O-ring

A

: Installed condition

B

: Clip mounting groove

E

Open and remove clip (1). Remove fuel injector from fuel tube by pulling straight. CAUTION: • Be careful with remaining fuel that may go out from fuel tube. • Be careful not to damage injector nozzles during removal. • Never bump or drop fuel injector. • Never disassemble fuel injector.

F

G JPBIA1359ZZ

H

12. Remove fuel sub-tube and fuel damper, if necessary. I

INSTALLATION 1.

a.

b. c.

Install fuel damper (4) as follows: 2

: Cup

5

: Clip

C

: Cut-out

J

K

Install new O-ring (1) to fuel tube as shown. When handling new O-ring, pay attention to the following caution items: CAUTION: • Handle O-ring with bare hands. Never wear gloves. • Lubricate O-ring with new engine oil. • Never clean O-ring with solvent. • Check that O-ring and its mating part are free of foreign material. • When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it quickly into fuel tube. • Insert new O-ring straight into fuel tube. Never twist it. Install spacer (3) to fuel damper. Insert fuel damper straight into fuel tube. CAUTION: • Insert straight, checking that the axis is lined up. • Never pressure-fit with excessive force. Reference value

L

M

N

O

JPBIA1171ZZ

: 130 N (13.3 kg, 29.2 lb)

• Insert fuel damper until (A) is touching (B) of fuel tube.


EM-39

2009 G37 Coupe

P

FUEL INJECTOR AND FUEL TUBE < REMOVAL AND INSTALLATION > d. Install the cut-out (A) of the clip (2) to the projection (B), which ensures that the fuel tube does not move or rotate. 1

e.

: Fuel tube

Unlock the clip after making sure that the rib of the cup and the brim of the fuel damper are mated each other and positioned in the holes (C) of the clip.

JPBIA1172ZZ

f.

Check that the opening (B) and the slit (C) of the clip are positioned and fixed properly so it does not rotate or pull out. A

: Under view

JPBIA1173ZZ

2.

3.

Install fuel sub-tube. • When handling new O-rings, be careful of the following caution items: CAUTION: • Handle O-ring with bare hands. Never wear gloves. • Lubricate O-ring with new engine oil. • Never clean O-ring with solvent. • Check that O-ring and its mating part are free of foreign material. • When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly into fuel tube. • Insert new O-ring straight into fuel tube. Never decenter or twist it. • Insert fuel sub-tube straight into fuel tube. • Tighten mounting bolts evenly in turn. • After tightening mounting bolts, Check that there is no gap between flange and fuel tube. Install new O-rings to fuel injector, paying attention to the following items. CAUTION: • Upper and lower O-ring are different. Be careful not to confuse them. Fuel tube side Nozzle side

: Black : Green

• • • • •

Handle O-ring with bare hands. Never wear gloves. Lubricate O-ring with new engine oil. Never clean O-ring with solvent. Check that O-ring and its mating part are free of foreign material. When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly into fuel tube. • Insert O-ring straight into fuel injector. Never decenter or twist it.


EM-40

2009 G37 Coupe

FUEL INJECTOR AND FUEL TUBE < REMOVAL AND INSTALLATION > 4. Install fuel injector to fuel tube as follows: A

a.

b.

c.

2

: O-ring (Black)

4

: O-ring (Green)

EM

Insert clip (3) into clip mounting groove (F) on fuel injector (5). CAUTION: • Never reuse clip. Replace it with a new one. • Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring. • Insert clip so that protrusion (E) of fuel injector matches cut-out (C) of clip. Insert fuel injector into fuel tube (1) with clip attached. • Insert it while matching it to the axial center. • Insert fuel injector so that protrusion (A) of fuel tube matches cutout (B) of clip. • Check that fuel tube flange (G) is securely fixed in flange fixing groove (D) on clip. Check that installation is complete by checking that fuel injector does not rotate or come off. • Check that protrusions of fuel injectors and fuel tube are aligned with cutouts of clips after installation.

C

D

E

F

G JPBIA1358ZZ

5.

Install fuel tube and fuel injector assembly to intake manifold. CAUTION: Be careful not to let tip of injector nozzle come in contact with other parts. • Tighten mounting bolts in two steps in numerical order as shown in the figure.

H

I

: Engine front

J

1st step: 10.1 N·m (1.0 kg-m, 7 ft-lb) 2nd step: 23.6 N·m (2.4 kg-m, 17 ft-lb)

K JPBIA1170ZZ

6. 7. 8.

9. a. b. c.

Connect injector sub-harness. Install fuel sub tube mounting bolt. Connect fuel feed hose (with damper). • Handling procedure of O-ring is the same as that of fuel damper and fuel sub-tube. • Insert fuel damper straight into fuel sub-tube. • Tighten mounting bolts evenly in turn. • After tightening mounting bolts, check that there is no gap between flange and fuel sub-tube. Connect quick connector between fuel feed hose (with damper) and centralized under-floor piping connection as follows: Check that no foreign substances are deposited in and around centralized under-floor piping and quick connector, and that there is no damage to them. Thinly apply new engine oil around centralized under-floor piping from tip end to spool end. Align center to insert quick connector straightly into centralized under-floor piping. • Insert quick connector to centralized under-floor piping until top spool is completely inside quick connector and 2nd level spool exposes right below quick connector. CAUTION: • Hold align center to avoid inclined insertion to prevent damage to O-ring inside quick connector. • Insert until you hear a “click” sound and actually feel the engagement. • To avoid misidentification of engagement with a similar sound, be sure to perform the next step.


EM-41

2009 G37 Coupe

L

M

N

O

P

FUEL INJECTOR AND FUEL TUBE < REMOVAL AND INSTALLATION > d. Pull quick connector by hand holding position (A). Check it is completely engaged (connected) so that it does not come out from centralized under-floor piping (1).

PBIC3795E

e.

Install quick connector cap (3) to quick connector connection. 1

: Centralized under-floor piping

2

: Fuel feed hose

B

: Under view

• Install quick connector cap with arrow (A) on surface facing in direction of quick connector (fuel feed hose side). CAUTION: If quick connector cap cannot be installed smoothly, quick connector may have not been installed correctly. Check the connection again. 10. Install in the reverse order of removal after this step.

Inspection

JPBIA0039ZZ

INFOID:0000000004250493

INSPECTION AFTER INSTALLATION Check for Fuel Leakage

1.

2.

Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, check that there is no fuel leakage at connection points. NOTE: Use mirrors for checking at points out of clear sight. Start the engine. With engine speed increased, check that again that there is no fuel leakage at connection points. CAUTION: Never touch the engine immediately after it is stopped because the engine is extremely hot.


EM-42

2009 G37 Coupe

OIL PAN (LOWER) < REMOVAL AND INSTALLATION >

OIL PAN (LOWER)

A

Exploded View (2WD)

INFOID:0000000004496180

EM

C

D

E

F

G

H

I

J

K

L JPBIA1401GB

1.

Oil level gauge

2.

Oil level gauge guide

3.

O-ring

4.

O-ring

5.

Connector bolt

6.

Oil filter

7.

Relief valve

8.

Oil pressure switch

9.

Oil strainer

10. Oil temperature sensor

11. Washer

12. Oil pan (upper)

13. Drain plug

14. Drain plug washer

15. Oil pan (lower)

16. Rear plate cover

17. Rear cover plate (M/T models)

A.

B.

Refer to LU-9

To oil pump

C.

M

N

Oil pan side

O


P


EM-43

2009 G37 Coupe

OIL PAN (LOWER) < REMOVAL AND INSTALLATION >

Exploded View (AWD)

INFOID:0000000004496181

JPBIA2763GB

1.

Oil level gauge

2.


3.

O-ring

4.

O-ring

5.

Gasket

6.

Oil strainer

7.

Drain plug

8.

Drain plug washer

9.

Oil pan (lower)

10. Baffle plate

11. O-ring (small)

12. Axle pipe

13. O-ring (large)


15

Oil pan (upper)

A.

B.

C.

Oil pan side

Refer to LU-11

To oil pump



INFOID:0000000004250495

REMOVAL CAUTION: Never drain engine oil when the engine is hot to avoid the danger of being scalded. 1. Remove engine undercover with power tool. 2. Remove oil pan (lower) as follows:


EM-44

2009 G37 Coupe

OIL PAN (LOWER) < REMOVAL AND INSTALLATION > a. Loosen mounting bolts in reverse order as shown in the figure to remove.

A

: Engine front

EM

C JPBIA0021ZZ

D

b.

c.

Insert the seal cutter [SST: KV10111100 (J-37228)] (A) between oil pan (upper) and oil pan (lower). CAUTION: • Be careful not to damage the mating surfaces. • Never insert a screwdriver. This damages the mating surfaces. Slide the seal cutter by tapping on the side of tool with a hammer. Remove oil pan (lower).

E

F

G JPBIA0276ZZ

INSTALLATION 1. a.

H

Install oil pan (lower) as follows: Use scraper (A) to remove old liquid gasket from mating surfaces. • Remove old liquid gasket from the bolt holes and thread. CAUTION: Never scratch or damage the mating surfaces when cleaning off old liquid gasket.

I

J

K JPBIA0025ZZ

b.

L

Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to the oil pan (lower) as shown in the figure.

M a

: φ4.0 - 5.0 mm (0.157 - 0.197 in) : Engine front

N

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-17, "Recommended Chemical Products and Sealants". CAUTION: Attaching should be done within 5 minutes after coating. JPBIA1556ZZ

c.

O

Install oil pan (lower). P


EM-45

2009 G37 Coupe

OIL PAN (LOWER) < REMOVAL AND INSTALLATION > • Tighten mounting bolts in numerical order as shown in the figure. : Engine front

JPBIA0021ZZ

2.

3.

Install oil pan drain plug. • Refer to the figure of the components of on the prior page for installation direction of drain plug washer. Refer to EM-43, "Exploded View (2WD)". Install in the reverse order of removal after this step. NOTE: Wait at least 30 minutes after oil pan is installed before pouring engine oil.

Inspection

INFOID:0000000004250496

INSPECTION AFTER REMOVAL Clean oil strainer if any object is attached.

INSPECTION AFTER INSTALLATION 1. 2. 3. 4.

Check the engine oil level and adjust engine oil. Refer to LU-6, "Inspection". Start engine, and check there is no leakage of engine oil. Stop engine and wait for 10 minutes. Check the engine oil level again. Refer to LU-6, "Inspection".


EM-46

2009 G37 Coupe

IGNITION COIL, SPARK PLUG AND ROCKER COVER < REMOVAL AND INSTALLATION >

IGNITION COIL, SPARK PLUG AND ROCKER COVER

A

Exploded View

INFOID:0000000004250497

EM

C

D

E

F

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H

I JPBIA2803GB

1.

PCV hose

2.

Clamp

3.

PCV valve

4.

O-ring

5.

Clamp

6.

PCV hose

7.

Ignition coil

8.

Spark plug

9.

Rocker cover (bank 1)

10.

Oil filler cap

11.

Rocker cover gasket (bank 1)

12. Clamp

13.

PCV hose

14. PCV hose

15. Rocker cover gasket (bank 2)

16.

Rocker cover (bank 2) B.

C.

A.

To intake manifold collector

D.

Refer to EM-47

To air duct

J

K

VVEL ladder assembly side

L


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INFOID:0000000004250498

REMOVAL 1.

2. 3. 4. 5.

6.

N

Remove the following parts: • Engine cover: Refer to EM-25, "Exploded View". • Air cleaner case and air duct (RH and LH): Refer to EM-27, "Exploded View". • Intake manifold collector: Refer to EM-29, "Exploded View". Disconnect PCV hose from rocker cover. Remove PCV valve and O-ring from rocker cover, if necessary. Remove oil filler cap from rocker cover, if necessary. Remove ignition coil. CAUTION: Never shock ignition coil. Remove harness clips on the rocker cover.


EM-47

O

P

2009 G37 Coupe

IGNITION COIL, SPARK PLUG AND ROCKER COVER < REMOVAL AND INSTALLATION > 7. Loosen mounting bolts with power tool in reverse order as shown in the figure. A

: Bank 1

B


JPBIA2423ZZ

8. 9.

Remove rocker cover gasket from rocker cover. Use scraper to remove all traces of liquid gasket from cylinder head and VVEL ladder assembly. CAUTION: Never scratch or damage the mating surface when cleaning off old liquid gasket.

INSTALLATION 1.

Apply liquid gasket to the position shown in the figure with the following procedure: 2

: Actuator bracket (rear)

3

: VVEL actuator sub assembly

A

: Liquid gasket application point

F

: View F

I

: End surface of VVEL ladder assembly

b

: 4 mm (0.16 in)

c

: φ2.5 - 3.5 mm (0.098 - 0.138 in)

d

: 5 mm (0.20 in)

g

: 10 mm (0.39 in) : Engine front

a. b.

Refer to figure (E) to apply liquid gasket to joint part of VVEL ladder assembly (1) and cylinder head. Refer to figure (H) to apply liquid gasket in 90 degrees to figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-17, "Recommended Chemical Products and Sealants".

JPBIA1347ZZ

2. 3.

Install rocker cover gasket to rocker cover. Install rocker cover. • Check that rocker cover gasket does not drop from the installation groove of rocker cover.


EM-48

2009 G37 Coupe

IGNITION COIL, SPARK PLUG AND ROCKER COVER < REMOVAL AND INSTALLATION > 4. Tighten bolts in two steps separately in numerical order as shown in the figure. A

: Bank 1

B

: Bank 2

A

EM

: Engine front

C

1st step: 2.0 N·m (0.2 kg-m, 18 in-lb) 2nd step: 8.3 N·m (0.85 kg-m, 73 in-lb)

D

E

F

G JPBIA2423ZZ

5.

Install in the reverse order of removal after this step. H

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EM-49

2009 G37 Coupe

TIMING CHAIN < REMOVAL AND INSTALLATION >

TIMING CHAIN Exploded View

INFOID:0000000004250499

JPBIA1101GB

1.

Timing chain (secondary)

2.

Camshaft sprocket (EXH)

3.

4.


5.


6.

Internal chain guide

7.

Timing chain (primary)

8.

Camshaft sprocket (INT) (bank 1)

9.

Timing chain tensioner (primary)


EM-50

O-ring

2009 G37 Coupe

TIMING CHAIN < REMOVAL AND INSTALLATION > 10.

Slack guide

11. Crankshaft sprocket

12. Camshaft sprocket (INT) (bank 2)

13.

Tension guide

Intake valve timing control cover 14. gasket (bank 1)

15. Seal ring

16.

Intake valve timing control cover (bank 1)

17. O-ring

18.

19.

Oil level gauge

20. Oil level gauge guide

21. O-ring

22.

Intake valve timing control solenoid Intake valve timing control cover 23. (bank 2) valve (bank 2)

24.

25.

Intake valve timing control cover gasket (bank 2)

26. Front oil seal

27. Crankshaft pulley

28.

Crankshaft pulley bolt

29.

31.

Idler pulley bracket

32. Alternator bracket

33. Water outlet (front)

34.


35. Rear timing chain case

36. O-ring

37.

O-ring

38. O-ring

A.

Refer to EM-51

B.

A

Camshaft position sensor (PHASE) (bank 1) Camshaft position sensor (PHASE) (bank 2)

Intake valve timing control solenoid 30. Power steering oil pump bracket valve (bank 1)

EM

C

D

E

Refer to EM-90

C.

Oil filter

Refer to GI-4, "Components" for symbol marks in the figure.

F


INFOID:0000000004250500

REMOVAL 1. 2. 3. 4. 5. 6. 7.

8. 9.

10. 11. 12. 13. 14. 15. 16. 17.

18. 19. 20. 21.

G

Release the fuel pressure. Refer to EC-614, "Inspection". Disconnect the battery cable from the negative terminal. Remove engine cover with power tool. Refer to EM-25, "Exploded View". Remove radiator reservoir tank. Refer to CO-13, "Exploded View". Remove air duct and air cleaner case assembly (RH and LH). Refer to EM-27, "Exploded View". Remove engine undercover with power tool. Drain engine coolant from radiator. Refer to CO-7, "Draining". CAUTION: • Perform this step when the engine is cold. • Never spill engine coolant on drive belt. Remove radiator hose (upper and lower). Refer to CO-13, "Exploded View". Drain engine oil. Refer to LU-8, "Draining". CAUTION: Perform this step when the engine is cold. Remove radiator cooling fan assembly. Refer to CO-13, "Exploded View". Remove drive belt. Refer to EM-13, "Removal and Installation". Separate engine harnesses by removing their brackets from front timing chain case. Remove intake manifold collector. Refer to EM-29, "Exploded View". Remove fuel sub tube mounting bolt. Refer to EM-37, "Exploded View". Remove oil level gauge and oil level gauge guide. Remove A/C compressor from bracket with piping connected, and temporarily secure it aside. Refer to HA-39, "Exploded View". Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside. Refer to ST-48, "FOR MODELS WITHOUT 4WAS AND MODELS EXCEPT SPORT MODELS : Exploded View" or ST-53, "FOR MODELS WITH 4WAS AND SPORT MODELS : Exploded View". Remove power steering oil pump bracket. Remove idler pulley, drive belt auto-tensioner and bracket. Refer to EM-26, "Exploded View". Remove alternator and alternator bracket. Refer to CHG-25, "2WD : Exploded View" (2WD models) or CHG-27, "AWD : Exploded View" (AWD models). Remove water pipe. Refer to CO-23, "Exploded View".


EM-51

2009 G37 Coupe

H

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TIMING CHAIN < REMOVAL AND INSTALLATION > 22. Remove camshaft position sensor (PHASE). A

: Keep free from magnetic materials

CAUTION: • Handle carefully to avoid dropping and shocks. • Never disassemble. • Never allow metal powder to adhere to magnetic part at sensor tip. • Never place sensors in a location where they are exposed to magnetism. JPBIA0454ZZ

23. Remove intake valve timing control covers and gasket as follows: a. Disconnect intake valve timing control solenoid valve harness connector. b. Loosen mounting bolts in reverse order as shown in the figure. A

: Bank 1

B

: Bank 2

C

: Dowel pin hole

CAUTION: Shaft is internally jointed with camshaft sprocket (INT) center hole. When removing, keep it horizontal until it is completely disconnected. JPBIA1333ZZ

c.

Shaft is engaged with camshaft sprocket (INT) center hole on inside. Pull straight out so that it does not tilt until the joint is disengaged. 24. Remove intake valve timing control solenoid valve, if necessary. CAUTION: Intake valve timing control solenoid valve is nonreusable. Never remove it unless required. 25. Remove rocker covers (bank 1 and bank 2). Refer to EM-47, "Exploded View". 26. Obtain No.1 cylinder at TDC of its compression stroke as follows: a. Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator. : Timing mark (grooved line without color)

JPBIA0043ZZ

b.

Check that exhaust cam noses on No.1 cylinder (engine front side of bank 1) is located as shown in the figure. 1


• If not, turn crankshaft one revolution (360 degrees) and align as shown in the figure.

JPBIA1127ZZ

27. Remove crankshaft pulley as follows: Revision: 2009 October

EM-52

2009 G37 Coupe

TIMING CHAIN < REMOVAL AND INSTALLATION > a. Remove rear cover plate and set the ring gear stopper [SST: KV10118600 (J-48641)] (A) as shown in the figure. 1

: Oil pan (upper)

2

: Flywheel (M/T models) or drive plate (A/T models)

A

EM

: Vehicle front

C JPBIA0408ZZ

D

b.

Loosen crankshaft pulley bolt and rotate bolt seating surface at 10 mm (0.39 in) from its original position. 1

E

: Crankshaft pulley

CAUTION: Never remove crankshaft pulley bolt because it is used as a supporting point for suitable puller.

F

G JPBIA1364ZZ

c.

Place suitable puller tab on holes of crankshaft pulley, and pull crankshaft pulley through. CAUTION: Never put suitable puller tab on crankshaft pulley periphery, because this damages internal damper.

H

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JPBIA1368ZZ

28. Remove oil pan (lower). Refer to EM-43, "Exploded View (2WD)" (2WD models) or EM-44, "Exploded View (AWD)" (AWD models). 29. Loosen two mounting bolts in front of oil pan (upper) with power tool in reverse order as shown in the figure.

K

L

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: Engine front

N

JPBIA0047ZZ

O

30. Remove front timing chain case as follows: P


EM-53

2009 G37 Coupe

TIMING CHAIN < REMOVAL AND INSTALLATION > a. Loosen mounting bolts in reverse order as shown in the figure.

JPBIA0046ZZ

b. c.

Insert a suitable tool (A) into the notch at the top of front timing chain case as shown. Pry off case by moving the suitable tool as shown. • Use the seal cutter [SST: KV10111100 (J-37228)] to cut liquid gasket for removal. CAUTION: • Never use a screwdriver or a similar item. • After removal, handle front timing chain case carefully so it does not tilt, cant, or warp under a load. JPBIA0048ZZ

31. Remove front oil seal from front timing chain case using a suitable tool. • Use a screwdriver for removal. CAUTION: Be careful not to damage front timing chain case.

JPBIA0049ZZ

32. Remove O-ring (1) from rear timing chain case. A

: Bank 1

B

: Bank 2

JPBIA1111ZZ


EM-54

2009 G37 Coupe

TIMING CHAIN < REMOVAL AND INSTALLATION > 33. Remove timing chain tensioner (primary) (1) as follows: a. Remove lower mounting bolt (A). b. Loosen upper mounting bolt (B) slowly, and then turn timing chain tensioner (primary) on the upper mounting bolt so that plunger (C) is fully expanded. NOTE: Even if plunger is fully expanded, it does not drop from the body of timing chain tensioner (primary). c. Remove upper mounting bolt, and then remove timing chain tensioner (primary).

A

EM

C JPBIA1537ZZ

D

34. Remove internal chain guide (1), slack guide (2) and tension guide (3). E

F

G

H

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J

JPBIA1104ZZ

35. Remove timing chain (primary) and crankshaft sprocket. CAUTION: After removing timing chain (primary), never turn crankshaft and camshaft separately, or valves strike the piston heads. 36. Remove timing chain (secondary) and camshaft sprockets as follows: a. Attach suitable stopper pin (C) to the timing chain tensioners (secondary) (1), (2). A

: Bank 1

B

: Bank 2

M

O

JPBIA1105ZZ

Remove camshaft sprocket (EXH) mounting bolt. • Secure the hexagonal portion of camshaft (EXH) using a wrench to loosen mounting bolt. CAUTION: Never loosen the mounting bolt by securing anything other than the camshaft (EXH) hexagonal portion or with tensioning the timing chain.


L

N

NOTE: • Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a stopper pin. • For removal of timing chain tensioners (secondary), refer to EM-94, "Exploded View". (Removing VVEL ladder assembly is required.) b.

K

EM-55

2009 G37 Coupe

P

TIMING CHAIN < REMOVAL AND INSTALLATION > c. Remove camshaft sprocket (INT) mounting bolt. • Secure the hexagonal portion (located in between journal No. 1 and journal No. 2) of drive shaft (A) using a wrench to loosen mounting bolt. 1


CAUTION: • Never loosen the mounting bolt by securing anything other than the drive shaft hexagonal portion or with tensioning the timing chain. JPBIA1332ZZ • When holding the hexagonal part of drive shaft on the intake side with a wrench, be careful not to allow the wrench to cause interference with other parts. • Never disassemble camshaft sprocket (INT). [Never loosen bolts (A) as shown in the figure.]

JPBIA1106ZZ

d. Remove timing chain (secondary) together with camshaft sprockets. 37. Use a scraper to remove all traces of old liquid gasket from front and rear timing chain cases and oil pan (upper), and liquid gasket mating surfaces. CAUTION: Be careful not to allow gasket fragments to enter oil pan.

JPBIA0050ZZ

38. Remove old liquid gasket from bolt hole and thread. A

: Remove old liquid gasket that is stuck

B

: Bolt hole

JPBIA0051ZZ

INSTALLATION NOTE: The figure below shows the relationship between the matching mark on each timing chain and that on the corresponding sprocket with the components installed.


EM-56

2009 G37 Coupe

TIMING CHAIN < REMOVAL AND INSTALLATION > A

EM

C

D

E

F

G

H JPBIA1107ZZ

1.


2.

Camshaft sprocket (INT)

3.


4.


5.


6.

Slack guide

7.


8.

Crankshaft sprocket

9.

Water pump

10. Tension guide A.

1.

Timing chain tensioner (secondary) 11. (bank 2)


Matching mark [punched (back side)] B.

Matching mark (yellow link)

C.

Matching mark (punched)

D.

Matching mark (orange link)

Matching mark (notched)

F.

Crankshaft key

G.

Matching mark [punched]

E.

Check that dowel pin (A) and crankshaft key (1) are located as shown in the figure. (No. 1 cylinder at compression TDC) NOTE: Though camshaft does not stop at the position as shown in the figure, for the placement of cam noses, it is generally accepted that camshaft is placed in the same direction as that of the figure.

L

M

N JPBIA0094ZZ

O

Install timing chains (secondary) and camshaft sprockets as follows: CAUTION: Matching marks between timing chain and sprockets slip easily. Confirm all matching mark positions repeatedly during the installation process.


J

K

Camshaft dowel pin : At cylinder head upper face side in each bank. Crankshaft key : At cylinder head side of bank 1. 2.

I

EM-57

2009 G37 Coupe

P

TIMING CHAIN < REMOVAL AND INSTALLATION > a. Push plunger of timing chain tensioner (secondary) and keep it pressed in with a stopper pin (A).

JPBIA0095ZZ

b.

Install timing chains (secondary) and camshaft sprockets. NOTE: Figure shows bank 1 (rear view). A

: Camshaft sprocket (INT) back face

B

: Orange link

C

: Dowel groove

D

: Matching mark (oval)

E

: Matching mark (2 oval: on front face)

F

: Matching mark (circle)

G

: Camshaft sprocket (EXH) back face

H

: Matching mark (2 circle: on front face)

I

: Timing chain (secondary)

• Align the matching marks on timing chain (secondary) (orange link) with the ones on intake and exhaust camshaft sprockets (punched), and install them. NOTE: • Matching marks for camshaft sprockets (INT) are on the back side of camshaft sprockets (secondary). • There are two types of matching marks, the circle and oval types. They should be used for the bank 1 and bank 2, respectively. Bank 1 Bank 2

JPBIA1109ZZ

: Use circle type : Use oval type

• Shape (orientation of signal plate) of camshaft sprocket (INT) varies depending on the bank position. See the right figure to install. A

: Bank 1

B

: Bank 2

JPBIA1516ZZ

• Align dowel pin camshafts with the pin groove on sprockets, and install them. • In case that positions of each matching mark and each dowel pin do not fit with matching parts, make fine adjustment to the position holding the hexagonal portion on camshaft (EXH) or drive shaft with wrench or equivalent tool. • Mounting bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand is sufficient to prevent the dislocation of dowel pins.


EM-58

2009 G37 Coupe

TIMING CHAIN < REMOVAL AND INSTALLATION > • It may be difficult to visually check the dislocation of matching marks during and after installation. To make the matching easier, make a matching mark on the top of sprocket teeth and its extended line in advance with paint. A

: Matching mark (painted)

B

: Matching mark (orange link)

A

EM

C JPBIA1110ZZ

D

c. d.

Tighten camshaft sprocket (EXH) mounting bolt. • Secure camshaft (EXH) using a wrench at the hexagonal portion to tighten mounting bolt. After confirming the matching marks are aligned, tighten camshaft sprocket (INT) mounting bolt. • Secure the hexagonal portion (located in between journal No. 1 and journal No. 2) of drive shaft (A) using a wrench to tighten mounting bolt. 1

E

F


G

CAUTION: When holding the hexagonal part of drive shaft on the intake side with a wrench, be careful not to allow the wrench to cause interference with other parts.

H JPBIA1332ZZ

e.

Pull stopper pins (C) out from timing chain tensioners (secondary) (1), (2). A

: Bank 1

B

: Bank 2

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JPBIA1105ZZ

3. a.

Install timing chain (primary) as follows: Install crankshaft sprocket (1). A

L

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: Matching mark (front side) : Engine front

N

• Check that the matching marks on crankshaft sprocket face the front of the engine.

O

JPBIA1108ZZ

b.

Install timing chain (primary).


EM-59

2009 G37 Coupe

P

TIMING CHAIN < REMOVAL AND INSTALLATION > • Install timing chain (primary) so that the matching mark (punched) (B) on camshaft sprocket (INT) (1) is aligned with the yellow link (A) on timing chain, while the matching mark (notched) (C) on crankshaft sprocket (2) is aligned with the orange link (D) one on timing chain, as shown in the figure. 3

: Water pump

• When it is difficult to align matching marks of timing chain (primary) with each sprocket, gradually turn drive shaft using wrench on the hexagonal portion to align it with the matching marks.

JPBIA1601ZZ

4.

Install internal chain guide (1), slack guide (2), and tension guide (3).

JPBIA1104ZZ

CAUTION:


EM-60

2009 G37 Coupe

TIMING CHAIN < REMOVAL AND INSTALLATION > Never overtighten slack guide mounting bolt (2). It is normal for a gap (A) to exist under the bolt seats when mounting bolt are tightened to the specification. 1

: Slack guide

3

: Cylinder block

A

EM

C JPBIA0117ZZ

D

5. a.

b. c. d.

e.

f.

Install the timing chain tensioner (primary) with the following procedure: Pull plunger stopper tab (A) up (or turn lever downward) so as to remove plunger stopper tab from the ratchet of plunger (D). NOTE: Plunger stopper tab and lever (C) are synchronized. Push plunger into the inside of tensioner body. Hold plunger in the fully compressed position by engaging plunger stopper tab with the tip of ratchet. To secure lever, insert stopper pin (E) through hole of lever into tensioner body hole (B). • The lever parts and the plunger stopper tab are synchronized. JPBIA0118ZZ Therefore, the plunger is secured under this condition. NOTE: Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin. Install timing chain tensioner (primary) (1). • Remove any dirt and foreign materials completely from the back and the mounting surfaces of timing chain tensioner (primary). Pull out stopper pin (A) after installing, and then release plunger.

E

F

G

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JPBIA0119ZZ

6. 7.

Check again that the matching marks on sprockets and timing chain have not slipped out of alignment. Install new O-rings (1) on rear timing chain case. A

: Bank 1

B

: Bank 2

L

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O

JPBIA1111ZZ


EM-61

2009 G37 Coupe

P

TIMING CHAIN < REMOVAL AND INSTALLATION > 8. Install new front oil seal on front timing chain case. : Engine inside : Engine outside

• Apply new engine oil to both oil seal lip (A) and dust seal lip (B). • Install it so that each seal lip is oriented as shown in the figure.

JPBIA0054ZZ

• Using a suitable drift [outer diameter: 60 mm (2.36 in)] (A), press-fit oil seal until it becomes flush with front timing chain case end face. • Check that the garter spring is in position and seal lip is not inverted.

JPBIA0055ZZ

9. a.

Install front timing chain case as follows: • Check that O-rings stay in place during installation to rear timing chain case. Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to front timing chain case back side as shown in the figure. B

: Protrusion

c

: φ3.4 - 4.4 mm (0.134 - 0.173 in)

d

: φ2.6 - 3.6 mm (0.102 - 0.142 in)

e

: 4.0 - 5.6 mm (0.157 - 0.220 in)

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-17, "Recommended Chemical Products and Sealants".

JPBIA1138ZZ


EM-62

2009 G37 Coupe

TIMING CHAIN < REMOVAL AND INSTALLATION > b. Apply liquid gasket to top surface of oil pan (upper) as shown in the figure. A

A

: φ4.0 - 5.0 mm (0.157 - 0.197 in)

Use Genuine RTV Silicone Sealant or equivalent. Refer toGI-17, "Recommended Chemical Products and Sealants".

EM

C JPBIA0056ZZ

D

c.

Assemble front timing chain case. 1

: Front timing chain case

2

: Oil pan (upper)

3

: Cylinder block

E

: Engine front

d. e.

F

CAUTION: • Be careful not to damage front oil seal by interference with front end of crankshaft. • Attaching should be done within 5 minutes after liquid JPBIA0058ZZ gasket application. Install front timing chain case fitting its dowel pin hole together with dowel pin on rear timing chain case. Tighten mounting bolts to the specified torque in numerical order as shown in the figure. • There are two types of mounting bolts. Refer to the following for locating bolts. M10 bolts

: 1, 2, 3, 4, 5, 6, 7

G

H

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: 55.0 N·m (5.6 kg-m, 41 ft-lb) M6 bolts : Except the above K

: 12.7 N·m (1.3 kg-m, 9 ft-lb) JPBIA0046ZZ

f.

g.

After all bolts are tightened, retighten them to the specified torque in numerical order shown in the figure. CAUTION: Be sure to wipe off any excessive liquid gasket leaking on surface mating with oil pan (upper). Install two mounting bolts in front of oil pan (upper) in numerical order shown in the figure.

L

M

: Engine front

N

Tightening torque

: Refer to EM-82, "2WD : Exploded View". O

JPBIA0047ZZ

10. Install intake valve timing control covers as follows:


EM-63

2009 G37 Coupe

P

TIMING CHAIN < REMOVAL AND INSTALLATION > a. Install new seal rings (1) in shaft grooves. A

: Bank 2

CAUTION: When replacing seal ring, replace all rings with new ones. NOTE: The figure shows an example of bank 2.

JPBIA1113ZZ

b.

c.

d.

Install intake valve timing control cover with new gasket to front timing chain case. CAUTION: • Align the center of both shaft holes of the shaft and the intake side camshaft sprocket, and then insert them. • Be careful not to drop the seal ring from the shaft groove. Being careful not to move seal ring from the installation groove, align dowel pins on front timing chain case with dowel pin holes (C) to install intake valve timing control covers. A

: Bank 1

B

: Bank 2

Tighten mounting bolts in numerical order as shown in the figure. • After all bolts are tightened, tighten No.1 bolt to the specified torque again. JPBIA1333ZZ

11. Install oil pan (lower). Refer to EM-43, "Exploded View (2WD)" (2WD models) or EM-44, "Exploded View (AWD)" (AWD models). 12. Install rocker covers (bank 1 and bank 2). Refer to EM-47, "Exploded View". 13. Install crankshaft pulley as follows: a. Fix crankshaft using the ring gear stopper [SST: KV10118600 (J-48641)]. b. Install crankshaft pulley, taking care not to damage front oil seal. • When press-fitting crankshaft pulley with plastic hammer, tap on its center portion (not circumference). c. Tighten crankshaft pulley bolt. : 44.1 N·m (4.5 kg-m, 33 ft-lb) d.

Tighten the bolt 90 degrees (one mark) (b). • Place a matching mark (A) on crankshaft pulley (2) aligning with the matching (C) of crankshaft pulley bolt (1).

JPBIA0120ZZ

e.

Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly. 14. Install power steering oil pump bracket and idler pulley bracket as follows:


EM-64

2009 G37 Coupe

TIMING CHAIN < REMOVAL AND INSTALLATION > a. Tighten mounting bolts in numerical order as shown in the figure. (temporarily) 1

: Idler pulley bracket

2

: Power steering oil pump bracket

3

: Crankshaft pulley

A

: Engine front side

B

: Engine right side

A

EM

C

: Engine front

b.

Tighten mounting bolts to specified torque in numerical order as shown in the figure.

D

E

F

G JPBIA1786ZZ

15. For the following operations, perform steps in the reverse order of removal.

Inspection

H INFOID:0000000004250501

INSPECTION AFTER REMOVAL

I

Timing Chain Check for cracks and any excessive wear at link plates and roller links of timing chain. Replace timing chain if necessary.

J

A

: Crack

B

: Wear

K

L JPBIA0091ZZ

M

INSPECTION AFTER INSTALLATION Inspection for Leakage

N

The following are procedures for checking fluid leakage, lubricant leakage.

• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the required quantity, fill them to the specified level. Refer to MA-10, "Fluids and Lubricants". • Follow the procedure below to check for fuel leakage. - Turn ignition switch to the “ON” position (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. - Start engine. With engine speed increased, check again for fuel leakage at connection points. • Run engine to check for unusual noise and vibration. NOTE: If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a pounding noise during and just after the engine start. However, this does not indicate a malfunction. The noise will stop after hydraulic pressure rises. • Warm up engine thoroughly to check that there is no leakage of fuel, or any oil/fluids including engine oil and engine coolant. • Bleed air from lines and hoses of applicable lines, such as in cooling system. Revision: 2009 October

EM-65

2009 G37 Coupe

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TIMING CHAIN < REMOVAL AND INSTALLATION > • After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to the specified level, if necessary. Summary of the inspection items:

Items

Before starting engine

Engine running

After engine stopped

Engine coolant

Level

Leakage

Level

Engine oil

Level

Leakage

Level

Other oils and fluids*

Level

Leakage

Level

Leakage

Leakage

Leakage

Fuel

*: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.


EM-66

2009 G37 Coupe

OIL SEAL < REMOVAL AND INSTALLATION >

OIL SEAL

A

FRONT OIL SEAL FRONT OIL SEAL : Removal and Installation

INFOID:0000000004250502

EM

REMOVAL 1.

2.

Remove the following parts: • Engine undercover with power tool. • Drive belt: Refer to EM-13, "Exploded View". • Crankshaft pulley: Refer to EM-50, "Exploded View". Remove front oil seal using a suitable tool. CAUTION: Be careful not to damage front timing chain case and crankshaft.

C

D

E

F

PBIC2931E

G

INSTALLATION 1. 2.

H

Apply new engine oil to both oil seal lip and dust seal lip of new front oil seal. Install front oil seal. • Install front oil seal so that each seal lip is oriented as shown in the figure. A

: Oil seal lip

B

: Dust seal lip

I

J

: Engine inside : Engine outside

K

JPBIA0054ZZ

3.

• Using a suitable drift, press-fit until the height of front oil seal is level with the mounting surface. - Suitable drift: outer diameter 60 mm (2.36 in), inner diameter 50 mm (1.97 in). • Check that the garter spring is in position and seal lips are not inverted. CAUTION: • Be careful not to damage front timing chain case and crankshaft. • Press-fit straight and avoid causing burrs or tilting oil seal. Install in the reverse order of removal after this step.

M

N

O PBIC2931E

P

REAR OIL SEAL REAR OIL SEAL : Removal and Installation

INFOID:0000000004250503

REMOVAL 1.

Remove transmission assembly. Refer to TM-26, "Exploded View" (M/T models), TM-294, "2WD : Exploded View" (2WD A/T models) or TM-297, "AWD : Exploded View" (AWD A/T models).


L

EM-67

2009 G37 Coupe

OIL SEAL < REMOVAL AND INSTALLATION > 2. Remove drive plate (A/T models) or fly wheel (M/T models). Refer to EM-121, "Exploded View". 3. Remove rear oil seal with a suitable tool. CAUTION: Be careful not to damage crankshaft and cylinder block.

PBIC2932E

INSTALLATION 1.

Install rear oil seal. • Install rear oil seal so that each seal lip is oriented as shown in the figure. A B

: Oil seal lip : Dust seal lip : Engine inside : Engine outside

JPBIA0054ZZ

• Press in rear oil seal (1) to the position as shown in the figure. B

: Cylinder block rear end face

a

: 0 - 0.5 mm (0 - 0.020 in)

JPBIA0152ZZ

• Using a suitable drift (A), press-fit until the height of rear oil seal is level with the mounting surface. - Suitable drift: outer diameter 100 mm (3.94 in), inner diameter 85 mm (3.35 in). CAUTION: • Be careful not to damage crankshaft and cylinder block. • Press-fit straight and avoid causing burrs or tilting oil seal.

JPBIA0153ZZ

2.

Install in the reverse order of removal after this step.


EM-68

2009 G37 Coupe

ENGINE ASSEMBLY < UNIT REMOVAL AND INSTALLATION >

UNIT REMOVAL AND INSTALLATION

A

ENGINE ASSEMBLY 2WD

EM

2WD : Exploded View

INFOID:0000000004496182

C

D

E

F

G

H

I

J JPBIA1555GB

1.

Engine mounting bracket (RH)

2.

Engine mounting insulator (RH)

3.

Engine mounting bracket (LH)

4.

Engine mounting insulator (LH)

5.

Rear engine mounting member

6.

Engine mounting insulator (rear)

7.

Dynamic damper (M/T models)

8.

Dynamic damper (A/T models)

A.

Front mark

L

2WD : Removal and Installation

INFOID:0000000004496183

WARNING: • Situate the vehicle on a flat and solid surface. • Place chocks at the front and back of rear wheels. • For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS CATALOG. CAUTION: • Always be careful to work safely, and avoid forceful or uninstructed operations. • Never start working until exhaust system and engine coolant are cool enough. • If items or work required are not covered by the engine section, refer to the applicable sections. • Always use the support point specified for lifting. • Use either 2-pole lift type or separate type lift as much as possible. If board-on type is used for unavoidable reasons, support at rear axle jacking point with transmission jack or similar tool before starting work, in preparation for the backward shift of the center of gravity. • For supporting points for lifting and jacking point at rear axle, refer to GI-32, "Garage Jack and Safety Stand and 2-Pole Lift".

REMOVAL Outline


K

EM-69

2009 G37 Coupe

M

N

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P

ENGINE ASSEMBLY < UNIT REMOVAL AND INSTALLATION > At first, remove the engine and the transmission assembly with front suspension member facing downward. Then separate the engine from transmission. Preparation

1. 2. 3.

4.

5. 6.

Release fuel pressure. Refer to EC-614, "Inspection". Disconnect both battery cables. Refer to PG-99, "Exploded View". Drain engine coolant from radiator. Refer to CO-7, "Draining". CAUTION: • Perform this step when engine is cold. • Never spill engine coolant on drive belt. Remove the following parts: • Radiator reservoir tank: Refer to CO-13, "Exploded View". • Engine cover: Refer to EM-25, "Exploded View". • Front road wheel and tires (power tool) • Engine undercover (power tool) • Cowl top cover: Refer to EXT-21, "Exploded View". • Air duct and air cleaner case assembly (RH and LH): Refer to EM-27, "Exploded View". • Cooling fan assembly: Refer to CO-13, "Exploded View". Discharge refrigerant from A/C circuit. Refer to HA-26, "Collection and Charge". Remove radiator hoses (upper and lower). Refer to CO-13, "Exploded View".

Engine Room LH

1. 2. 3. 4.

Disconnect heater hose at vehicle side, and fit a plug onto hose end to prevent engine coolant leakage. Disconnect A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope. Refer to HA41, "Exploded View". Disconnect brake booster vacuum hose. Disconnect ground cable.

Engine Room RH

1. 2. 3.

4.

Disconnect battery positive cable at vehicle side and temporarily fasten it on engine. Disconnect all clips and connectors of the engine room harness from engine back side. Disconnect fuel feed hose (with damper) and EVAP hose. Refer to EM-37, "Exploded View". CAUTION: Fit plugs onto disconnected hoses to prevent fuel leakage. Remove reservoir tank of power steering oil pump and piping from vehicle, and temporarily secure them on engine. Refer to ST-59, "2WD : Exploded View". CAUTION: When temporarily securing, keep the reservoir tank upright to avoid fluid leakage.

Vehicle Inside Follow the procedure below to disconnect engine room harness connectors at passenger room side, and temporarily secure them on engine. 1. Remove passenger-side kicking plate and dash side finisher. Refer to INT-14, "Exploded View". 2. Disconnect engine room harness connectors at unit sides TCM, ECM and other locations. 3. Disengage intermediate fixing point. Pull out engine room harnesses to engine room side, and temporarily secure them on engine. CAUTION: • When pulling out harnesses, take care not to damage harnesses and connectors. • After temporarily securing, cover connectors with vinyl or similar material to protect against adhesion of foreign materials. Vehicle Underbody

1. 2. 3.

Remove A/T fluid cooler hoses (A/T models) and power steering oil pump oil cooler hoses. • Install plug to avoid leakage of A/T fluid and power steering fluid. Disconnect heated oxygen sensor 2 harness. Refer to EX-5, "Exploded View". Remove three way catalyst and exhaust front tube. Refer to EX-5, "Exploded View".


EM-70

2009 G37 Coupe

ENGINE ASSEMBLY < UNIT REMOVAL AND INSTALLATION > 4. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Refer to ST-24, "WITHOUT 4WAS : Exploded View" (without 4WAS models) or ST-25, "WITH 4WAS : A Exploded View" (with 4WAS models). 5. Remove rear propeller shaft. Refer to DLN-90, "Exploded View" (M/T models) or DLN-97, "Exploded View" (A/T models). EM 6. Disengage shift lever and remove clutch tube (M/T models). Refer to TM-18, "Exploded View". 7. Disengage A/T control rod at A/T shift selector side. Then, temporarily secure it on the transmission assembly, so that it does not sag (A/T models). Refer to TM-281, "Exploded View". C 8. Remove rear plate cover from oil pan (upper). Then remove bolts fixing drive plate to torque converter (A/ T models). Refer to EM-43, "Exploded View (2WD)". 9. Remove transmission joint bolts that pierce at oil pan (upper) lower rear side. Refer to EM-82, "2WD : D Exploded View". 10. Remove front stabilizer connecting rod from transverse link. Refer to FSU-9, "Exploded View". 11. Remove lower ends of left and right steering knuckle from transverse link. Refer to FAX-6, "Exploded E View". 12. Separate steering outer sockets from steering knuckle. Refer to ST-30, "2WD : Exploded View". 13. Remove transverse links mounting bolts at suspension member side. Refer to FSU-14, "Exploded View". F Removal Work

1.

Use a manual lift table caddy (commercial service tool) or equivalently rigid tool such as a transmission jack. Securely support bottom of suspension member and the transmission assembly. CAUTION: Use a piece of wood or a similar item as the supporting surface to secure a completely stable condition.

G

H

I

PBIC0804E

2. 3. 4.

Remove rear engine mounting member bolts. Remove front suspension member mounting bolts and nuts. Refer to FSU-21, "Exploded View". Carefully lower jack, or raise lift, to remove the engine, the transmission assembly and front suspension member. When performing work, observe the following caution items: CAUTION: • Confirm there is no interference with the vehicle. • Check that all connection points have been disconnected. • Keep in mind that the center of gravity of the vehicle changes. If necessary, use jack(s) to support the vehicle at rear jacking point(s) to prevent it from falling off the lift.

J

K

L

M

Separation Work

1.

Install engine slingers into front of cylinder head (bank 1) and rear of cylinder head (bank 2). 1

: Engine front slinger

2

: Engine rear slinger

N

O

A : Bank 1 B : Bank 2 : Engine front

P

Slinger bolts:

JPBIA1385ZZ

: 28.0 N·m (2.9 kg-m, 21 ft-lb) 2.

Remove power steering oil pump from engine side. Refer to ST-48, "FOR MODELS WITHOUT 4WAS AND MODELS EXCEPT SPORT MODELS : Exploded View".


EM-71

2009 G37 Coupe

ENGINE ASSEMBLY < UNIT REMOVAL AND INSTALLATION > 3. Remove engine mounting insulators (RH and LH) under side nuts with power tool. 4. Lift with hoist and separate the engine and the transmission assembly from front suspension member. CAUTION: • Before and during this lifting, always check that any harnesses are left connected. • Never damage engine mounting insulator and avoid oil/grease smearing or spills onto engine mounting insulator. 5. Remove alternator. Refer to CHG-25, "2WD : Exploded View". 6. Remove starter motor. Refer to STR-15, "Exploded View". 7. Separate the engine from the transmission assembly. Refer to TM-26, "Exploded View" (M/T models) or TM-294, "2WD : Exploded View" (A/T models). 8. Remove each engine mounting insulator and each engine mounting bracket from the engine with power tool.

INSTALLATION Note the following, and install in the reverse order of removal. • Do not damage engine mounting insulator and do not spill oil on it. • For a location with a positioning pin, insert it securely into hole of mating part. • For a part with a specified installation orientation, refer to component figure in EM-69, "2WD : Exploded View". • When installing engine mounting bracket (RH and LH) on cylinder block, tighten two upper bolts [shown as (B) in the figure] first. Then tighten two lower bolts [shown as (C) in the figure]. A : Example Left

JPBIA0159ZZ

• Check that all engine mounting insulators are seated properly, then tighten mounting nuts. • Tighten rear engine mounting member bolts in numerical order as shown in the figure. : Vehicle front

JPBIA0160ZZ

2WD : Inspection

INFOID:0000000004496184

INSPECTION AFTER INSTALLATION Inspection for Leakage The following are procedures for checking fluid leakage, lubricant leakage.

• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the required quantity, fill them to the specified level. Refer to MA-10, "Fluids and Lubricants". • Follow the procedure below to check for fuel leakage. - Turn ignition switch to the “ON” position (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. - Start engine. With engine speed increased, check again for fuel leakage at connection points. • Run engine to check for unusual noise and vibration. NOTE:


EM-72

2009 G37 Coupe

ENGINE ASSEMBLY < UNIT REMOVAL AND INSTALLATION > If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a pounding noise during and just after the engine start. However, this does not indicate a malfunction. The A noise will stop after hydraulic pressure rises. • Warm up engine thoroughly to check that there is no leakage of fuel, or any oil/fluids including engine oil and engine coolant. EM • Bleed air from lines and hoses of applicable lines, such as in cooling system. • After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to the specified level, if necessary. C

Summary of the inspection items:


Engine running


Engine coolant

Items

Level

Leakage

Level

Engine oil

Level

Leakage

Level


Level

Leakage

Level

Leakage

Leakage

Leakage

—

Leakage

—

Fuel Exhaust gases

D

E


F

AWD AWD : Exploded View

INFOID:0000000004496185

G

H

I

J

K

L

M

N

O

JPBIA2600GB

Dynamic damper

Engine mounting bracket (RH)

4.

Washer

5.

Engine mounting insulator (RH)

6.

Engine mounting bracket (LH)

7.

Engine mounting insulator (LH)

8.

Heat insulator

9.

Rear engine mounting member

10.

Engine mounting insulator (rear)

11.

Dynamic damper


2.

Engine mounting bracket (RH) (low3. er)

1.

EM-73

2009 G37 Coupe

P

ENGINE ASSEMBLY < UNIT REMOVAL AND INSTALLATION > A.

Front mark


AWD : Removal and Installation

INFOID:0000000004496186

WARNING: • Situate the vehicle on a flat and solid surface. • Place chocks at front and back of rear wheels. • For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS CATALOG. CAUTION: • Always be careful to work safely, avoid forceful or uninstructed operations. • Never start working until exhaust system and engine coolant are cool enough. • If items or work required are not covered by the engine section, refer to the applicable sections. • Always use the support point specified for lifting. • Use either 2-pole lift type or separate type lift as much as possible. If board-on type is used for unavoidable reasons, support at rear axle jacking point with 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-32, "Garage Jack and Safety Stand and 2-Pole Lift".

REMOVAL Outline At first, remove the engine, the transmission assembly, the transfer assembly and the front final drive assembly with front suspension member downward. Then separate the engine, the transmission assembly, the transfer and the front final drive assembly. Preparation

1. 2.

3. 4.

5. 6.

Release fuel pressure. Refer to EC-614, "Inspection". Drain engine coolant from radiator. Refer to CO-7, "Draining". CAUTION: • Perform this step when engine is cold. • Never spill engine coolant on drive belts. Disconnect both battery terminals. Refer to PG-99, "Exploded View". Remove the following parts: • Radiator reservoir tank: Refer to CO-13, "Exploded View". • Engine cover: Refer to EM-25, "Exploded View". • Front road wheel and tires (power tool) • Engine undercover (power tool) • Front cross bar: Refer to FSU-43, "Exploded View". • Cowl top cover: Refer to EXT-21, "Exploded View". • Air duct and air cleaner case assembly (RH and LH): Refer to EM-27, "Exploded View". • Cooling fan assembly: Refer to CO-16, "Exploded View". Discharge refrigerant from A/C circuit. Refer to HA-26, "Collection and Charge". Remove radiator hoses (upper and lower). Refer to CO-13, "Exploded View".

Engine Room LH

1. 2. 3. 4.

Disconnect heater hose from vehicle side, and fit a plug onto hose end to prevent engine coolant leak. Disconnect A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope. Refer to HA41, "Exploded View". Disconnect brake booster vacuum hose. Disconnect ground cables.

Engine Room RH

1. 2. 3.

Disconnect battery positive cable vehicle side and temporarily fasten it on engine. Disconnect all clips and connectors of the engine room harness from engine back side. Disconnect fuel feed hose (with damper) and EVAP hose. Refer to EM-37, "Exploded View". CAUTION:


EM-74

2009 G37 Coupe

ENGINE ASSEMBLY < UNIT REMOVAL AND INSTALLATION > Fit plugs onto disconnected hoses to prevent fuel leakage. 4. Remove reservoir tank of power steering oil pump and piping from vehicle, and temporarily secure them A on engine. Refer to ST-48, "FOR MODELS WITHOUT 4WAS AND MODELS EXCEPT SPORT MODELS : Exploded View" (EXCEPT FOR SPORT MODELS) or ST-53, "FOR MODELS WITH 4WAS AND SPORT MODELS : Exploded View" (SPORT MODELS). EM CAUTION: When temporarily securing, keep the reservoir tank upright to avoid a fluid leakage. Vehicle Inside Follow procedure below to disconnect engine room harness connectors at passenger room side, and temporarily secure them on engine. 1. Remove passenger-side kicking plate and dash side finisher. Refer to INT-14, "Exploded View". 2. Disconnect engine room harness connectors at unit sides TCM, ECM and other. 3. Disengage intermediate fixing point. Pull out engine room harnesses to engine room side, and temporarily secure them on engine. CAUTION: • When pulling out harnesses, take care not to damage harnesses and connectors. • After temporarily securing, cover connectors with vinyl or similar material to protect against adhesion of foreign materials.

C

D

E

F

Vehicle Underbody

1. 2. 3. 4.

5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Remove A/T fluid cooler hoses and power steering oil pump oil cooler hoses. • Install plug to avoid leakage of A/T fluid and power steering fluid. Disconnect heated oxygen sensor 2 harness. Refer to EX-5, "Exploded View". Remove three way catalyst and exhaust front tube. Refer to EX-5, "Exploded View". Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Refer to ST-24, "WITHOUT 4WAS : Exploded View" (without 4WAS models) or ST-25, "WITH 4WAS : Exploded View" (with 4WAS models). Remove rear propeller shaft. Refer to DLN-105, "Exploded View". Remove front drive shaft (both side). Refer to FAX-22, "Exploded View". Disconnect harness connector from transmission assembly and transfer assembly. Disengage A/T control rod at A/T shift selector side. Then, temporarily secure it on the transmission assembly, so that it does not sag. Refer to TM-281, "Exploded View". Remove rear plate cover from oil pan (upper). Then remove bolts fixing drive plate to torque converter. Refer to EM-85, "AWD : Exploded View". Remove transmission joint bolts that pierce at oil pan (upper) lower rear side. Refer to EM-44, "Exploded View (AWD)". Remove front stabilizer connecting rod from transverse link. Refer to FSU-41, "Exploded View". Remove lower ends of left and right steering knuckle from transverse link. Refer to FSU-31, "Exploded View". Separate steering outer sockets from steering knuckle. Refer to ST-37, "AWD : Exploded View". Remove transverse links mounting bolts at suspension member side. Refer to FSU-36, "Exploded View". Use a manual lift table caddy (commercial service tool) or equivalently rigid tool such as a transmission jack. Securely support bottom of suspension member and the transmission assembly. CAUTION: Use a piece of wood or a similar item as the supporting surface to secure a completely stable condition.

J

K

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P

Remove rear engine mounting member bolts.


I

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PBIC0804E

2.

H

N

Removal Work

1.

G

EM-75

2009 G37 Coupe

ENGINE ASSEMBLY < UNIT REMOVAL AND INSTALLATION > 3. Remove front suspension member mounting bolts and nuts. Refer to FSU-43, "Exploded View". 4. Carefully lower jack, or raise lift to remove the engine, transmission assembly, transfer, front final drive assembly and front suspension member. When performing work, observe the following caution: CAUTION: • Confirm there is no interference with the vehicle. • Check that all connection points have been disconnected. • Keep in mind that the center of gravity of the vehicle changes. If necessary, use jack(s) to support the vehicle at rear jacking point(s) to prevent it from falling it off the lift. Separation Work

1.

Install engine slingers into front of cylinder head (bank 1) and rear of cylinder head (bank 2). 1

: Engine front slinger

2

: Engine rear slinger

A : Bank 1 B : Bank 2 : Engine front

Slinger bolts:

JPBIA1385ZZ

: 28.0 N·m (2.9 kg-m, 21 ft-lb) Remove power steering oil pump from engine side. Refer to ST-48, "FOR MODELS WITHOUT 4WAS AND MODELS EXCEPT SPORT MODELS : Exploded View" (without 4WAS models). 3. Remove engine mounting insulators (RH and LH) under side nuts with power tool. 4. Lift with hoist and separate the engine, transmission assembly, transfer, front final drive assembly and front suspension member. CAUTION: • Before and during this lifting, always check any harnesses are left connected. • Never damage engine mounting insulator and avoid oil/grease smearing or spills onto engine mounting insulator. 5. Remove alternator. Refer to CHG-27, "AWD : Exploded View". 6. Remove starter motor. Refer toSTR-15, "Exploded View". 7. Remove front propeller shaft from the front final drive assembly side. Refer to DLN-83, "Exploded View". 8. Separate the engine from the transmission assembly. Refer to TM-297, "AWD : Exploded View". 9. Remove the front final drive assembly from oil pan (upper). Refer to DLN-120, "Exploded View". 10. Remove each engine mounting insulator and each engine mounting bracket from the engine with power tool. 2.

INSTALLATION Note the following, and install in the reverse order of removal. • Do not damage engine mounting insulator and do not spill oil on it. • For a location with a positioning pin, insert it securely into hole of mating part. • For a part with a specified installation orientation, refer to component figure in EM-73, "AWD : Exploded View".


EM-76

2009 G37 Coupe

ENGINE ASSEMBLY < UNIT REMOVAL AND INSTALLATION > • When installing engine mounting bracket (RH and LH) on cylinder block, tighten two upper bolts [shown as (B) in the figure] first. Then tighten two lower bolts [shown as (C) in the figure]. 3

A

: Engine mounting bracket (LH)

EM

A : Right side G : Left side

• Install engine mounting bracket (RH) (lower) (2) as follows: - Temporarily tighten mounting bolts [shown as (D), (E) and (F) in the figure]. - Tighten mounting bolts to the specified torque with following mounting surfaces touched. • Engine mounting bracket (RH) (1) to engine mounting bracket (RH) (lower) [shown as and in figure]. • Front final drive to engine mounting bracket (RH) (lower) [shown as in figure]. • Check all engine mounting insulators are seated properly, then tighten mounting nuts.

C

D

E

F

G JPBIA0163ZZ

• Tighten rear engine mounting member bolts in numerical order as shown in the figure.

H

: Vehicle front

I

J

JPBIA0407ZZ

AWD : Inspection

K

INFOID:0000000004496187

L

INSPECTION AFTER INSTALLATION Inspection for Leaks

M

The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.

• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the required quantity, fill to the specified level. Refer to MA-10, "Fluids and Lubricants". • Follow the procedure below to check for fuel leakage. - Turn ignition switch to the “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. - Start engine. With engine speed increased, check again for fuel leakage at connection points. • Run engine to check for unusual noise and vibration. NOTE: If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a pounding noise during and just after the engine start. However, this does not indicate a malfunction. The noise will stop after hydraulic pressure rises. • Warm up engine thoroughly to check that there is no leakage of fuel, or any oil/fluids including engine oil and engine coolant. • Bleed air from lines and hoses of applicable lines, such as in cooling system. • After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to the specified level, if necessary.


EM-77

2009 G37 Coupe

N

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P

ENGINE ASSEMBLY < UNIT REMOVAL AND INSTALLATION > Summary of the inspection items:

Items


Engine running


Engine coolant

Level

Leakage

Level

Engine oil

Level

Leakage

Level

Other oils and fluid*

Level

Leakage

Level

Leakage

Leakage

Leakage

—

Leakage

—

Fuel Exhaust gases



EM-78

2009 G37 Coupe

ENGINE STAND SETTING < UNIT DISASSEMBLY AND ASSEMBLY >

UNIT DISASSEMBLY AND ASSEMBLY

A

ENGINE STAND SETTING Setting

INFOID:0000000004250507

NOTE: Explained here is how to disassemble with engine stand supporting transmission surface. When using a different type of engine stand, note the difference in the steps, etc. 1. Remove the engine assembly from the vehicle. Refer to EM-69, "2WD : Exploded View" (2WD models) or EM-73, "AWD : Exploded View" (AWD models). 2. Remove the parts that may restrict installation of engine to a widely use engine stand. NOTE: The procedure is described assuming that you use a widely use engine stand holding the surface, to which transmission is installed. • Remove clutch cover and clutch disc (M/T models). Refer to CL-19, "Exploded View". • Remove drive plate (A/T models) or flywheel (M/T models) with power tool. Fix crankshaft with a ring gear stopper [SST: KV10118600 (J-48641)], and remove mounting bolts. • Loosen mounting bolts in diagonal order. • Check for deformation or damage of drive plate (A/T models) or flywheel (M/T models). CAUTION: • Never disassemble drive plate (A/T models) or flywheel (M/T models). • Never place drive plate (A/T models) or flywheel (M/T models) with signal plate facing down. • When handling signal plate, take care not to damage or scratch it. • Handle signal plate in a manner that prevents it from becoming magnetized. 3.

EM

C

D

E

F

G

H

Remove pilot converter (A/T models) using the pilot bushing puller [SST: ST16610001 (J-23907)] (A) if necessary. I

J

K JPBIA0193ZZ

4.

Lift the engine with hoist to install it onto the widely use engine stand. CAUTION: Use an engine stand that has a load capacity [220 kg (485 lb) or more] large enough for supporting the engine weight. • If the load capacity of the stand is not adequate, remove the following parts beforehand to reduce the potential risk of overturning the stand. - Remove intake manifold collector. Refer to EM-29, "Exploded View". - Remove intake manifold. Refer to EM-32, "Exploded View". - Remove fuel injector and fuel tube assembly. Refer to EM-37, "Exploded View". - Remove ignition coil. Refer to EM-47, "Exploded View". - Remove rocker cover. Refer to EM-47, "Exploded View". - Remove exhaust manifold. Refer to EM-34, "Exploded View". - Other removable brackets. NOTE:


EM-79

2009 G37 Coupe

L

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ENGINE STAND SETTING < UNIT DISASSEMBLY AND ASSEMBLY > The figure shows an example of widely use engine stand (A) that can hold mating surface of transmission with drive plate (A/T models) or flywheel (M/T models) removed. CAUTION: Before removing the hanging chains, check the engine stand is stable and there is no risk of overturning.

JPBIA0190ZZ

5. 6.

Drain engine oil. Refer to LU-8, "Draining". Drain engine coolant by removing water drain plug (1) from both sides of the cylinder block as shown in the figure. 2

: Washer

3

: Plug

4

: Drain plug : Engine front

JPBIA0191ZZ


EM-80

2009 G37 Coupe

ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY >

ENGINE UNIT

A

Disassembly

INFOID:0000000004250508

1. 2. 3. 4.

Remove intake manifold collector. Refer to EM-29, "Exploded View". EM Remove intake manifold. Refer to EM-32, "Exploded View". Remove exhaust manifold. Refer to EM-34, "Exploded View". Remove oil pan (lower). Refer to EM-43, "Exploded View (2WD)" (2WD models) or EM-44, "Exploded C View (AWD)" (AWD models). 5. Remove ignition coil, spark plug and rocker cover. Refer to EM-47, "Exploded View". D 6. Remove fuel injector and fuel tube. Refer to EM-37, "Exploded View". 7. Remove timing chain. Refer to EM-50, "Exploded View". 8. Remove rear timing chain case. Refer to EM-89, "Exploded View". E 9. Remove camshaft (EXH) and VVEL ladder assembly. Refer to EM-94, "Exploded View". 10. Remove cylinder head. Refer to EM-111, "Exploded View".

Assembly

INFOID:0000000004250509

F

Assemble in the reverse order of disassembly. G

H

I

J

K

L

M

N

O

P


EM-81

2009 G37 Coupe

OIL PAN (UPPER) AND OIL STRAINER < UNIT DISASSEMBLY AND ASSEMBLY >

OIL PAN (UPPER) AND OIL STRAINER 2WD 2WD : Exploded View

INFOID:0000000004496188

JPBIA1401GB

1.

Oil level gauge

2.


3.

O-ring

4.

O-ring

5.

Connector bolt

6.

Oil filter

7.

Relief valve

8.

Oil pressure switch

9.

Oil strainer

10. Oil temperature sensor

11. Washer

12. Oil pan (upper)

13. Drain plug

14. Drain plug washer

15. Oil pan (lower)


17. Rear cover plate (M/T models)

A.

B.

Refer to LU-9

To oil pump

C.

Oil pan side


2WD : Disassembly and Assembly

INFOID:0000000004496189

REMOVAL CAUTION: Never drain engine oil when the engine is hot to avoid the danger of being scalded. 1. Remove oil level gauge, oil pressure switch and oil temperature sensor. Revision: 2009 October

EM-82

2009 G37 Coupe

OIL PAN (UPPER) AND OIL STRAINER < UNIT DISASSEMBLY AND ASSEMBLY > 2. Remove oil pan (lower). Refer to EM-43, "Exploded View (2WD)". 3. Remove oil strainer. 4. Loosen mounting bolts in the reverse order as shown in the figure with power tool to remove.

A

EM : Engine front

• Insert the seal cutter [SST: KV10111100 (J-37228)] between oil pan (upper) and lower cylinder block. Slide seal cutter by tapping on the side of tool with a hammer. Remove oil pan (upper). CAUTION: • Be careful not to damage the mating surfaces. • Never insert a screwdriver, because this damages the mating surfaces. 5.

C

D JPBIA0022ZZ

E

Remove O-rings (2) from bottom of lower cylinder block (1) and oil pump (3). F : Engine front

G

H JPBIA1330ZZ

INSTALLATION 1. a.

I

Install oil pan (upper) as follows: Use a scraper (A) to remove old liquid gasket from mating surfaces. CAUTION: Never scratch or damage the mating surfaces when cleaning off old liquid gasket. • Also remove old liquid gasket from mating surface of lower cylinder block. • Remove old liquid gasket from the bolt holes and threads.

J

K

L JPBIA0027ZZ

b.

M

Install new O-rings (2) on the bottom of lower cylinder block (1) and oil pump (3).

N

: Engine front

O

P JPBIA1330ZZ


EM-83

2009 G37 Coupe

OIL PAN (UPPER) AND OIL STRAINER < UNIT DISASSEMBLY AND ASSEMBLY > c. Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to the cylinder block mating surface of oil pan (upper) to a limited portion as shown in the figure. a


d.

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-17, "Recommended Chemical Products and Sealants". CAUTION: • For bolt holes with marks (7 locations), apply liquid gasket outside the holes. • Attaching should be done within 5 minutes after coating. Install oil pan (upper). CAUTION: Never misalign both O-rings during installation. • Tighten mounting bolts in numerical order as shown in the figure.

JPBIA0388ZZ

: Engine front

• There are two types of mounting bolts. Refer to the following for locating bolts. M8 × 90 mm (3.54 in) M8 × 25 mm (0.98 in)

: 7, 10, 13 : Except the above JPBIA0022ZZ

2. 3. 4.

5.

Install oil strainer to oil pump. Install oil pan (lower). Refer to EM-43, "Exploded View (2WD)". Install oil pan drain plug. • Refer to the figure of components on the prior page for installation direction of drain plug washer. Refer to EM-43, "Exploded View (2WD)". Install in the reverse order of removal after this step. NOTE: Wait at least 30 minutes after oil pan is installed before pouring engine oil.

2WD : Inspection

INFOID:0000000004496190

INSPECTION AFTER REMOVAL Clean oil strainer if any object is attached.



AWD


EM-84

2009 G37 Coupe

OIL PAN (UPPER) AND OIL STRAINER < UNIT DISASSEMBLY AND ASSEMBLY >

AWD : Exploded View

INFOID:0000000004496191

A

EM

C

D

E

F

G

H

I

JPBIA2763GB

1.

Oil level gauge

2.


3.

O-ring

4.

O-ring

5.

Gasket

6.

Oil strainer

7.

Drain plug

8.

Drain plug washer

9.

Oil pan (lower)

10. Baffle plate

11. O-ring (small)

12. Axle pipe

13. O-ring (large)


15. Oil pan (upper)

A.

B.

C.

Refer to LU-11

To oil pump

J

K

L

Oil pan side


AWD : Disassembly and Assembly

INFOID:0000000004496192

M

REMOVAL N

CAUTION: Never drain engine oil when the engine is hot to avoid the danger of being scalded. 1. Remove oil level gauge, oil pressure switch and oil temperature sensor. 2. Remove oil filter bracket. Refer to LU-11, "Exploded View". 3. Remove oil pan (lower). Refer to EM-44, "Exploded View (AWD)". 4. Remove oil strainer.

O

P


EM-85

2009 G37 Coupe

OIL PAN (UPPER) AND OIL STRAINER < UNIT DISASSEMBLY AND ASSEMBLY > 5. Loosen mounting bolts in the reverse order as shown in the figure with power tool to remove. : Engine front

• Insert the seal cutter [SST: KV10111100 (J-37228)] between oil pan (upper) and lower cylinder block. Slide seal cutter by tapping on the side of tool with a hammer. Remove oil pan (upper). CAUTION: • Be careful not to damage the mating surfaces. • Never insert a screwdriver, because this will damage the mating surfaces. 6.

JPBIA0022ZZ

Remove O-rings (2) from bottom of lower cylinder block (1) and oil pump (3). : Engine front

JPBIA1330ZZ

7.

Remove axle pipe, if necessary. • Remove axle pipe from oil pan (upper) using a suitable drift (A) [outer diameter: 37 mm (1.46 in)].

JPBIA0028ZZ

INSTALLATION 1.

Install axle pipe (3) to oil pan (upper), if removed. • Lubricate O-ring groove of axle pipe, O-rings (1), (2), and Oring joint of oil pan with new engine oil. Unit: mm (in)

Items

O-ring inner diameter

Final drive side (right side)

31.4 (1.236)

Axle pipe flange side (left side)

33.6 (1.323)

JPBIA0452ZZ


EM-86

2009 G37 Coupe

OIL PAN (UPPER) AND OIL STRAINER < UNIT DISASSEMBLY AND ASSEMBLY > • Install axle pipe (1) to oil pan (upper) from axle pipe flange side (left side) using a suitable drift (A) [outer diameter: 43 to 57 mm (1.69 to 2.24 in)]. CAUTION: Insert it with care to prevent O-ring from sliding.

A

EM

C JPBIA0029ZZ

D

2. a.

Install oil pan (upper) as follows: Use a scraper (A) to remove old liquid gasket from mating surfaces. CAUTION: Never scratch or damage the mating surfaces when cleaning off old liquid gasket. • Also remove old liquid gasket from mating surface of lower cylinder block. • Remove old liquid gasket from the bolt holes and threads.

E

F

G JPBIA0027ZZ

b.

H

Install new O-rings (2) on the bottom of lower cylinder block (1) and oil pump (3).

I

: Engine front

J

K JPBIA1330ZZ

c.

Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to the cylinder block mating surface of oil pan (upper) to a limited portion as shown in the figure. a

L

: φ4.0 - 5.0 mm (0.157 - 0.197 in)

M

: Engine front

d.

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-17, "Recommended Chemical Products and Sealants". CAUTION: • For bolt holes with marks (7 locations), apply liquid gasket outside the holes. • Attaching should be done within 5 minutes after coating. Install oil pan (upper). CAUTION: Never misalign both O-rings during installation.


EM-87

N

JPBIA0388ZZ

O

P

2009 G37 Coupe

OIL PAN (UPPER) AND OIL STRAINER < UNIT DISASSEMBLY AND ASSEMBLY > • Tighten mounting bolts in numerical order as shown in the figure. : Engine front

• There are three types of mounting bolts. Refer to the following for locating bolts. M8 × 25 mm (0.98 in) M8 × 50 mm (1.97 in) M8 × 90 mm (3.54 in) 3. 4. 5.

6.

: 3, 6, 8, 9, 11, 12, 14, 15, 16 :2 : 1, 4, 5, 7, 10, 13

JPBIA0022ZZ

Install oil strainer to oil pump. Install oil pan (lower). Refer to EM-44, "Exploded View (AWD)". Install oil pan drain plug. • Refer to the figure of components on the prior page for installation direction of drain plug washer. Refer to EM-44, "Exploded View (AWD)". Install in the reverse order of removal after this step. NOTE: Wait at least 30 minutes after oil pan is installed before pouring engine oil.

AWD : Inspection

INFOID:0000000004496193

INSPECTION AFTER REMOVAL Clean oil strainer if any object attached.




EM-88

2009 G37 Coupe

REAR TIMING CHAIN CASE < UNIT DISASSEMBLY AND ASSEMBLY >

REAR TIMING CHAIN CASE

A

Exploded View

INFOID:0000000004250513

EM

C

D

E

F

G

H

I

J

K

L

M

N

O

P

JPBIA1101GB

1.


2.


3.

O-ring

4.


5.


6.


7.


8.

Camshaft sprocket (INT) (bank 1)

9.



EM-89

2009 G37 Coupe

REAR TIMING CHAIN CASE < UNIT DISASSEMBLY AND ASSEMBLY > 10.

Slack guide

11. Crankshaft sprocket

12. Camshaft sprocket (INT) (bank 2)

13.

Tension guide

Intake valve timing control cover 14. gasket (bank 1)

15. Seal ring

16.

Intake valve timing control cover (bank 1)

17. O-ring

18.

19.

Oil level gauge

20. Oil level gauge guide

21. O-ring

22.

Intake valve timing control solenoid Intake valve timing control cover 23. (bank 2) valve (bank 2)

24.

25.

Intake valve timing control cover gasket (bank 2)

26. Front oil seal

27. Crankshaft pulley

28.

Crankshaft pulley bolt

29.

31.

Idler pulley bracket

32. Alternator bracket

33. Water outlet (front)

34.


35. Rear timing chain case

36. O-ring

37.

O-ring

38. O-ring

A.

Refer to EM-51

B.

Camshaft position sensor (PHASE) (bank 1) Camshaft position sensor (PHASE) (bank 2)

Intake valve timing control solenoid 30. Power steering oil pump bracket valve (bank 1)

Refer to EM-90

C.

Oil filter



INFOID:0000000004250514

DISASSEMBLY 1. 2. 3. 4. a. b.

Remove front timing chain case and timing chain. Refer to EM-51, "Removal and Installation". Remove water pump. Refer to CO-18, "Exploded View". Remove oil pan (upper). Refer to EM-82, "2WD : Exploded View" (2WD models) or EM-85, "AWD : Exploded View" (AWD models). Remove rear timing chain case as follows: Loosen mounting bolts in reverse order as shown in the figure. Cut liquid gasket using the seal cutter [SST: KV10111100 (J37228)] and remove rear timing chain case.

JPBIA0089ZZ

CAUTION: • Never remove plate metal cover (1) of oil passage. • After removal, handle rear timing chain case carefully so it does not tilt, cant, or warp under a load.

JPBIA0088ZZ


EM-90

2009 G37 Coupe

REAR TIMING CHAIN CASE < UNIT DISASSEMBLY AND ASSEMBLY > 5. Remove O-rings (1) from cylinder block. A : Engine front

EM

C JPBIA0090ZZ

D

6. 7.

Use a scraper to remove all traces of liquid gasket from rear timing chain cases and opposite mating surfaces. Remove old liquid gasket from bolt hole and thread. A

: Remove old liquid gasket that is stuck

B

: Bolt hole

E

F

G

JPBIA0051ZZ

H

ASSEMBLY 1. a.

I

Install rear timing chain case as follows: Install new O-rings (1) onto cylinder block.

J

: Engine front

K

L JPBIA0090ZZ

b.

Apply liquid gasket with the tube presser (commercial service tool) to rear timing chain case back side as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-17, "Recommended Chemical Products and Sealants". CAUTION: • For in the figure, completely wipe off liquid gasket extended on a portion touching at engine coolant. • Apply liquid gasket on installation position of water pump and cylinder head completely.

M

N

O

P


EM-91

2009 G37 Coupe

REAR TIMING CHAIN CASE < UNIT DISASSEMBLY AND ASSEMBLY >

JPBIA0092ZZ

C.

Protrusion

D.

Clearance 1 mm (0.04 in)

F.

Run along bolt hole inner side

G.

Protrusions at beginning and end of gasket

h.

φ3.4 - 4.4 mm (0.134 - 173 in)

i.

φ2.6 - 2.8 mm (0.102 - 0.110 in)

E.

Do not protrude in this area


c.

d.

Align rear timing chain case with dowel pins (bank 1 and bank 2) on cylinder block and install rear timing chain case. • Check that O-rings stay in place during installation to cylinder block. Tighten mounting bolts in numerical order as shown in the figure. • There are three types of mounting bolts. Refer to the following for locating bolts. Bolt length: 20 mm (0.79 in) 16 mm (0.63 in)

Bolt position : 1, 2, 3, 6, 7, 8, 9, 10 : 4, 5, 11, 12, 13 : 12.7 N·m (1.3 kg-m, 9 ft-lb) JPBIA0089ZZ

16 mm (0.63 in)

: Except the above : 15.0 N·m (1.5 kg-m, 11 ft-lb)

e.

After all bolts are tightened, retighten them to the specified torque in numerical order shown in the figure. • If liquid gasket protrudes, wipe it off immediately.


EM-92

2009 G37 Coupe

REAR TIMING CHAIN CASE < UNIT DISASSEMBLY AND ASSEMBLY > f. After installing rear timing chain case, check the surface height difference between the following parts on the oil pan (upper) mounting surface. 1

: Rear timing chain case

2

: Lower cylinder block

EM

Standard Rear timing chain case to lower cylinder block: –0.24 to 0.14 mm (–0.0094 to 0.0055 in) 2. 3.

5.

C JPBIA1363ZZ

• If not within the standard, repeat the installation procedure. Install water pump with new O-rings. Refer to CO-18, "Exploded View". Install timing chains, camshaft sprockets and front timing chain case. Refer to EM-51, "Removal and Installation". • After installing front timing chain case, check the surface height difference between the following parts on the oil pan (upper) mounting surface. 1

: Front timing chain case

2

: Rear timing chain case

3

: Lower cylinder block

D

E

F

G

Standard Front timing chain case to rear timing chain case: –0.14 to 0.14 mm (–0.0055 to 0.0055 in) 4.

A

H JPBIA0093ZZ

• If not within the standard, repeat the installation procedure. Install oil pan (upper). Refer to EM-82, "2WD : Exploded View" (2WD models) or EM-85, "AWD : Exploded View" (AWD models). Install in the reverse order of removal after this step.

I

J

K

L

M

N

O

P


EM-93

2009 G37 Coupe

CAMSHAFT < UNIT DISASSEMBLY AND ASSEMBLY >

CAMSHAFT Exploded View

INFOID:0000000004250515

JPBIA1102GB

VVEL control shaft position sensor (bank 1)

2.

VVEL actuator sub assembly (bank 1) 3.

Actuator bracket (rear) (bank 1)

4.

Washer

5.

VVEL ladder assembly (bank 1)

6.

Washer

7.

Timing chain tensioner (secondary) (bank 1)

8.

Camshaft (EXH) (bank 1)

9.

Valve lifter (EXH)

10. Valve lifter (INT)

11.

Oil filter

12. Cylinder head (bank 1)



16. VVEL ladder assembly (bank 2)

17. VVEL actuator sub assembly (bank 2) 18.

1.

15. Camshaft (EXH) (bank 2) VVEL control shaft position sensor (bank 2)

19. Actuator bracket (rear) (bank 2) A.

Refer to EM-95


CAUTION: As for replacement of parts on the intake side as shown in the exploded view, replace VVEL ladder assembly and cylinder head assembly. NOTE: Revision: 2009 October

EM-94

2009 G37 Coupe

CAMSHAFT < UNIT DISASSEMBLY AND ASSEMBLY > VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinder head assembly.

A

VVEL Ladder Assembly and Cylinder Head Assembly Features EM

C

D

E

F JPBIA1508ZZ

G A.

Control shaft

B.

Drive shaft

C.

Hexagonal part of drive shaft (for holding)

D.

Hexagonal part of camshaft (EXH) (for holding)

E.

Stopper of control shaft

F.

Two flat area of control shaft (for holding)

H

: Engine front

NOTE: The figure shows an example of bank 2.

I


INFOID:0000000004250516

J

DISASSEMBLY K

L

M

N

JPBIA1128ZZ

CAUTION: Never loosen adjusting bolts (A) and mounting bolts (black color) (B) of VVEL ladder assembly. If loosened, the stroke of cam lift becomes out of adjustment. In such case, replacement of VVEL ladder assembly and cylinder head assembly is required. NOTE: VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinder head assembly. 1. Remove rocker covers (bank 1 and bank 2). Refer to EM-47, "Exploded View". 2. Remove VVEL actuator sub assembly as follows: CAUTION: Revision: 2009 October

EM-95

2009 G37 Coupe

O

P

CAMSHAFT < UNIT DISASSEMBLY AND ASSEMBLY > VVEL actuator sub assembly and VVEL control shaft position sensor are nonreusable. Never remove them unless they are required. a. Remove VVEL control shaft position sensor. b. Turn control shaft to the large lift side and fix it in order to prevent the interference of the stopper surface. • If control shaft cannot be moved, set crankshaft in position referring to the information below. (To displace cam nose) Bank 1 Bank 2 c.

: Turn 120 degrees from no.1 cylinder at TDC : No.1 cylinder at TDC

Fix two flat areas (C) of control shaft with a wrench to remove mounting bolts of control shaft. A

: Bank 1

B


CAUTION: • During the operation, never allow a wrench to interfere with other parts. • Fix control shaft to prevent the interference of the stopper surface.

JPBIA1331ZZ

d.

Remove VVEL actuator sub assembly. • Loosen mounting bolts in the reverse order as shown in the figure. A

: Bank 2

B

: Bank 1

CAUTION: • When removing, prepare wastes because oil spills. • When installing, be careful with VVEL actuator sub assembly (bank 2) mounting bolt No. 1 because its length is different. JPBIA1114ZZ

e.

Remove actuator bracket (rear). • Loosen mounting bolts in the reverse order as shown in the figure. A

: Bank 1

B


JPBIA1131ZZ


EM-96

2009 G37 Coupe

CAMSHAFT < UNIT DISASSEMBLY AND ASSEMBLY > 3. 4. 5.

Remove front timing chain case, camshaft sprockets, and timing chain. Refer to EM-50, "Exploded View". A Remove rear timing chain case. Refer to EM-89, "Exploded View". Remove VVEL ladder assembly. • Loosen mounting bolts (gold color) in the reverse order as EM shown in the figure. A

: Bank 1

B

: Bank 2

C

: Engine front

CAUTION: • Never loosen adjusting bolts and mounting bolts (black color). • When removing VVEL ladder assembly, hold the drive shaft from below so as not to drop it.

D

E

F

G

H JPBIA1103ZZ

6. 7. 8.

Remove camshaft (EXH). Remove valve lifter. • Identify installation positions, and store them without mixing them up. Remove timing chain tensioners (secondary) (1) from cylinder head. A

: Bank 1

B

: Bank 2

I

J

K

• Remove timing chain tensioners (secondary) with its stopper pin (C) attached. NOTE: Stopper pin should be attached when timing chain (secondary) is removed.

L

JPBIA0121ZZ

9.

Remove oil filter from cylinder head, if necessary.

ASSEMBLY 1.

M

N

Install timing chain tensioners (secondary) (1) on both sides of cylinder head. A

: Bank 1

B

: Bank 2

O

• Install timing chain tensioner with its stopper pin (C) attached. • Install timing chain tensioner with sliding part facing downward on cylinder head (bank 1), and with sliding part facing upward on cylinder head (bank 2).

P

JPBIA0121ZZ


EM-97

2009 G37 Coupe

CAMSHAFT < UNIT DISASSEMBLY AND ASSEMBLY > 2. Install oil filter (1), if removed. • Do not project from the cylinder head (2) surface.

JPBIA1390ZZ

3. 4.

Install valve lifter. • Install it in the original position. Install camshaft (EXH). • Distinction between camshaft (EXH) (bank 1 and bank 2) is performed with the identification mark. Paint marks M1 (C)

M2 (D)

M3 (E)

Identification mark (F)

Bank 1 (A)

No

Blue

Light blue

1N

Bank 2 (B)

No

Blue

Light blue

1P

Bank

JPBIA1129ZZ

5. a.

Install VVEL ladder assembly as follows: Apply a continuous bead of liquid gasket with tube presser (commercial service tool) to the cylinder head as shown in the figure. A

: Bank 1

B

: Bank 2

c



JPBIA1123ZZ


EM-98

2009 G37 Coupe

CAMSHAFT < UNIT DISASSEMBLY AND ASSEMBLY > b. Tighten mounting bolts in the following step, in numerical order as shown in the figure. A

: Bank 1

B

: Bank 2

A

EM

: Engine front

i.

Tighten bolts in numerical order as shown in the figure. C

: 1.96 N·m (0.20 kg-m, 1 ft-lb) ii.

Tighten bolts in numerical order as shown in the figure.

D

: 5.88 N·m (0.60 kg-m, 4 ft-lb) E

iii. Tighten bolts in numerical order as shown in the figure. : 10.4 N·m (1.1 kg-m, 8 ft-lb)

F

G JPBIA1103ZZ

6.

Measure difference in levels between front end faces of VVEL ladder assembly and cylinder head. Standard

H

: −0.14 to 0.14 mm (−0.0055 to 0.0055 in) I

• Measure two positions (both intake and exhaust side) for a single bank. • If the measured value is out of the standard, re-install VVEL ladder assembly.

J EMQ0044D

K

7. 8. 9. a.

Install rear timing chain case. Refer to EM-89, "Exploded View". Install camshaft sprockets and timing chains. Refer to EM-50, "Exploded View". Install actuator bracket (rear) as follows: Apply a continuous bead of liquid gasket with tube presser (commercial service tool) to the actuator bracket (rear) as shown in the figure. A

: Bank 1

B

: Bank 2

c

: φ3.4 - 4.4 mm (0.134 - 0.173 in)

L

M

N

: Engine front

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-17, "Recommended Chemical Products and Sealants". CAUTION: Never apply gasket to the oil passage.


EM-99

O JPBIA1130ZZ

P

2009 G37 Coupe

CAMSHAFT < UNIT DISASSEMBLY AND ASSEMBLY > b. Tighten mounting bolts in the following steps, in numerical order as shown in the figure. A

: Bank 1

B


i.

Tighten bolts in numerical order as shown in the figure. : 1.96 N·m (0.20 kg-m, 1 ft-lb) JPBIA1131ZZ

ii.

Tighten bolts in numerical order as shown in the figure. : 5.88 N·m (0.60 kg-m, 4 ft-lb)

iii. Tighten bolts in numerical order as shown in the figure. : 31.4 N·m (3.2 kg-m, 23 ft-lb) 10. Install new VVEL actuator sub assembly as follows: CAUTION: Regarding replacement, because VVEL actuator sub assembly and VVEL control shaft position sensor are controlled on a one-on-one basis, replace them as a set. NOTE: • VVEL actuator arm (B) is factory-fixed at 5.5 degrees from the small lift with a holding jig (A). • The holding jig is supplied in the new VVEL actuator sub assembly.

JPBIA1137ZZ

CAUTION: • Never disassemble VVEL actuator sub assembly. [Never loosen actuator motor mounting bolts (A) shown in the figure] • Never shock VVEL actuator sub assembly.

JPBIA1120ZZ

a.

Move control shaft to the position of small lift stopper.


EM-100

2009 G37 Coupe

CAMSHAFT < UNIT DISASSEMBLY AND ASSEMBLY > • The position where a part of the stopper of control shaft contacts VVEL ladder bracket. 1

: VVEL ladder assembly (bank 2)

2

: VVEL ladder assembly (bank 1)

A

: Stopper of control shaft

A

EM

: Small lift side

C

CAUTION: Be careful not to damage the stopper surface.

D

E

F

G JPBIA1122ZZ

• If control shaft cannot be moved, set crankshaft in position referring to the information below. (To displace cam nose) Bank 1 Bank 2 b.

: Turn 120 degrees from No. 1 cylinder at TDC : No. 1 cylinder at TDC

I

Hold two flat areas of control shaft with a wrench, and rotate the control shaft (5.5 degrees from the stopper) to the large lift side. (This is for aligning the bolt hole of control shaft and the hole of VVEL actuator arm.) 1

: VVEL actuator sub assembly (bank 1)

A

: Control shaft

b

: 5.5 degrees

H

J

K

L

: Large lift side

M

N

O

P JPBIA1132ZZ


EM-101

2009 G37 Coupe

CAMSHAFT < UNIT DISASSEMBLY AND ASSEMBLY > c. Apply a continuous bead of liquid gasket with tube presser (commercial service tool) to the VVEL actuator sub assembly as shown in the figure. 1


2


a

: 4.0 - 5.6 mm (0.157 - 0.220 in)

b

: φ3.4 - 4.4 mm (0.134 - 0.173 in)

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-17, "Recommended Chemical Products and Sealants". CAUTION: Never apply gasket to the oil passage.

JPBIA1125ZZ

d.

e. f.

Install new VVEL actuator sub assembly. • Tighten mounting bolts in the following step, in numerical order as shown. A

: Bank 2

B

: Bank 1

CAUTION: • When installing, be careful with VVEL actuator sub assembly (bank 2) mounting bolt No. 1 because its length is different. • Be sure to check that the VVEL actuator sub assembly is JPBIA1114ZZ in contact with the cylinder head before tightening the mounting bolts. Remove holding jig. Check that VVEL actuator arm bolt hole is aligned with control shaft tapped hole. If it is not aligned, turn control shaft for alignment.


EM-102

2009 G37 Coupe

CAMSHAFT < UNIT DISASSEMBLY AND ASSEMBLY > g. Fix two flat areas (C) of control shaft with a wrench to install mounting bolts of control shaft. A

: Bank 1

B

: Bank 2

A

EM

: Engine front

CAUTION: • During the operation, never allow a wrench to interfere with other parts. • Fix control shaft to prevent the interference of the stopper surface.

C

D

E

F

G JPBIA1331ZZ

11. Install new VVEL control shaft position sensor as follows: CAUTION: Regarding replacement, because VVEL actuator sub assembly and VVEL control shaft position sensor are controlled on a one-on-one basis, replace them as a set. a. Apply engine oil to O-ring or contact surface of O-ring. b. Align matching marks (B) of VVEL control shaft position sensor and upper housing.

H

I

J C

: Bank 2

• Face connector toward matching mark (A). K

L

M

N

O

JPBIA1124ZZ

c. d.

e.

Temporarily tighten bolt. Adjust VVEL control shaft position sensor after setting the engine assembly in the vehicle. Refer to EC-21, "VVEL CONTROL SHAFT POSITION SENSOR ADJUSTMENT : Description". CAUTION: Be sure to adjust VVEL control shaft position sensor. After adjusting VVEL control shaft position sensor, tighten bolts to the specified torque.


EM-103

2009 G37 Coupe

P

CAMSHAFT < UNIT DISASSEMBLY AND ASSEMBLY > 12. Inspect the valve clearance. Refer to EM-18, "Inspection and Adjustment". 13. Install in the reverse order of removal after this step.

Inspection

INFOID:0000000004250517

INSPECTION AFTER REMOVAL (EXHAUST SIDE) Camshaft (EXH) Runout

1.

2. 3.

Put V-block on precise flat table, and support No. 2 and 4 journals of camshaft. CAUTION: Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other three locations. Set a dial indicator vertically to No. 3 journal. Turn camshaft (EXH) to one direction with hands, and measure the camshaft runout on a dial indicator. (Total indicator reading) PBIC0929E

Standard and limit : Refer to EM-149, "Camshaft". 4.

If it exceeds the limit, replace camshaft (EXH).

Camshaft (EXH) Cam Height • Measure the camshaft (EXH) cam height with a micrometer.

Standard


• If wear exceeds the limit, replace camshaft (EXH).

EMQ0072D

Camshaft (EXH) Journal Oil Clearance CAMSHAFT (EXH) JOURNAL DIAMETER

• Measure the outer diameter of camshaft (EXH) journal with a micrometer (A). Standard


JPBIA0122ZZ

VVEL LADDER ASSEMBLY (EXHAUST SIDE) INNER DIAMETER

• Tighten VVEL ladder assembly bolts to the specified torque. Refer to “INSTALLATION” for the tightening procedure.


EM-104

2009 G37 Coupe

CAMSHAFT < UNIT DISASSEMBLY AND ASSEMBLY > • Measure inner diameter (A) of VVEL ladder assembly (Exhaust side) with a bore gauge. Standard

A

: Refer to EM-149, "Camshaft". EM

C PBIC1645E

D CAMSHAFT (EXH) JOURNAL OIL CLEARANCE

• (Oil clearance) = [VVEL ladder assembly (Exhaust side) inner diameter] – [Camshaft (EXH) journal diameter]. Standard and limit

E


• If the calculated value exceeds the limit, replace either or both camshaft (EXH) and VVEL ladder assembly and cylinder head assembly. NOTE: VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinder head assembly. Camshaft (EXH) End Play • Install a dial indicator in thrust direction on front end of camshaft. Measure the end play of a dial indicator when camshaft (EXH) is moved forward/backward (in direction of axis).

Standard and limit

F

G

H

I


J

SEM864E

• Measure the following parts if out of the limit. - Dimension “A” for camshaft (EXH) No. 1 journal Standard

L

: 27.500 - 27.548 mm (1.0827 - 1.0846 in)

- Dimension “B” for cylinder head No. 1 journal bearing Standard

K

M

: 27.360 - 27.385 mm (1.0772 - 1.0781 in)

• Refer to the standards above, and then replace camshaft (EXH) and/or VVEL ladder assembly and cylinder head assembly. NOTE: Cylinder head assembly cannot be replaced as a single part, because it is machined together with VVEL ladder assembly.

N KBIA2404J

O

Camshaft Sprocket (EXH) Runout

1.

Put V-block on precise flat table, and support No. 2 and 4 journals of camshaft (EXH). CAUTION: Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other three locations.


EM-105

2009 G37 Coupe

P

CAMSHAFT < UNIT DISASSEMBLY AND ASSEMBLY > 2. Measure the camshaft sprocket (EXH) runout with a dial indicator. (Total indicator reading) Limit 3.


If it exceeds the limit, replace camshaft sprocket (EXH).

PBIC0930E

Valve Lifter (EXH) • Check if surface of valve lifter has any wear or crack. • If wear or crack is found, replace valve lifter (EXH). Refer to EM149, "Camshaft".

KBIA0182E

Valve Lifter Clearance (EXH) VALVE LIFTER OUTER DIAMETER

• Measure the outer diameter at 1/2 height of valve lifter with a micrometer (A) since valve lifter is in barrel shape. Standard


JPBIA0125ZZ

VALVE LIFTER HOLE DIAMETER

• Measure the inner diameter of valve lifter hole of cylinder head with an inside micrometer. Standard


SEM867E

VALVE LIFTER CLEARANCE

• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter) Standard


• If the calculated value is out of the standard, referring to each standard of valve lifter outer diameter and valve lifter hole diameter, replace either or both valve lifter and VVEL ladder assembly and cylinder head assembly. Revision: 2009 October

EM-106

2009 G37 Coupe

CAMSHAFT < UNIT DISASSEMBLY AND ASSEMBLY > NOTE: Cylinder head assembly cannot be replaced as a single part, because it is machined together with VVEL ladder assembly.

A

INSPECTION AFTER REMOVAL (INTAKE SIDE) EM

Drive Shaft End Play • Install a dial indicator in thrust direction on front end of drive shaft. Measure the end play of a dial indicator when drive shaft is moved forward/backward (in direction of axis).

Standard and limit

C

: Refer to EM-149, "Camshaft". D

E JPBIA1337ZZ

F

• Measure the following parts if out of the limit. - Dimension “A” for drive shaft No. 1 journal Standard

G

: 27.500 - 27.548 mm (1.0827 - 1.0846 in)

- Dimension “B” for cylinder head No. 1 journal bearing Standard

H

: 27.360 - 27.385 mm (1.0772 - 1.0781 in)

• If it exceeds the limit, replace VVEL ladder assembly and cylinder head assembly. NOTE: Cylinder head assembly cannot be replaced as a single part, because it is machined together with VVEL ladder assembly.

I KBIA2404J

J

Camshaft Sprocket (INT) Runout

1.

2.

Put V-block on precise flat table, and support No. 2 and 4 journals of drive shaft. CAUTION: Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other three locations. Measure the camshaft sprocket (INT) runout with a dial indicator. (Total indicator reading) Limit

3.

K

L


If it exceeds the limit, replace camshaft sprocket (INT).

M

Valve Lifter (INT) • Check if surface of valve lifter has any wear or crack. • If wear or crack is found, replace VVEL ladder assembly and cylinder head assembly. Refer to EM-149, "Camshaft". NOTE: Since the valve lifter (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head assembly replacement are required.

N

O

P KBIA0182E

Valve Lifter Clearance (INT) VALVE LIFTER OUTER DIAMETER


EM-107

2009 G37 Coupe

CAMSHAFT < UNIT DISASSEMBLY AND ASSEMBLY > • Measure the outer diameter at 1/2 height of valve lifter (INT) with a micrometer (A) since valve lifter is in barrel shape. Standard


JPBIA0125ZZ

VALVE LIFTER HOLE DIAMETER

• Measure the inner diameter of valve lifter hole of cylinder head with an inside micrometer. Standard


SEM867E

VALVE LIFTER CLEARANCE

• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter) Standard


• If the calculated value is out of the standard, replace VVEL ladder assembly and cylinder head assembly. NOTE: Since the valve lifter (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head assembly replacement are required. VVEL Ladder Assembly DRIVE SHAFT OPERATIONAL CHECK

• Hold the both ends of the drive shaft (A) and rotate it to check that it rotates smoothly. CAUTION: Turn VVEL ladder assembly upside down to prevent the drive shaft from dropping off.

JPBIA1327ZZ

CONTROL SHAFT OPERATIONAL CHECK


EM-108

2009 G37 Coupe

CAMSHAFT < UNIT DISASSEMBLY AND ASSEMBLY > • Move control shaft (A) to the small stopper and large stopper to check that the control shaft functions smoothly. CAUTION: Turn VVEL ladder assembly upside down to prevent the drive shaft from dropping off.

A

EM

C JPBIA1328ZZ

D RINK CHECK FOR BACK-LASH (BONDING)

• Check that the link and the shaft of drive shaft and control shaft are not fixed. • Check this by moving drive shaft and control shaft in the axial and rotation directions.

E

F

G JPBIA1509ZZ

H

• If there is an unusualness related to the above three, replace VVEL ladder assembly and cylinder head assembly. NOTE: VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinder head assembly.

I

INSPECTION AFTER INSTALLATION

J

Inspection of Camshaft Sprocket (INT) Oil Groove CAUTION: • Perform this inspection only when DTC P0011, P0012 is detected in self-diagnostic results of CONSULT-III and it is directed according to inspection procedure of EC section. Refer to EC-112, "Diagnosis Description". • Check when engine is cold to prevent burns from the splashing engine oil. 1. Check engine oil level. Refer to LU-6, "Inspection". 2. Perform the following procedure to prevent the engine from being unintentionally started while checking. a. Release the fuel pressure. Refer to EC-614, "Inspection". b. Disconnect ignition coil and injector harness connectors. Refer to EM-47, "Exploded View". 3. Remove intake valve timing control solenoid valve. Refer to EM-50, "Exploded View". 4. Crank engine, and then check that engine oil comes out from intake valve timing control solenoid valve hole (A). End crank after checking.

K

L

M

N

O 1

: Intake valve timing control cover (bank 1) : Engine front

WARNING: Be careful not to touch rotating parts (drive belt, idler pulley, and crankshaft pulley, etc.). CAUTION: • Prevent splashing by using a shop cloth to prevent the worker from injury from engine oil and to prevent engine oil contamination.


EM-109

P

JPBIA0410ZZ

2009 G37 Coupe

CAMSHAFT < UNIT DISASSEMBLY AND ASSEMBLY > • Prevent splashing by using a shop cloth to prevent engine oil from being splashed to engine and vehicle. Especially, be careful no to apply engine oil to rubber parts of drive belt, engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed. 5. Perform the following inspection if engine oil does not come out from intake valve timing control solenoid valve oil hole of the cylinder head. • Remove oil filter, and then clean it. Refer to EM-50, "Exploded View". • Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-2, "Engine Lubrication System". 6. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT), and then check each oil groove for clogging. • Clean oil groove if necessary. Refer to LU-2, "Engine Lubrication System". 7. After inspection, install removed parts in the reverse order. Inspection for Leakage The following are procedures for checking fluid leakage, lubricant leakage.

• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the required quantity, fill them to the specified level. Refer to MA-10, "Fluids and Lubricants". • Follow the procedure below to check for fuel leakage. - Turn ignition switch to the “ON” position (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. - Start engine. With engine speed increased, check again for fuel leakage at connection points. • Run engine to check for unusual noise and vibration. NOTE: If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a pounding noise during and just after the engine start. However, this does not indicate a malfunction. The noise will stop after hydraulic pressure rises. • Warm up engine thoroughly to check that there is no leakage of fuel, or any oil/fluids including engine oil and engine coolant. • Bleed air from lines and hoses of applicable lines, such as in cooling system. • After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to the specified level, if necessary. Summary of the inspection items:


Engine running


Engine coolant

Items

Level

Leakage

Level

Engine oil

Level

Leakage

Level


Level

Leakage

Level

Leakage

Leakage

Leakage

Fuel



EM-110

2009 G37 Coupe

CYLINDER HEAD < UNIT DISASSEMBLY AND ASSEMBLY >

CYLINDER HEAD

A

Exploded View

INFOID:0000000004250518

EM

C

D

E

F

G

H

I

J

K

L JPBIA1126GB

1.

Valve lifter (EXH)

2.

Valve collet (EXH)

3.

Valve spring retainer (EXH)

4.

Valve oil seal (EXH)

5.

Valve spring (EXH)

6.

Valve spring seat (EXH)

7.

Valve guide (EXH)

8.

Spark plug

9.

Valve lifter (INT)

10. Valve collet (INT)

11. Valve spring retainer (INT)

12. Valve oil seal (INT)

13. Valve spring (INT)

14. Valve spring seat (INT)

15. Cylinder head bolt

N


17. Valve seat (EXH)

18. Valve (EXH)

19. Cylinder head gasket (bank 1)

20. Valve (INT)

21. Cylinder head gasket (bank 2)


23. Engine rear lower slinger

A.

M

O

Refer to EM-112


P

CAUTION: As for replacement of parts on the intake side as shown in the exploded view, replace VVEL ladder assembly and cylinder head assembly. (Only valve oil seals are replaceable as a single part.) NOTE: VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinder head assembly. Revision: 2009 October

EM-111

2009 G37 Coupe

CYLINDER HEAD < UNIT DISASSEMBLY AND ASSEMBLY >


INFOID:0000000004250519

DISASSEMBLY 1.

2.

Remove the following parts: • Intake manifold collector: Refer to EM-29, "Exploded View". • Rocker cover: Refer to EM-47, "Exploded View". • Fuel tube and fuel injector assembly: Refer to EM-37, "Exploded View". • Intake manifold: Refer to EM-32, "Exploded View". • Exhaust manifold: Refer to EM-34, "Exploded View". • Water inlet and thermostat assembly: Refer to CO-21, "Exploded View". • Water outlet, water pipe and heater pipe: Refer to CO-23, "Exploded View". • Timing chain: Refer to EM-50, "Exploded View". • Rear timing chain case: Refer to EM-89, "Exploded View". • Camshaft (EXH) and VVEL ladder assembly: Refer to EM-94, "Exploded View". Remove cylinder head. • Loosen mounting bolts in reverse order as shown in the figure. A

: Bank 1

B


• Use the cylinder head bolt wrench [commercial service tool: — (J-24239-01)] and power tool.

JPBIA0172ZZ

3. 4. 5. 6.

Remove cylinder head gaskets. Remove spark plug with spark plug wrench (commercial service tool). Remove valve lifter. • Identify installation positions, and store them without mixing them up. Remove valve collet. • Compress valve spring with the valve spring compressor [SST: KV10116200 (J-26336-A)] (A), the attachment [SST: KV10115900 (J-26336-20)] (C) and the adapter [SST: KV10109220 ( — )] (B). Remove valve collet with a magnet hand. CAUTION: When working, take care not to damage valve lifter holes.

JPBIA1365ZZ

7. 8.

Remove valve spring retainer, valve spring and valve spring seat. Push valve stem to combustion chamber side, and remove valve. • Identify installation positions, and store them without mixing them up.


EM-112

2009 G37 Coupe

CYLINDER HEAD < UNIT DISASSEMBLY AND ASSEMBLY > 9. Remove valve oil seal using the valve oil seal puller [SST: KV10107902 (J-38959)] (A).

A

EM

C JPBIA1366ZZ

D

10. Remove valve seat (EXH), if valve seat (EXH) must be replaced. • Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess in cylinder head. Set the machine depth stop to ensure this. Refer to EM-151, "Cylinder Head". CAUTION: Prevent to scratch cylinder head by excessive boring. 11. Remove valve guide (EXH), if valve guide (EXH) must be replaced. a. To remove valve guide (EXH), heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil (A).

E

F

G

H

I JPBIA0184ZZ

b.

Drive out valve guide (EXH) with a press [under a 20 kN (2 ton, 2.2 US ton, 2.0 lmp ton) pressure] or a hammer and the valve guide drift (commercial service tool). WARNING: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.

J

K

L

SEM931C

M

ASSEMBLY 1. a.

If valve guide (EXH) is removed in step 11 (DISASSEMBLY), install it. Replace with oversized [0.2 mm (0.008 in)] valve guide (EXH). Using the valve guide reamer (commercial service tool) (A), ream cylinder head valve guide (EXH) hole.

N

O

Oversize (service) [0.2 mm (0.008 in)]: : Refer to EM-151, "Cylinder Head".

P

JPBIA0185ZZ


EM-113

2009 G37 Coupe

CYLINDER HEAD < UNIT DISASSEMBLY AND ASSEMBLY > b. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil (A).

JPBIA0184ZZ

c.

Using the valve guide drift (commercial service tool), press valve guide (EXH) from camshaft side to the dimensions as shown in the figure. Projection (A) : Refer to EM-151, "Cylinder Head". WARNING: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned. JPBIA0186ZZ

d.

Using the valve guide reamer (commercial service tool) (A), apply reamer finish to valve guide (EXH). Standard

: Refer to EM-151, "Cylinder Head".

JPBIA0185ZZ

2. a.

If valve seat (EXH) is removed in step 10 (DISASSEMBLY), install it. Replace with oversize [0.5 mm (0.020 in)] valve seat (EXH). Ream cylinder head recess diameter (a) for service valve seat (EXH). Oversize (service) [0.5 mm (0.020 in)]: : Refer to EM-151, "Cylinder Head". • Be sure to ream in circles concentric to valve guide center. This will enable valve to fit correctly.

JPBIA0188ZZ


EM-114

2009 G37 Coupe

CYLINDER HEAD < UNIT DISASSEMBLY AND ASSEMBLY > b. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil (A).

A

EM

C JPBIA0184ZZ

D

c.

d.

Provide valve seats (EXH) cooled well with dry ice. Force fit valve seat (EXH) into cylinder head. WARNING: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned. CAUTION: Avoid directly touching cold valve seats. Using the valve seat cutter set (commercial service tool) or valve seat grinder, finish seat to the specified dimensions. Refer to EM-151, "Cylinder Head". CAUTION: When using the valve seat cutter, firmly grip cutter handle with both hands. Then, press on the contacting surface all around the circumference to cut in a single drive. Improper pressure on cutter or cutting many different times may result in staged valve seat. SEM934C

e. f. 3. a. b.

Using compound, grind to adjust valve fitting. Check again for normal contact. Refer to "VALVE SEAT CONTACT". Install new valve oil seals as follows. Apply new engine oil on new valve oil seal joint and seal lip. Using the valve oil seal drift [SST: KV10115600 (J-38958)] (A), press fit valve seal to height (b) shown in figure. NOTE: Dimension: Height measured before valve spring seat installation Height (b)

E

F

G

H

I

J

K

L

: 14.3 - 14.9 mm (0.563 - 0.587 in) M

JPBIA1367ZZ

4. 5.

6.

Install valve spring seat. Install valve. NOTE: Larger diameter valves are for intake side. Install new cylinder head gaskets.

N

O

P


EM-115

2009 G37 Coupe

CYLINDER HEAD < UNIT DISASSEMBLY AND ASSEMBLY > 7. Turn crankshaft until No. 1 piston is set at TDC. 1

: Crankshaft key : Bank 1 side

• Crankshaft key should line up with the cylinder center line (bank 1) as shown in the figure.

JPBIA0174ZZ

8.

Install cylinder head, and tighten cylinder head bolts in numerical order as shown in figure as follows: A

: Bank 1

B


a. b.

• Use the cylinder head bolt wrench [commercial service tool: — (J-24239-01)] and power tool. CAUTION: • If cylinder head bolts are re-used, check their outer diameters before installation. Refer to EM-117, "Inspection". • Before installing cylinder head, inspect cylinder head distortion. Refer to EM-117, "Inspection". Apply new engine oil to threads and seat surfaces of cylinder head bolts. Tighten all cylinder head bolts. : 105 N·m (11 kg-m, 77 ft-lb)

c.

Completely loosen all cylinder head bolts. JPBIA0172ZZ

: 0 N·m (0 kg-m, 0 ft-lb)

d.

CAUTION: In step “c”, loosen bolts in the reverse order of that indicated in the figure. Tighten all cylinder head bolts. : 40.0 N·m (4.1 kg-m, 30 ft-lb)

e.

f.

Turn all cylinder head bolts 95 degrees clockwise (angle tightening). CAUTION: Check the tightening angle using the angle wrench [SST: KV10112100 (BT8653-A)] (A). Never make judgment by visual inspection. • Check tightening angle indicated on the angle wrench indicator plate. Turn all cylinder head bolts 95 degrees clockwise again (angle tightening).

JPBIA0175ZZ


EM-116

2009 G37 Coupe

CYLINDER HEAD < UNIT DISASSEMBLY AND ASSEMBLY > 9. After installing cylinder head, measure distance between front end faces of cylinder block and cylinder head (bank 1 and bank 2). Standard

A

: 14.1 - 14.9 mm (0.555 - 0.587 in)

EM

• If measured value is out of the standard, re-install cylinder head. C EMQ0662D

D

10. Install valve spring (uneven pitch type). • Install narrow pitch (B) end [paint mark (C)] to cylinder head side (valve spring seat side). A

E

: Wide pitch : Cylinder head side

F

Paint mark color Intake : Purple Exhaust : Yellowish green

G JPBIA0179ZZ

H

11. Install valve spring retainer. 12. Install valve collet. • Compress valve spring with the valve spring compressor [SST: KV10116200 (J-26336-A)] (A), the attachment [SST: KV10115900 (J-26336-20)] (C) and the adapter [SST: KV10109220 ( — )] (B). Install valve collet with a magnet hand. CAUTION: When working, take care not to damage valve lifter holes. • Tap valve stem edge lightly with plastic hammer after installation to check its installed condition.

I

J

K JPBIA1365ZZ

L

13. Install valve lifter. • Install it in the original position. 14. Install spark plug with spark plug wrench (commercial service tool). 15. Install in the reverse order of removal after this step.

Inspection

M

INFOID:0000000004250520

N

INSPECTION AFTER DISASSEMBLY Cylinder Head Bolts Outer Diameter

O

P


EM-117

2009 G37 Coupe

CYLINDER HEAD < UNIT DISASSEMBLY AND ASSEMBLY > • Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between (B) and (A) exceeds the limit, replace them with new one. c

: 48 mm (1.89 in)

d

: 11 mm (0.43 in)

Limit [(B) - (A)]

: 0.18 mm (0.0071 in)

• If reduction of outer diameter appears in a position other than (A), use it as (A) point.

JPBIA1134ZZ

Cylinder Head Distortion NOTE: When performing this inspection, cylinder block distortion should be also checked. Refer to EM-131, "Inspection". 1. Using a scraper, wipe off oil, scale, gasket, sealant and carbon deposits from surface of cylinder head. CAUTION: Never allow gasket fragments to enter engine oil or engine coolant passages. 2. At each of several locations on bottom surface of cylinder head, measure the distortion in six directions (A), (B), (C), (D), (E), and (F).

Limit


• If it exceeds the limit, replace VVEL ladder assembly and cylinder head assembly. NOTE: Cylinder head assembly cannot be replaced as a single part, because it is machined together with VVEL ladder assembly. JPBIA0176ZZ

Valve Dimensions • Check the dimensions of each valve. For the dimensions, refer to EM-151, "Cylinder Head". • If dimensions are out of the standard. - Replace valve (EXH) and check valve seat contact. Refer to "VALVE SEAT CONTACT". (Exhaust side) - Replace VVEL ladder assembly and cylinder head assembly. Refer to EM-94, "Exploded View". (Intake side) NOTE: Since the valve (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head assembly replacement are required. Valve Guide Clearance Valve Stem Diameter

• Measure the diameter of valve stem with micrometer (A). Standard


Valve Guide Inner Diameter

• Measure the inner diameter of valve guide with bore gauge. Standard


Valve Guide Clearance

• (Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter) Standard

JPBIA0183ZZ


• If the calculated value exceeds the limit. - Replace valve (EXH) and/or valve guide (EXH). Refer to EM-111, "Exploded View". (Exhaust side) - Replace VVEL ladder assembly and cylinder head assembly. Refer to EM-94, "Exploded View". (Intake side) NOTE: Revision: 2009 October

EM-118

2009 G37 Coupe

CYLINDER HEAD < UNIT DISASSEMBLY AND ASSEMBLY > Since the valve (INT) and valve guide (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head assembly replacement are required.

A

Valve Seat Contact • After confirming that the dimensions of valve guides and valves are within the specifications, perform this EM procedure. • Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve contact on the surface. • Check if the contact area band is continuous all around the circumC ference. A

: OK

B

: NG

D

- If not, grind to adjust valve fitting and check again. If the contacting surface still has “NG” conditions even after the recheck, replace valve seat (EXH). Refer to EM-111, "Exploded View". (Exhaust side) - If not, replace VVEL ladder assembly and cylinder head assembly. JPBIA0187ZZ Refer to EM-94, "Exploded View". (Intake side) NOTE: Since the valve seat (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head assembly replacement are required. Valve Spring Squareness • Set a try square (A) along the side of valve spring and rotate spring. Measure the maximum clearance between the top of spring and try square. B

E

F

G

H

: Contact

I

Limit


• If it exceeds the limit. - Replace valve spring (EXH). Refer to EM-111, "Exploded View". (Exhaust side) JPBIA0189ZZ - Replace VVEL ladder assembly and cylinder head assembly. Refer to EM-94, "Exploded View". (Intake side) NOTE: Since the valve spring (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head assembly replacement are required.

J

K

L

Valve Spring Dimensions and Valve Spring Pressure Load • Check the valve spring pressure at specified spring height. M

Standard : Refer to EM-151, "Cylinder Head". • If the installation load or load with valve open is out of the standard. - Replace valve spring (EXH). Refer to EM-111, "Exploded View". (Exhaust side) - Replace VVEL ladder assembly and cylinder head assembly. Refer to EM-94, "Exploded View". (Intake side) SEM113 NOTE: Since the valve spring (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head assembly replacement are required.

INSPECTION AFTER INSTALLATION Inspection for Leakage The following are procedures for checking fluid leakage, lubricant leakage.


EM-119

2009 G37 Coupe

N

O

P

CYLINDER HEAD < UNIT DISASSEMBLY AND ASSEMBLY > • Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the required quantity, fill them to the specified level. Refer to MA-10, "Fluids and Lubricants". • Follow the procedure below to check for fuel leakage. - Turn ignition switch to the “ON” position (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. - Start engine. With engine speed increased, check again for fuel leakage at connection points. • Run engine to check for unusual noise and vibration. NOTE: If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a pounding noise during and just after the engine start. However, this does not indicate a malfunction. The noise will stop after hydraulic pressure rises. • Warm up engine thoroughly to check that there is no leakage of fuel, or any oil/fluids including engine oil and engine coolant. • Bleed air from lines and hoses of applicable lines, such as in cooling system. • After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to the specified level, if necessary. Summary of the inspection items:


Engine running


Engine coolant

Items

Level

Leakage

Level

Engine oil

Level

Leakage

Level


Level

Leakage

Level

Leakage

Leakage

Leakage

Fuel



EM-120

2009 G37 Coupe

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY >

CYLINDER BLOCK

A

Exploded View

INFOID:0000000004250521

EM

C

D

E

F

G

H

I

J

K

L

M JPBIA1771GB

N 1.

Sub harness

2.

Knock sensor

3.

Crankshaft position sensor

4.

Cylinder block heater (for Canada)

5.

Cylinder block

6.

Thrust bearing

7.

Main bearing (upper)

8.

Crankshaft

9.

Crankshaft key

10. Main bearing (lower)

11. O-ring

O

12. Lower cylinder block bolt

13. Baffle plate

14. Lower cylinder block

15. Pilot bush (M/T models)

16. Pilot converter (A/T models)

17. Reinforcement plate (A/T models)

18. Drive plate (A/T models)

19. Rear oil seal

20. Flywheel (M/T models)

21. Oil jet

22. Top ring

23. Second ring

24. Oil ring

25. Piston

26. Piston pin

27. Snap ring

28. Connecting rod

29. Connecting rod bearing

30. Connecting rod bearing cap

31. Connecting rod bolt


EM-121

2009 G37 Coupe

P

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > A.

Refer to EM-122

B.

Chamfered

C.

Front mark

: Crankshaft side


INFOID:0000000004250522

DISASSEMBLY 1.

2.

3. 4.

a. b. c.

Remove the following parts: • Oil pans (upper and lower): Refer to EM-43, "Exploded View (2WD)" and EM-82, "2WD : Exploded View" (2WD models) or EM-44, "Exploded View (AWD)" or EM-85, "AWD : Exploded View" (AWD models). • Front and rear timing chain case: Refer to EM-50, "Exploded View" and EM-89, "Exploded View". • Cylinder head: Refer to EM-111, "Exploded View". Remove knock sensor. CAUTION: Carefully handle sensor avoiding shocks. Remove baffle plate from lower cylinder block. Remove piston and connecting rod assembly with the following procedure: • Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to EM-131, "Inspection". CAUTION: Be careful not to drop connecting rod bearing, and to scratch the surface. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center. Remove connecting rod bearing cap. Using a hammer handle or similar tool, push piston and connecting rod assembly out to the cylinder head side. CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.

PBIC2940E

5.

6.

Remove connecting rod bearings from connecting rod and connecting rod bearing cap. CAUTION: • Be careful not to drop connecting rod bearing, and to scratch the surface. • Identify installation positions, and store them without mixing them up. Remove piston rings from piston. • Before removing piston rings, check the piston ring side clearance. Refer to EM-131, "Inspection". • Use a piston ring expander (commercial service tool) (A). CAUTION: • When removing piston rings, be careful not to damage piston. • Be careful not to damage piston rings by expanding them excessively.

JPBIA0194ZZ

7.

Remove piston from connecting rod as follows:


EM-122

2009 G37 Coupe

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > a. Using snap ring pliers (A), remove snap rings. A

EM

C JPBIA0195ZZ

D

b.

Heat piston to 60 to 70°C (140 to 158°F) with an industrial use dryer (A) or equivalent. E

F

G JPBIA0196ZZ

c.

Push out piston pin using a stick than has an outer diameter of approximately 20 mm (0.79 in).

H

I

J

PBIC0262E

8.

Remove lower cylinder block bolts. • Before loosening lower cylinder block bolts, measure the crankshaft end play. Refer to EM-131, "Inspection". • Loosen lower cylinder block bolts in the reverse order shown in the figure in several different steps.

K

L

M

: Engine front

N

O JPBIA0197ZZ

9.

Remove lower cylinder block as follows:


P

EM-123

2009 G37 Coupe

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > Screw M8 bolt [pitch: 1.25 mm (0.049 in) length: approximately 50 mm (1.97 in)] into bolt holes (A). Then equally tighten each bolt, and remove lower cylinder block. : Engine front

10. 11. 12.

13.

CAUTION: • Be careful not to damage the mounting surfaces. • Never tighten bolts excessively. • Never insert screwdriver, this will damage the mating surface. Remove crankshaft. Pull rear oil seal out from rear end of crankshaft. Remove main bearings and thrust bearings from cylinder block and lower cylinder block. CAUTION: • Be careful not to drop main bearing, and to scratch the surface. • Identify installation positions, and store them without mixing them up. Remove oil jet.

JPBIA0414ZZ

ASSEMBLY 1.

2.

Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to remove any foreign material. CAUTION: Use goggles to protect your eyes. Install each plug to cylinder block as shown in the figure. 3

: Plug : Engine front

• Apply sealant to the thread of water drain plug (1). Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-17, "Recommended Chemical Products and Sealants". • Apply sealant to the thread of plug (4). Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to GI-17, "Recommended Chemical Products and Sealants". • Replace washers (2) with new ones.

JPBIA0191ZZ

• Tighten each plug as specified below. Unit: N·m (kg-m, ft-lb)

3.

Part

Washer

Tightening torque

1

No

19.6 (2.0, 14)

3

Yes

78.0 (8.0, 58)

4

Yes

12.3 (1.3, 9)

Install oil jet.


EM-124

2009 G37 Coupe

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > • Insert oil jet dowel pin (A) into cylinder block dowel pin hole, and tighten mounting bolts.

A

: Engine front

EM

C JPBIA0198ZZ

4.

a. b.

Install main bearings and thrust bearings as follows: CAUTION: Be careful not to drop main bearing, and to scratch the surface. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and lower cylinder block. Install thrust bearings (1) to both sides of the No. 3 journal housing on cylinder block. A

: No. 1

B

: No. 2

C

: No. 3

D

: No. 4

F

: Thrust bearing installation position

E

F

G

H

: Engine front

• Install thrust bearings with the oil groove (E) facing crankshaft arm (outside). c.

D

JPBIA0199ZZ

I

Install main bearings paying attention to the direction. A

: Cylinder block side

D

: Lower cylinder block side

J

: Engine front

• Main bearing with oil hole (B) and groove (C) goes on cylinder block. The one without them goes on lower cylinder block. • Before installing main bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it. • When installing, align main bearing stopper protrusion to cutout of cylinder block and lower cylinder block. • Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned. 5. 6.

K

L JPBIA0200ZZ

Install crankshaft to cylinder block. • While turning crankshaft by hand, check that it turns smoothly. Install lower cylinder block. NOTE: Lower cylinder block cannot be replaced as a single part, because it is machined together with cylinder block.

M

N

O

P


EM-125

2009 G37 Coupe

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > • Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to lower cylinder block as shown in the figure. B

: Apply to end

a

: φ4.0 - 5.0 mm (0.157 - 0.197 in)


JPBIA1354ZZ

7. 8. a. b.

Inspect the outer diameter of lower cylinder block bolt. Refer to EM-131, "Inspection". Install lower cylinder block bolts in numerical order as shown in the figure as follows: Apply new engine oil to threads and seat surfaces of lower cylinder block bolts. Tighten bolts (No. 17 to 26) in numerical order as shown in the figure. : Engine front

: 25.0 N·m (2.6 kg-m, 18 ft-lb) c.

Repeat step b.

JPBIA0197ZZ

d.

Tighten bolts (No. 1 to 16) in numerical order as shown in the figure. : Engine front

NOTE: Use TORX socket for bolts No.1 to 16. : 35.3 N·m (3.6 kg-m, 26 ft-lb) JPBIA0197ZZ

e.

Turn bolts (No. 1 to 16) 90 degrees clockwise (angle tightening). CAUTION: Use the angle wrench [SST: KV10112100 (BT8653-A)] (A) to check tightening angle. Never make judgment by visual inspection.

JPBIA0202ZZ

9. a.

• After installing lower cylinder block bolts, check that crankshaft can be rotated smoothly by hand. • Check the crankshaft end play. Refer to EM-131, "Inspection". Install piston to connecting rod as follows: Using snap ring pliers, install new snap ring to the groove of piston rear side. • Insert it fully into groove to install.


EM-126

2009 G37 Coupe

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > b. Install piston to connecting rod. • Using an industrial use dryer or similar tool, heat piston until piston pin can be pushed in by hand without A excess force [approximately 60 to 70°C (140 to 158°F)]. From the front to the rear, insert piston pin into piston and connecting rod. • Assemble so that the front mark on the piston head and the EM cylinder number on connecting rod are positioned as shown in the figure. A

: Example RH

B

: Piston grade number

C

: Front mark

D

: Pin grade number

E

: Cylinder number

F

: Front mark

C

D

JPBIA1213ZZ

: Engine front

c.

Install new snap ring to the groove of the piston front side. • Insert it fully into groove to install. • After installing, check that connecting rod moves smoothly.

E

F

10. Using a piston ring expander (commercial service tool) (A), install piston rings. CAUTION: • When installing piston rings, be careful not to damage piston. • Be careful not to damage piston rings by expending them excessively.

G

H

I

JPBIA0194ZZ

J

• If there is stamped mark on ring, mount it with marked side up. K

Stamped mark: Top ring (A) : 1 N Second ring (B) : 2 N

L

M JPBIA1720ZZ

N

• Position each ring with the gap as shown in the figure referring to the piston front mark (D).

O

C

: Top ring gap

E

: Oil ring upper or lower rail gap (either of them)

F

: Second ring and oil ring spacer gap

a

: 90 degrees

b

: 45 degrees

P

JPBIA0205ZZ

• Check the piston ring side clearance. Refer to EM-131, "Inspection". 11. Install connecting rod bearings to connecting rod and connecting rod bearing cap. Revision: 2009 October

EM-127

2009 G37 Coupe

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > CAUTION: Be careful not to drop connecting rod bearing, and to scratch the surface. • Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it. • When installing, align connecting rod bearing stopper protrusion (B) with cutout (C) of connecting rods and connecting rod bearing caps to install. • Ensure the oil hole (A) on connecting rod and that on the corresponding bearing are aligned.

JPBIA0206ZZ

12. Install piston and connecting rod assembly to crankshaft. • Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center. • Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal. • Match the cylinder position with the cylinder number on connecting rod to install. • Be sure that front mark on piston crown is facing the front of the engine. • Using a piston ring compressor [SST: EM03470000 (J-8037)] (A) or suitable tool, install piston with the front mark on the piston crown facing the front of the engine. CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.

JPBIA0207ZZ

13. Install connecting rod bearing cap. • Match the stamped cylinder number marks on connecting rod with those on connecting rod bearing cap to install.

14. a. b. c.

A

: Sample codes

B

: Bearing stopper groove

C

: Small-end diameter grade

D

: Big-end diameter grade

E

: Weight grade

F

: Cylinder No.

G

: Management code

I

: Management code

JPBIA0208ZZ

• Be sure that front mark (H) on connecting rod bearing cap is facing the front of the engine. Tighten connecting rod bolt as follows: Inspect the outer diameter of connecting rod bolt. Refer to EM-131, "Inspection". Apply engine oil to the threads and seats of connecting rod bolts. Tighten connecting rod bolts. : 28.4 N·m (2.9 kg-m, 21 ft-lb)

d.

Completely loosen connecting rod bolts. : 0 N·m (0 kg-m, 0 ft-lb)

e.

Tighten connecting rod bolts.


EM-128

2009 G37 Coupe

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > A

: 24.5 N·m (2.5 kg-m, 18 ft-lb) f.

Then turn connecting rod bolts 90 degrees clockwise (angle tightening). CAUTION: Always use the angle wrench [SST: KV10112100 (BT8653A)] (A). Never make judgment by visual inspection. • After tightening connecting rod bolts, check that crankshaft rotates smoothly. • Check the connecting rod side clearance. Refer to EM-131, "Inspection".

EM

C

D

E JPBIA0209ZZ

15. Install baffle plate. 16. Install new rear oil seal. Refer to EM-67, "REAR OIL SEAL : Removal and Installation". • Apply new engine oil to both oil seal lip and dust seal lip.

F

17. Install pilot converter (A/T models) or pilot bushing (M/T models). • With a drift of the following outer diameter, press-fit as far as it will go. Pilot bushing Pilot converter

G

H

: Approx. 17 mm (0.67 in) : Approx. 33 mm (1.30 in)

I

PBIC2947E

• Press-fit pilot converter with its chamfer facing crankshaft as shown in the figure. (A/T models)

J

K

: Crankshaft side

L

M JPBIA0210ZZ

N

• Press-fit pilot bushing (1) as the dimension shown in the figure. (M/T models)

O

A : Crankshaft (rear end surface) : 10.20 – 10.85 mm (0.402 – 0.427 in) b [Target: 10.20 mm (0.402 in)]

P

JPBIA0415ZZ


EM-129

2009 G37 Coupe

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > 18. Install knock sensors. A

: Bank 1

B


• Install knock sensor so that connector faces the rear of the engine. • After installing knock sensor, connect harness connector, and lay it out to rear of the engine. CAUTION: • Never tighten mounting bolts while holding connector. • If any impact by dropping is applied to knock sensor, replace it with new one. NOTE: • Check that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor. • Check that knock sensor does not interfere with other parts.

JPBIA0211ZZ

19. Note the following, assemble in the reverse order of disassembly after this step. Flywheel (M/T models)

• Ensure the dowel pin (1) is installed in the crankshaft. 4

: Rear oil seal

• When installing flywheel (3) to crankshaft (2), be sure to correctly align crankshaft side dowel pin and flywheel side dowel pin hole (A).

JPBIA0322ZZ

• There is a matching mark (B) on the clutch cover side of flywheel (4). Refer it during installation. 1

: Dowel pin

2

: Rear oil seal

3

: Crankshaft

A

: Hole

JPBIA0323ZZ

Drive plate (A/T models)

• When installing drive plate to crankshaft, be sure to correctly align crankshaft side dowel pin and drive plate side dowel pin hole. CAUTION: If these are not aligned correctly, engine runs roughly and “MIL” illuminates.


EM-130

2009 G37 Coupe

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > • Install drive plate (2) and reinforcement plate (3) as shown in the figure. 1

: Ring gear

4

: Pilot converter

5

: Crankshaft

A

: Rounded

A

EM

: Engine front

C

• Holding ring gear with the ring gear stopper [SST: KV10118600 (J-48641)]. • Tighten the mounting bolts crosswise over several times.

Inspection

JPBIA0212ZZ

D INFOID:0000000004250523

E

CRANKSHAFT END PLAY • Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with a dial indicator. Standard and limit

F

: Refer to EM-153, "Cylinder Block".

G

• If the measured value exceeds the limit, replace thrust bearings, and measure again. If it still exceeds the limit, replace crankshaft also.

H

PBIC2953E

I

CONNECTING ROD SIDE CLEARANCE • Measure the side clearance between connecting rod and crankshaft arm with a feeler gauge. Standard and limit

J


• If the measured value exceeds the limit, replace connecting rod, and measure again. If it still exceeds the limit, replace crankshaft also.

K

L PBIC2954E

PISTON TO PISTON PIN OIL CLEARANCE

M

Piston Pin Hole Diameter Measure the inner diameter of piston pin hole with an inside micrometer (A).

N

Standard

: Refer to EM-153, "Cylinder Block". O

P

JPBIA0217ZZ

Piston Pin Outer Diameter


EM-131

2009 G37 Coupe

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > Measure the outer diameter of piston pin with a micrometer (A). Standard


JPBIA0218ZZ

Piston to Piston Pin Oil Clearance (Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)

Standard


• If the calculated value is out of the standard, replace piston and piston pin assembly. • When replacing piston and piston pin assembly, refer to EM-142, "Description". NOTE: • Piston is available together with piston pin as assembly. • Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no piston pin grades can be selected. (Only “0” grade is available.)

PISTON RING SIDE CLEARANCE • Measure the side clearance of piston ring (1) and piston ring groove with a feeler gauge (C). A

: NG

B

: OK

Standard and limit


• If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, replace piston also. JPBIA0219ZZ

PISTON RING END GAP • Check that the cylinder bore inner diameter is within the specification. Refer to EM-122, "Disassembly and Assembly". • Lubricate with new engine oil to piston (1) and piston ring (2), and then insert piston ring until middle of cylinder with piston, and measure the piston ring end gap with a feeler gauge (B). A

: Press-fit

C : Measuring point

Standard and limit : Refer to EM-153, "Cylinder Block". • If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, rebore cylinder and use oversize piston and piston rings.

JPBIA0220ZZ

CONNECTING ROD BEND AND TORSION


EM-132

2009 G37 Coupe

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > • Check with a connecting rod aligner. A A

: Bend

B

: Torsion

C

: Feeler gauge

Bend limit Torsion limit

EM


C

• If it exceeds the limit, replace connecting rod assembly. D

E

F

G JPBIA0221ZZ

CONNECTING ROD BIG END DIAMETER • Install connecting rod bearing cap without installing connecting rod bearing, and tighten connecting rod bolts to the specified torque. Refer to EM-122, "Disassembly and Assembly" for the tightening procedure. 1

H

I

: Connecting rod

• Measure the inner diameter of connecting rod big end with an inside micrometer. Standard

J


• If out of the standard, replace connecting rod assembly.

JPBIA0222ZZ

K

CONNECTING ROD BUSHING OIL CLEARANCE L

Connecting Rod Bushing Inner Diameter Measure the inner diameter of connecting rod bushing with an inside micrometer (A).

M

Standard

: Refer to EM-153, "Cylinder Block". N

O JPBIA0223ZZ

Piston Pin Outer Diameter


P

EM-133

2009 G37 Coupe

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > Measure the outer diameter of piston pin with a micrometer (A). Standard


JPBIA0218ZZ

Connecting Rod Bushing Oil Clearance (Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diameter)

Standard and limit


• If the calculated value exceeds the limit, replace connecting rod assembly and/or piston and piston pin assembly. • If replacing piston and piston pin assembly, refer to EM-142, "Description". • If replacing connecting rod assembly, refer to EM-143, "Connecting Rod Bearing" to select the connecting rod bearing. A

: Sample codes

B


C


D

: Big-end diameter grade

E

: Weight grade

F

: Cylinder No.

G

: Management code

H

: Front mark

I

: Management code

JPBIA0208ZZ

Factory installed parts grading:

• Service parts apply only to grade “0”. A

: RH

B

: LH

C

: Piston pin grade number

D


E

: Front mark

F

: Identification code Unit: mm (in)

Grade

0

1

Connecting rod bushing inner diameter *

22.000 - 22.006 (0.8661 - 0.8664)

22.006 - 22.012 (0.8664 - 0.8666)

Piston pin hole diameter

21.993 - 21.999 (0.8659 - 0.8661)

21.999 - 22. 005 (0.8661 - 0.8663)

Piston pin outer diameter

21.989 - 21.995 (0.8657 - 0.8659)

21.995 - 22.001 (0.8659 - 0.8662)

*: After installing in connecting rod

JPBIA1212ZZ

CYLINDER BLOCK DISTORTION Revision: 2009 October

EM-134

2009 G37 Coupe

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > • Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or other contamination. A CAUTION: Be careful not to allow gasket flakes to enter engine oil or engine coolant passages. • Measure the distortion on the cylinder block upper face at some EM different points in six directions (C), (D), (E), (F), (G), and (H) with a straightedge (A) and a feeler gauge (B). Limit

C


• If it exceeds the limit, replace cylinder block. D

JPBIA0224ZZ

E

MAIN BEARING HOUSING INNER DIAMETER • Install lower cylinder block (2) without installing main bearings, and tighten lower cylinder block bolts to the specified torque. Refer to EM-122, "Disassembly and Assembly" for the tightening procedure. • Measure the inner diameter of main bearing housing with a bore gauge. Standard

F

G


• If out of the standard, replace cylinder block (1) and lower cylinder block as assembly. NOTE: Cylinder block cannot be replaced as a single part, because it is machined together with lower cylinder block.

H JPBIA0225ZZ

I

PISTON TO CYLINDER BORE CLEARANCE

J

Cylinder Bore inner Diameter • Using a bore gauge, measure cylinder bore for wear, out-of-round and taper at six different points on each cylinder. [(A) and (B) directions at (C), (D) and (E)] is in longitudinal direction of engine.

f g h

K

: 10 mm (0.39 in) : 60 mm (2.36 in) : 125 mm (4.92 in)

Standard and limit

L

M

: Refer to EM-153, "Cylinder Block". JPBIA0226ZZ

N

• If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, hone or rebore the inner wall. • Oversize piston is provided. When using oversize piston, rebore cylinder so that the clearance of the piston-to-cylinder bore satisfies the standard. CAUTION: When using oversize piston, use oversize pistons for all cylinders with oversize piston rings. Oversize (O/S)

: 0.2 mm (0.008 in)

O

P

SEM843E

Piston Skirt Diameter


EM-135

2009 G37 Coupe

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > Measure the outer diameter of piston skirt with a micrometer (A). Measure point Standard


JPBIA0227ZZ

Piston-to-Cylinder Bore Clearance Calculate by piston skirt diameter and cylinder bore inner diameter [direction (B), position (D)].

A C E f g h

: Direction A : Position C : Position E : 10 mm (0.39 in) : 60 mm (2.36 in) : 125 mm (4.92 in) JPBIA0226ZZ

(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter). Standard and limit


• If the calculated value exceeds the limit, replace piston and piston pin assembly. Refer to EM-153, "Cylinder Block". Reboring Cylinder Bore

1.

Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter. Re-bored size calculation: D = A + B – C where, A: Piston skirt diameter as measured B: Piston to cylinder bore clearance (standard value) C: Honing allowance 0.02 mm (0.0008 in) D: Bored diameter

2. 3.

4. 5.

Install lower cylinder block, and tighten to the specified torque. Otherwise, cylinder bores may be distorted in final assembly. Cut cylinder bores. NOTE: • When any cylinder needs boring, all other cylinders must also be bored. • Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a time. Hone cylinders to obtain the specified piston to cylinder bore clearance. Measure finished cylinder bore for the out-of-round and taper. NOTE: Perform measurement after cylinder bore cools down.

CRANKSHAFT MAIN JOURNAL DIAMETER • Measure the outer diameter of crankshaft main journals with a micrometer. Standard



EM-136

2009 G37 Coupe

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > • If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to EM146, "Main Bearing".

A

CRANKSHAFT PIN JOURNAL DIAMETER • Measure the outer diameter of crankshaft pin journal with a micrometer (A). Standard

EM

: Refer to EM-153, "Cylinder Block". C

• If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer to EM-143, "Connecting Rod Bearing".

D

JPBIA0228ZZ

CRANKSHAFT OUT-OF-ROUND AND TAPER • Measure the dimensions at four different points as shown in the figure on each main journal and pin journal with a micrometer. • Out-of-round is indicated by the difference in the dimensions between (d) and (c) at (a) and (b). • Taper is indicated by the difference in the dimensions between.

E

F

G

Limit


• If the measured value exceeds the limit, correct or replace crankshaft. • If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select the main bearing and/ or connecting rod bearing. Refer to EM-146, "Main Bearing" and/ or EM-143, "Connecting Rod Bearing".

H JPBIA0229ZZ

I

CRANKSHAFT RUNOUT • Place V-block on precise flat table, and support the journals on both ends of crankshaft. • Place a dial indicator straight up on the No. 3 journal. • While rotating crankshaft, read the movement of the pointer on a dial indicator. (Total indicator reading) Standard and limit

J

K


L

• If it exceeds the limit, replace crankshaft.

SEM346D

M

CONNECTING ROD BEARING OIL CLEARANCE Method by Calculation • Install connecting rod bearings (1) to connecting rod (2) and connecting rod cap, and tighten connecting rod bolts to the specified torque. Refer to EM-122, "Disassembly and Assembly" for the tightening procedure.

N

O

P

JPBIA0230ZZ

• Measure the inner diameter of connecting rod bearing with an inside micrometer. (Oil clearance) = (Connecting rod bearing inner diameter) – (Crankshaft pin journal diameter) Revision: 2009 October

EM-137

2009 G37 Coupe

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > Standard and limit

: Refer to EM-158, "Connecting Rod Bearing".

• If the calculated value exceeds the limit, select proper connecting rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer to EM-142, "Description". Method of Using Plastigage • Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely. • Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes. • Install connecting rod bearings to connecting rod and connecting rod bearing cap, and tighten connecting rod bolts to the specified torque. Refer to EM-122, "Disassembly and Assembly" for the tightening procedure. CAUTION: Never rotate crankshaft. • Remove connecting rod bearing cap and bearings, and using the scale on the plastigage bag, measure the plastigage width. NOTE: The procedure when the measured value exceeds the limit is the same as that described in the “Method by Calculation”.

JPBIA0231ZZ

MAIN BEARING OIL CLEARANCE Method by Calculation • Install main bearings (3) to cylinder block (1) and lower cylinder block (2), and tighten lower cylinder block bolts to the specified torque. Refer to EM-122, "Disassembly and Assembly" for the tightening procedure. • Measure the inner diameter of main bearing with a bore gauge. (Oil clearance) = (Main bearing inner diameter) – (Crankshaft main journal diameter)

Standard and limit : Refer to EM-157, "Main Bearing". • If the calculated value exceeds the limit, select proper main bearing according to main bearing inner diameter and crankshaft main journal diameter to obtain the specified bearing oil clearance. Refer to EM-142, "Description".

JPBIA0232ZZ

Method of Using Plastigage • Remove engine oil and dust on crankshaft journal and the surfaces of each bearing completely. • Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes. • Install main bearing to cylinder block and lower cylinder block, and tighten lower cylinder block bolts with lower cylinder block to the specified torque. Refer to EM-122, "Disassembly and Assembly" for the tightening procedure. CAUTION: Never rotate crankshaft.


EM-138

2009 G37 Coupe

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > • Remove lower cylinder block and bearings, and using the scale on the plastigage bag, measure the plastigage width. NOTE: The procedure when the measured value exceeds the limit is the same as that described in the “Method by Calculation”.

A

EM

C JPBIA0231ZZ

D

MAIN BEARING CRUSH HEIGHT • When lower cylinder block is removed after being tightened to the specified torque with main bearings (1) installed, the tip end of bearing must protrude. Refer to EM-122, "Disassembly and Assembly" for the tightening procedure. A

E

: Crush height

Standard

F

: There must be crush height. G

• If the standard is not met, replace main bearings. JPBIA0233ZZ

CONNECTING ROD BEARING CRUSH HEIGHT

H

• When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings (1) installed, the tip end of bearing must protrude. Refer to EM-122, "Disassembly and Assembly" for the tightening procedure. A

I

: Crush height

J

Standard

: There must be crush height.

• If the standard is not met, replace connecting rod bearings.

K JPBIA0233ZZ

LOWER CYLINDER BLOCK BOLT OUTER DIAMETER

L

• Measure the outer diameters (c), (d) at two positions as shown in the figure. a

: 20 mm (0.79 in)

b

: 30 mm (1.18 in)

e

: 10 mm (0.39 in)

M

N

• If reduction appears in (a) range, regard it (c). Limit [(d) – (c)]

: 0.11 mm (0.0043 in)

• If it exceeds the limit (large difference in dimensions), replace lower cylinder block bolt with new one.

JPBIA0234ZZ

CONNECTING ROD BOLT OUTER DIAMETER


EM-139

O

P

2009 G37 Coupe

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > 1. Measure the outer diameters [(a), (b) and (c)] at the position shown in the figure.

2. 3.

a

: Value at the end of the smaller diameter of the bolt

b

: Value at the end of the smaller diameter of the bolt [opposite side of (a)]

c

: Value of the smallest diameter of the smaller of the bolt

Obtain a mean value (d) of (a) and (b). Subtract (c) from (d). Limit [(d) – (c)]

4.

: 0.09 mm (0.0035 in)

JPBIA0262ZZ

If it exceeds the limit (large difference in dimensions), replace the bolt with new one.

FLYWHEEL DEFLECTION (M/T models) • Measure the deflection of flywheel contact surface to clutch with a dial indicator (A). • Measure the deflection at 210 mm (8.27 in) dia. Standard

: 0.45 mm (0.0177 in) or less.

• If measured value is out of the standard, replace flywheel.

JPBIA0236ZZ

MOVEMENT AMOUNT OF FLYWHEEL (M/T models) CAUTION: Never disassemble double mass flywheel. Movement Amount in Radial (Rotation) Direction Check the movement amount of radial (rotation) direction with the following procedure: 1. Install a bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel center line. • Tighten bolt at a force of 9.8 N·m (1.0 kg-m, 87 in-lb) to keep it from loosening. 2. Put a matching mark on circumferences of the two flywheel masses without applying any load (measurement standard points).

3.

4.

1

: Clutch cover mounting bolt

2

: Flywheel (transaxle side)

A

: Torque wrench

b

: 9.8 N·m (1.0 kg-m, 87 in-lb)

Apply a force of 9.8 N·m (1.0 kg-m, 87 in-lb) in each direction, and mark the movement amount on the mass on the transaxle JPBIA0237ZZ side. Measure the dimensions of movement amounts (C) and (D) on circumference of the flywheel on the transaxle side. Standard: Less than 29.9 mm (1.177 in)

• If measured value is out of the standard, replace flywheel.

DRIVE PLATE (A/T models)


EM-140

2009 G37 Coupe

CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > • Check drive plate and signal plate for deformation or damage. CAUTION: • Never disassemble drive plate. • Never place drive plate with signal plate facing down. • When handling signal plate, take care not to damage or scratch it. • Handle signal plate in a manner that prevents it from becoming magnetized. • If anything is found, replace drive plate.

A

EM

C JPBIA0192ZZ

D

OIL JET • Check nozzle for deformation and damage. • Blow compressed air from nozzle, and check for clogs. • If it is not satisfied, clean or replace oil jet.

E

OIL JET RELIEF VALVE • Using a clean plastic stick, press check valve in oil jet relief valve. Check that valve moves smoothly with proper reaction force. • If it is not satisfied, replace oil jet relief valve.

F

G

H

EMU0468D

I

J

K

L

M

N

O

P


EM-141

2009 G37 Coupe

HOW TO SELECT PISTON AND BEARING < UNIT DISASSEMBLY AND ASSEMBLY >

HOW TO SELECT PISTON AND BEARING Description

INFOID:0000000004250524

Selection points

Selection parts

Selection items

Selection methods

Main bearing

Main bearing grade (bearing thickness)

Determined by match of cylinder block bearing housing grade (inner diameter of housing) and crankshaft journal grade (outer diameter of journal)

Between crankshaft and connecting rod

Connecting rod bearing

Connecting rod bearing grade (bearing thickness)

Combining service grades for connecting rod big end diameter and crankshaft pin outer diameter determine connecting rod bearing selection.

Between cylinder block and piston

Piston and piston pin assembly (Piston is available together with piston pin as assembly.)

Piston grade (piston skirt diameter)

Piston grade = cylinder bore grade (inner diameter of bore)

Between piston and connecting rod*

—

Between cylinder block and crankshaft

—

—

*: For the service parts, the grade for fitting cannot be selected between piston pin and connecting rod. (Only “0” grade is available.) The information at the shipment from the plant is described as a reference.

• The identification grade stamped on each part is the grade for the dimension measured in new condition. This grade cannot apply to reused parts. • For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the measurement with the values of each selection table. • For details of the measurement method of each part, the reuse standards and the selection method of the selective fitting parts, refer to the text.

Piston

INFOID:0000000004250525

WHEN NEW CYLINDER BLOCK IS USED Check the cylinder bore grade (“1”, “2” or “3”) on rear side of cylinder block, and select piston of the same grade. A

: Bearing housing grade No. 1

B


C


D


E

: Cylinder bore grade No. 1

F


G


H


I


J


K

: Identification

JPBIA0268ZZ

: Engine front

NOTE: Piston is available with piston pin as a set for the service part. (Only “0” grade piston pin is available.)

WHEN NEW CYLINDER BLOCK IS REUSED 1.

Measure the cylinder bore inner diameter. Refer to EM-131, "Inspection".


EM-142

2009 G37 Coupe

HOW TO SELECT PISTON AND BEARING < UNIT DISASSEMBLY AND ASSEMBLY > 2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner diameter of the “PISTON SELECTION TABLE”. A

: RH

B

: LH

C

: Piston pin grade number

D


E

: Front mark

F

: Identification code

A

EM

C

D

E

F

G JPBIA1212ZZ

3.

Select piston of the same grade. H

PISTON SELECTION TABLE Unit: mm (in)

Grade

1

2

3

Cylinder bore inner diameter

95.500 - 95.510 (3.7598 - 3.7602)

95.510 - 95.520 (3.7602 - 3.7606)

95.520 - 95.530 (3.7606 - 3.7610)

Piston skirt diameter

95.480 - 95.490 (3.7590 - 3.7594)

95.490 - 95.500 (3.7594 - 3.7598)

95.500 - 95.510 (3.7598 - 3.7602)

I

NOTE: • Piston is available together with piston pin as assembly. • Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no piston pin grades can be selected. (Only “0” grade is available.) • No second grade mark is available on piston.

Connecting Rod Bearing

: Sample codes

B


C


E

: Weight grade

F

: Cylinder No.

G

: Management code

H

: Front mark

I

: Management code


L

M

Apply connecting rod big end diameter grade stamped (D) on connecting rod side face to the row in the “CONNECTING ROD BEARING SELECTION TABLE”. A

K

INFOID:0000000004250526

WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED 1.

J

N

O

P JPBIA0208ZZ

EM-143

2009 G37 Coupe

HOW TO SELECT PISTON AND BEARING < UNIT DISASSEMBLY AND ASSEMBLY > 2. Apply crankshaft pin journal diameter grade stamped on crankshaft front side to the column in the “CONNECTING ROD BEARING SELECTION TABLE”

3. 4.

A

: Journal diameter grade No. 1

B


C


D


E

: Pin diameter grade No. 1

F


G


H


I


J


K

: Identification

JPBIA0269ZZ

Read the symbol at the cross point of selected row and column in the “CONNECTING ROD BEARING SELECTION TABLE”. Apply the symbol obtained to the “CONNECTING ROD BEARING GRADE TABLE” to select connecting rod bearing.

WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED 1. 2. 3. 4.

Measure connecting rod big end diameter and crankshaft pin journal diameter. Refer to EM-131, "Inspection". Correspond the measured dimension in “connecting rod big end diameter” row of “CONNECTING ROD BEARING SELECTION TABLE”. Correspond the measured dimension in “crankshaft pin diameter” column of “CONNECTING ROD BEARING SELECTION TABLE”. Follow step 3 and later in “WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED”.

CONNECTING ROD BEARING SELECTION TABLE


EM-144

2009 G37 Coupe

HOW TO SELECT PISTON AND BEARING < UNIT DISASSEMBLY AND ASSEMBLY > A

EM

C

D

E

F

G

H

I

J

K

PBIC5435E

CONNECTING ROD BEARING GRADE TABLE L

Connecting rod bearing grade table


UNDERSIZE BEARING USAGE GUIDE • When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod bearings, use undersize (US) bearings. • When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing installed, and grind crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard. CAUTION: In grinding crankshaft pin to use undersize bearings, keep the fillet R (A) [1.5 - 1.7 mm (0.059 - 0.067 in)].

M

N

O

P

JPBIA0216ZZ


EM-145

2009 G37 Coupe

HOW TO SELECT PISTON AND BEARING < UNIT DISASSEMBLY AND ASSEMBLY > Bearing undersize table


Main Bearing

INFOID:0000000004250527

WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE USED 1.

“MAIN BEARING SELECTION TABLE” rows correspond to bearing housing grade on rear side of cylinder block. A


B


C


D


E


F


G


H


I


J


K


JPBIA0268ZZ

: Engine front

2.

3. 4.

“MAIN BEARING SELECTION TABLE” columns correspond to journal diameter grade on front side of crankshaft. A


B


C


D


E


F


G


H


I


J


K


JPBIA0269ZZ

Select main bearing grade at the point where selected row and column meet in “MAIN BEARING SELECTION TABLE”. Apply sign at crossing in above step 3 to “MAIN BEARING GRADE TABLE”. NOTE: • “MAIN BEARING GRADE TABLE” applies to all journals. • Service parts are available as a set of both upper and lower.

WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED 1. 2. 3. 4.

Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter. Refer to EM-131, "Inspection". Correspond the measured dimension in “Cylinder block main bearing housing inner diameter” row of “MAIN BEARING SELECTION TABLE”. Correspond the measured dimension in “Crankshaft main journal diameter” column of “MAIN BEARING SELECTION TABLE”. Follow step 3 and later in “When New Cylinder Block and Crankshaft are Used”.


EM-146

2009 G37 Coupe

HOW TO SELECT PISTON AND BEARING < UNIT DISASSEMBLY AND ASSEMBLY > MAIN BEARING SELECTION TABLE A

EM

C

D

E

F

G

H

I

J

K

JPBIA0264ZZ

MAIN BEARING GRADE TABLE (ALL JOURNALS) L

Main bearing grade table (All journals)

: Refer to EM-157, "Main Bearing".

UNDERSIZE BEARING USAGE GUIDE • When the specified main bearing oil clearance is not obtained with standard size main bearings, use underside (US) bearing. • When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and grind main journal so that the main bearing oil clearance satisfies the standard. CAUTION: In grinding crankshaft main journal to use undersize bearings, keep the fillet R (A) [1.5 - 1.7 mm (0.059 - 0.067 in)]. Bearing undersize table : Refer to EM-157, "Main Bearing".

EM-147

N

O

P

JPBIA0216ZZ


M

2009 G37 Coupe


SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) General Specification

INFOID:0000000004250528

GENERAL SPECIFICATIONS Cylinder arrangement

V-6

3

3,696 (225.53)

Displacement cm (cu in) Bore and stroke

mm (in)

95.5 x 86.0 (3.76 x 3.386)

Valve arrangement

DOHC

Firing order Number of piston rings

1-2-3-4-5-6 Compression

2

Oil

1

Number of main bearings

4

Compression ratio

11

Compression pressure kPa (kg/cm2, psi)/200 rpm

Standard

1,667 - 2,354 (17 - 24, 242 - 341)

Minimum

1,226 (12.5, 178)

Differential limit between cylinders

98 (1.0, 14)

Cylinder number

SEM713A

Unit: degree

Valve timing

Intake valve open (BTDC)

63 - −64

Intake valve close (ABDC)

−73 - 82

Exhaust valve open (BBDC)

64

Exhaust valve close (ATDC)

12

Drive Belt

INFOID:0000000004250529

DRIVE BELT Tension of drive belt

Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.

Spark Plug

INFOID:0000000004250530

SPARK PLUG Unit: mm (in)

Make

DENSO

Standard type

FXE24HR11

Gap (Nominal)

1.1 (0.043)


EM-148

2009 G37 Coupe


Intake Manifold

INFOID:0000000004250531

A

INTAKE MANIFOLD Unit: mm (in)

Items Surface distortion

EM

Limit

Intake manifold

0.1 (0.004)

Exhaust Manifold

INFOID:0000000004250532

C

Unit: mm (in)

D

EXHAUST MANIFOLD Items Surface distortion

Limit

Exhaust manifold

0.7 (0.028)

Camshaft

E INFOID:0000000004250533

CAMSHAFT (EXH)

F Unit: mm (in)

Items Camshaft (EXH) journal oil clearance

VVEL ladder assembly bracket inner diameter (EXH)

Camshaft (EXH) journal diameter

Standard No. 1

0.045 - 0.086 (0.0018 - 0.0034)

No. 2, 3, 4

0.035 - 0.076 (0.0014 - 0.0030)

G 0.150 (0.0059)

No. 1

26.000 - 26.021 (1.0236 - 1.0244)

—

No. 2, 3, 4

23.500 - 23.521 (0.9252 - 0.9260)

—

No. 1

25.935 - 25.955 (1.0211 - 1.0218)

—

No. 2, 3, 4

23.445 - 23.465 (0.9230 - 0.9238)

—

0.115 - 0.188 (0.0045 - 0.0074)

0.24 (0.0094)

Camshaft (EXH) end play Camshaft (EXH) cam height “A”

Limit

Bank 1

45.015 - 45.205 (1.7722 - 1.7797)

Bank 2

46.735 - 46.925 (1.8400 - 1.8474)

Camshaft (EXH) runout [TIR*2]

0.2 (0.008)*1

Less than 0.02 (0.001)

0.05 (0.002)

—

0.15 (0.0059)

Camshaft sprocket (EXH) runout [TIR*2]

H

I

J

K

L

M

N

SEM671

O

*1: Cam wear limit *2: Total indicator reading

P

CAMSHAFT (INT) Unit: mm (in)

Items Drive shaft end play Camshaft sprocket (INT) runout [TIR*1]

Standard

Limit

0.115 - 0.188 (0.0045 - 0.0074)

0.24 (0.0094)

—

0.15 (0.0059)

*1: Total indicator reading


EM-149

2009 G37 Coupe

SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) VALVE LIFTER Unit: mm (in)

Items

Standard

Valve lifter outer diameter

33.980 - 33.990 (1.3378 - 1.3382)

Valve lifter hole diameter

34.000 - 34.016 (1.3386 - 1.3392)

Valve lifter clearance

0.010 - 0.036 (0.0004 - 0.0014)

VALVE CLEARANCE Unit: mm (in)

Items

Cold

Hot* (reference data)

Intake

0.26 - 0.34 (0.010 - 0.013)

0.304 - 0.416 (0.012 - 0.016)

Exhaust

0.29 - 0.37 (0.011 - 0.015)

0.308 - 0.432 (0.012 - 0.017)

*: Approximately 80°C (176°F)

AVAILABLE VALVE LIFTER Unit: mm (in)

Identification (stamped) mark

Thickness

788

7.88 (0.3102)

790

7.90 (0.3110)

792

7.92 (0.3118)

794

7.94 (0.3126)

796

7.96 (0.3134)

798

7.98 (0.3142)

800

8.00 (0.3150)

802

8.02 (0.3157)

804

8.04 (0.3165)

806

8.06 (0.3173)

808

8.08 (0.3181)

810

8.10 (0.3189)

812

8.12 (0.3197)

814

8.14 (0.3205)

816

8.16 (0.3213)

818

8.18 (0.3220)

820

8.20 (0.3228)

822

8.22 (0.3236)

824

8.24 (0.3244)

826

8.26 (0.3252)

828

8.28 (0.3260)

830

8.30 (0.3268)

832

8.32 (0.3276)

834

8.34 (0.3283)

836

8.36 (0.3291)

838

8.38 (0.3299)


EM-150

2009 G37 Coupe

SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) Identification (stamped) mark

Thickness

840

8.40 (0.3307)

A

EM

C

D

SEM758G

E

Cylinder Head

INFOID:0000000004250534

CYLINDER HEAD

F Unit: mm (in)

Items Head surface distortion Normal cylinder head height “H”

Standard

Limit

Less than 0.03 (0.0012)

0.1 (0.004)

126.4 (4.98)

—

G

H

I

J

K PBIC0924E

VALVE DIMENSIONS Unit: mm (in)

L

M

N

O SEM188

Valve head diameter “D”

Valve length “L”

Valve stem diameter “d”


Intake

36.6 - 36.9 (1.441 - 1.453)

Exhaust

30.2 - 30.5 (1.189 - 1.201)

Intake

100.11 (3.94)

Exhaust

94.67 (3.7272)

Intake

5.965 - 5.980 (0.2348 - 0.2354)

Exhaust

5.962 - 5.970 (0.2347 - 0.2350)

EM-151

2009 G37 Coupe

P

SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) Intake

Valve seat angle “α”

45°15′ - 45°45′

Exhaust

Valve margin “T”

Intake

1.1 (0.043)

Exhaust

1.3 (0.051)

Valve margin “T” limit

0.5 (0.020)

Valve stem end surface grinding limit

0.2 (0.008)

VALVE GUIDE Unit: mm (in)

SEM950E

Items Outer diameter

Valve guide

Standard

Oversize (Service) [0.2 (0.008)]*

10.023 - 10.034 (0.3946 - 0.3950)

10.223 - 10.234 (0.4025 - 0.4029)*

Inner diameter (Finished size)

Cylinder head valve guide hole diameter

6.000 - 6.018 (0.2362 - 0.2369) 9.975 - 9.996 (0.3927 - 0.3935)

Interference fit of valve guide

0.027 - 0.059 (0.0011 - 0.0023)

Items Valve guide clearance

10.175 - 10.196 (0.4006 - 0.4014)*

Standard

Limit

Intake

0.020 - 0.053 (0.0008 - 0.0021)

0.08 (0.003)

Exhaust

0.030 - 0.056 (0.0012 - 0.0022)

0.09 (0.004)

Projection length “L”

12.6 - 12.8 (0.496 - 0.504)

*: Parts settings are for exhaust side only

VALVE SEAT Unit: mm (in)

PBIC2745E

Standard

Oversize (Service) [0.5 (0.02)] *4

Intake

38.000 - 38.016 (1.4961 - 1.4967)

—

Exhaust

31.600 - 31.616 (1.2441 - 1.2447)

32.100 - 32.116 (1.2638 - 1.2644)*4

Intake

38.097 - 38.113 (1.4999 - 1.5005)

—

Exhaust

31.680 - 31.696 (1.2472 - 1.2479)

32.180 - 32.196 (1.2669 - 1.2676)*4

Items Cylinder head seat recess diameter “D”

Valve seat outer diameter “d”


EM-152

2009 G37 Coupe

SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) Valve seat interference fit

Diameter “d1”*1 Diameter “d2”*2

Angle “α1”

Angle “α2”

Angle “α3”

Contacting width “W”*3

Height “h”

Intake

0.081 - 0.113 (0.0032 - 0.0044)

Exhaust

0.064 - 0.096 (0.0025 - 0.0038)

Intake

34.6 (1.362)

Exhaust

27.7 (1.091)

EM

Intake

35.9 - 36.4 (1.413 - 1.433)

Exhaust

29.3 - 29.8 (1.154 - 1.173)

Intake

60°

Exhaust

60°

C

Intake

88°45′ - 90°15′

Exhaust

88°45′ - 90°15′

Intake

120°

Exhaust

120°

A

D

E

Intake

1.0 - 1.4 (0.039 - 0.055)

Exhaust

1.2 - 1.6 (0.047 - 0.063)

F

Intake

5.9 - 6.0 (0.232 - 0.236)

—

Exhaust

5.9 - 6.0 (0.232 - 0.236)

4.95 - 5.05 (0.1949 - 0.1988)*4

Depth “H”

G

6.0 (0.236)

*1: Diameter made by intersection point of conic angles “α1” and “α2” *2: Diameter made by intersection point of conic angles “α2” and “α3”

H

*3: Machining data *4: Parts settings are for exhaust side only

I

VALVE SPRING Items

Standard

J

Intake

Exhaust

45.66 mm (1.7976 in)

43.85 mm (1.7264 in)

Installation

191.1 - 215.5 N (19.5 - 22 kg, 43 - 48 lb) at 40.90 mm (1.6102 in)

166 - 188 N (16.9 - 19.2 kg, 37 - 42 lb) at 37.00 mm (1.4567 in)

Valve open

830.9 - 936.9 N (84.8 - 95.6 kg, 187 - 211 lb) at 28.07 mm (1.1051 in)

502 - 566 N (51.2 - 57.7 kg, 113 - 127 lb) at 26.80 mm (1.0551 in)

Purple

Yellowish green

Free height

Pressure

Identification color

Items Out-of-square

Limit

K

L

M

Intake

Exhaust

2.0 mm (0.079 in)

1.9 mm (0.075 in)

N

Cylinder Block

INFOID:0000000004250535

CYLINDER BLOCK

O

P


EM-153

2009 G37 Coupe

SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) Unit: mm (in)

JPBIA1050GB

Standard

Surface flatness Main bearing housing inner diameter

Cylinder bore

Less than 0.03 (0.0012)

Limit

Inner diameter

0.1 (0.004)

Standard

Standard

69.993 - 70.017 (2.7556 - 2.7566) Grade No. 1

95.500 - 95.510 (3.7598 - 3.7602)

Grade No. 2

95.510 - 95.520 (3.7602 - 3.7606)

Grade No. 3

95.520 - 95.530 (3.7606 - 3.7610)

Wear limit Out-of-round Taper

0.015 (0.0006)

Limit

0.010 (0.0004)

Main bearing housing inner diameter grade (Without bearing)

Difference in inner diameter between cylinders

0.2 (0.008)

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. 4 Grade No. 7

Standard

69.993 - 69.994 (2.7556 - 2.7557) 69.994 - 69.995 (2.7557 - 2.7557) 69.995 - 69.996 (2.7557 - 2.7557) 69.996 - 69.997 (2.7557 - 2.7558) 69.997 - 69.998 (2.7558 - 2.7558) 69.998 - 69.999 (2.7558 - 2.7559) 69.999 - 70.000 (2.7559 - 2.7559) 70.000 - 70.001 (2.7559 - 2.7559) 70.001 - 70.002 (2.7559 - 2.7560) 70.002 - 70.003 (2.7560 - 2.7560) 70.003 - 70.004 (2.7560 - 2.7561) 70.004 - 70.005 (2.7561 - 2.7561) 70.005 - 70.006 (2.7561 - 2.7561) 70.006 - 70.007 (2.7561 - 2.7562) 70.007 - 70.008 (2.7562 - 2.7562) 70.008 - 70.009 (2.7562 - 2.7563) 70.009 - 70.010 (2.7563 - 2.7563) 70.010 - 70.011 (2.7563 - 2.7563) 70.011 - 70.012 (2.7563 - 2.7564) 70.012 - 70.013 (2.7564 - 2.7564) 70.013 - 70.014 (2.7564 - 2.7565) 70.014 - 70.015 (2.7565 - 2.7565) 70.015 - 70.016 (2.7565 - 2.7565) 70.016 - 70.017 (2.7565 - 2.7566) Less than 0.03 (0.0012)

AVAILABLE PISTON


EM-154

2009 G37 Coupe

SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) Unit: mm (in)

A

EM

C

D SEM882E

Items

Piston skirt diameter “A”

Standard

Oversize (Service) [0.2 (0.008)]

Grade No. 1

95.480 - 95.490 (3.7590 - 3.7594)

—

Grade No. 2

95.490 - 95.500 (3.7594 - 3.7598)

—

Grade No. 3

95.500 - 95.510 (3.7598 - 3.7602)

—

—

95.680 - 95.710 (3.7669 - 3.7681)

Standard

Limit

38.8 (1.528)

—

Grade No. 0

21.993 - 21.999 (0.8659 - 0.8661)

—

Grade No. 1

21.999 - 22.005 (0.8661 - 0.8663)

—

0.010 - 0.030 (0.0004 - 0.0012)

0.08 (0.0031)

Service Items “a” dimension Piston pin hole diameter Piston to cylinder bore clearance

E

F

G

H

PISTON RING Unit: mm (in)

Items

Side clearance

End gap

Standard

Limit

Top

0.040 - 0.080 (0.0016 - 0.0031)

0.11 (0.0043)

2nd

0.030 - 0.070 (0.0012 - 0.0028)

0.10 (0.0039)

Oil ring

0.055 - 0.155 (0.0022 - 0.0061)

0.19 (0.0075)

Top

0.23 - 0.33 (0.0091 - 0.0130)

0.42 (0.0169)

2nd

0.23 - 0.33 (0.0091 - 0.0130)

0.57 (0.0224)

Oil (rail ring)

0.17 - 0.47 (0.0067 - 0.0185)

0.63 (0.0248)

I

J

K

L

PISTON PIN Unit: mm (in)

Items Piston pin outer diameter

Standard

Limit

Grade No. 0

21.989 - 21.995 (0.8657 - 0.8659)

—

Grade No. 1

M

21.995 - 22.001 (0.8659 - 0.8662)

—

Piston to piston pin oil clearance

0.002 - 0.006 (0.0001 - 0.0002)

—

Connecting rod bushing oil clearance

0.005 - 0.017 (0.0002 - 0.0007)

0.030 (0.0012)

N

O

CONNECTING ROD Unit: mm (in)

Items

Standard

Limit

149.45 - 149.55 (5.88 - 5.89)

—

Bend [per 100 (3.94)]

—

0.15 (0.0059)

Torsion [per 100 (3.94)]

—

0.30 (0.0118)

Grade No. 0

22.000 - 22.006 (0.8661 - 0.8664)

—

Grade No. 1

22.006 - 22.012 (0.8664 - 0.8666)

—

Center distance

Connecting rod bushing inner diameter*


EM-155

2009 G37 Coupe

P


Connecting rod big end diameter (Without bearing)

Grade No. A

57.000 - 57.001 (2.2441 - 2.2441)

—

Grade No. B

57.001 - 57.002 (2.2441 - 2.2442)

—

Grade No. C

57.002 - 57.003 (2.2442 - 2.2442)

—

Grade No. D

57.003 - 57.004 (2.2442 - 2.2442)

—

Grade No. E

57.004 - 57.005 (2.2442 - 2.2443)

—

Grade No. F

57.005 - 57.006 (2.2443 - 2.2443)

—

Grade No. G

57.006 - 57.007 (2.2443 - 2.2444)

—

Grade No. H

57.007 - 57.008 (2.2444 - 2.2444)

—

Grade No. J

57.008 - 57.009 (2.2444 - 2.2444)

—

Grade No. K

57.009 - 57.010 (2.2444 - 2.2445)

—

Grade No. L

57.010 - 57.011 (2.2445 - 2.2445)

—

Grade No. M

57.011 - 57.012 (2.2445 - 2.2446)

—

Grade No. N

57.012 - 57.013 (2.2446 - 2.2446)

—

Standard

Limit

0.20 - 0.35 (0.0079 - 0.0138)

0.40 (0.0157)

Items Side clearance *: After installing in connecting rod

CRANKSHAFT Unit: mm (in)

SEM645

Main journal diameter. “Dm” grade


Standard

SBIA0535E

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. 4 Grade No. 7

EM-156

64.975 - 64.974 (2.5581 - 2.5580) 64.974 - 64.973 (2.5580 - 2.5580) 64.973 - 64.972 (2.5580 - 2.5579) 64.972 - 64.971 (2.5579 - 2.5579) 64.971 - 64.970 (2.5579 - 2.5579) 64.970 - 64.969 (2.5579 - 2.5578) 64.969 - 64.968 (2.5578 - 2.5578) 64.968 - 64.967 (2.5578 - 2.5578) 64.967 - 64.966 (2.5578 - 2.5577) 64.966 - 64.965 (2.5577 - 2.5577) 64.965 - 64.964 (2.5577 - 2.5576) 64.964 - 64.963 (2.5576 - 2.5576) 64.963 - 64.962 (2.5576 - 2.5576) 64.962 - 64.961 (2.5576 - 2.5575) 64.961 - 64.960 (2.5575 - 2.5575) 64.960 - 64.959 (2.5575 - 2.5574) 64.959 - 64.958 (2.5574 - 2.5574) 64.958 - 64.957 (2.5574 - 2.5574) 64.957 - 64.956 (2.5574 - 2.5573) 64.956 - 64.955 (2.5573 - 2.5573) 64.955 - 64.954 (2.5573 - 2.5572) 64.954 - 64.953 (2.5572 - 2.5572) 64.953 - 64.952 (2.5572 - 2.5572) 64.952 - 64.951 (2.5572 - 2.5571)

2009 G37 Coupe


Pin journal diameter. “Dp” grade

Standard

Grade No. A

53.974 - 53.973 (2.1250 - 2.1249)

Grade No. B

53.973 - 53.972 (2.1249 - 2.1249)

Grade No. C

53.972 - 53.971 (2.1249 - 2.1248)

Grade No. D

53.971 - 53.970 (2.1248 - 2.1248)

Grade No. E

53.970 - 53.969 (2.1248 - 2.1248)

Grade No. F

53.969 - 53.968 (2.1248 - 2.1247)

Grade No. G

53.968 - 53.967 (2.1247 - 2.1247)

Grade No. H

53.967 - 53.966 (2.1247 - 2.1246)

Grade No. J

53.966 - 53.965 (2.1246 - 2.1246)

Grade No. K

53.965 - 53.964 (2.1246 - 2.1246)

Grade No. L

53.964 - 53.963 (2.1246 - 2.1245)

Grade No. M

53.963 - 53.962 (2.1245 - 2.1245)

Grade No. N

53.962 - 53.961 (2.1245 - 2.1244)

Grade No. P

53.961 - 53.960 (2.1244 - 2.1244)

Grade No. R

53.960 - 53.959 (2.1244 - 2.1244)

Grade No. S

53.959 - 53.958 (2.1244 - 2.1243)

Grade No. T

53.958 - 53.957 (2.1243 - 2.1243)

Grade No. U

53.957 - 53.956 (2.1243 - 2.1242)

Center distance “r”

42.96 - 43.04 (1.6913 - 1.6945)

Taper (Difference between “A” and “B”) Out-of-round (Difference between “X” and “Y”) Crankshaft runout [TIR*]

Crankshaft end play

0.0025 (0.0001)

Limit

A

EM

C

D

E

F

G

H

0.0025 (0.0001)

Standard

Less than 0.05 (0.002)

Limit

I

0.10 (0.0039)

Standard

0.10 - 0.25 (0.0039 - 0.0098)

Limit

J

0.30 (0.0118)

*: Total indicator reading

Main Bearing

INFOID:0000000004250536

K

Unit: mm (in)

L

MAIN BEARING

M

N

O PBIC2969E

Grade number


Thickness

Width

EM-157

Identification color

Remarks

2009 G37 Coupe

P

SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) 0

2.500 - 2.503 (0.0984 - 0.0985)

Black

1

2.503 - 2.506 (0.0985 - 0.0987)

Brown

2

2.506 - 2.509 (0.0987 - 0.0988)

Green

3

2.509 - 2.512 (0.0988 - 0.0989)

Yellow

4

2.512 - 2.515 (0.0989 - 0.0990)

Blue

5

2.515 - 2.518 (0.0990 - 0.0991)

Pink

6

2.518 - 2.521 (0.0991 - 0.0993)

Purple

7

2.521 - 2.524 (0.0993 - 0.0994)

White

UPR

2.503 - 2.506 (0.0985 - 0.0987)

Brown

LWR

2.500 - 2.503 (0.0984 - 0.0985)

Black

UPR

2.506 - 2.509 (0.0987 - 0.0988)

LWR

2.503 - 2.506 (0.0985 - 0.0987)

01

12

23

34

45

56

67

19.9 - 20.1 (0.783 - 0.791)

Grade is the same for upper and lower bearings.

Green Brown

UPR

2.509 - 2.512 (0.0988 - 0.0989)

Yellow

LWR

2.506 - 2.509 (0.0987 - 0.0988)

Green

UPR

2.512 - 2.515 (0.0989 - 0.0990)

Blue

LWR

2.509 - 2.512 (0.0988 - 0.0989)

Yellow

UPR

2.515 - 2.518 (0.0990 - 0.0991)

Pink

LWR

2.512 - 2.515 (0.0989 - 0.0990)

Blue

UPR

2.518 - 2.521 (0.0991 - 0.0993)

Purple

LWR

2.515 - 2.518 (0.0990 - 0.0991)

Pink

UPR

2.521 - 2.524 (0.0993 - 0.0994)

White

LWR

2.518 - 2.521 (0.0991 - 0.0993)

Purple

Grade and color are different for upper and lower bearings.

UNDERSIZE Unit: mm (in)

Items

Thickness

0.25 (0.0098)

2.633 - 2.641 (0.1037 - 0.1040)

Main journal diameter 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:0000000004250537

CONNECTING ROD BEARING Unit: mm (in)

Grade number

Thickness

Identification color (mark)

0

1.497 - 1.500 (0.0589 - 0.0591)

Black

1

1.500 - 1.503 (0.0591 - 0.0592)

Brown

2

1.503 - 1.506 (0.0592 - 0.0593)

Green

3

1.506 - 1.509 (0.0593 - 0.0594)

Yellow

4

1.509 - 1.512 (0.0594 - 0.0595)

Blue

UNDERSIZE Unit: mm (in)

Items

Thickness

0.25 (0.0098)

1.626 - 1.634 (0.0640 - 0.0643)


EM-158

Crank pin journal diameter Grind so that bearing clearance is the specified value.

2009 G37 Coupe

SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) CONNECTING ROD BEARING OIL CLEARANCE Unit: mm (in)

Items Connecting rod bearing oil clearance

Standard

Limit

0.040 - 0.053 (0.0016 - 0.0021)*

0.070 (0.0028)

*: Actual clearance

A

EM

C

D

E

F

G

H

I

J

K

L

M

N

O

P


EM-159

2009 G37 Coupe

ENGINE

SECTION

EX

EXHAUST SYSTEM

A

EX

C

D

E

CONTENTS

F

PRECAUTION ............................................... 2

PERIODIC MAINTENANCE ......................... 4

PRECAUTIONS ................................................... 2

EXHAUST SYSTEM ........................................... 4

Removal and Installation ........................................... 2

Inspection ................................................................. 4

PREPARATION ............................................ 3

REMOVAL AND INSTALLATION ................ 5

PREPARATION ................................................... 3

EXHAUST SYSTEM ........................................... 5

H

Special Service Tool ................................................. 3 Commercial Service Tool .......................................... 3

Exploded View .......................................................... 5 Removal and Installation .......................................... 6 Inspection ................................................................. 6

I

G

J

K

L

M

N

O

P


EX-1

2009 G37 Coupe


PRECAUTION PRECAUTIONS Removal and Installation

INFOID:0000000004251110

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.


EX-2

2009 G37 Coupe


PREPARATION

A

PREPARATION Special Service Tool

INFOID:0000000004251111

EX

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number (Kent-Moore No.) Tool name

Description

C

KV10114400 (J-38365) Heated oxygen sensor wrench

Loosening or tightening heated oxygen sensor 2 For 22 mm (0.87 in) (a) width hexagon nut

D

E S-NT636

F


INFOID:0000000004251112

G

(Kent-Moore No.) Tool name

Description

A: (J-43897-18) B: (J-43897-12) Heated oxygen sensor thread cleaner

JPBIA0238ZZ

Reconditioning the exhaust system threads before installing a new heated oxygen sensor (Use with anti-seize lubricant shown below.) A: J-43897-18 [18 mm (0.71 in) dia.] for zirconia heated oxygen sensor B: J-43897-12 [12 mm (0.47 in) dia.] for titania heated oxygen sensor C: Mating surface shave cylinder D: Flutes Lubricating heated oxygen sensor thread cleaner when reconditioning exhaust system threads

( — ) Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907)

H

I

J

K

L AEM489

( — ) Power tool

Loosening bolts and nuts

M

N PBIC0190E

O

P


EX-3

2009 G37 Coupe

EXHAUST SYSTEM < PERIODIC MAINTENANCE >

PERIODIC MAINTENANCE EXHAUST SYSTEM Inspection

INFOID:0000000004251113

Check exhaust pipes, muffler and mounting for improper attachment, leaks, cracks, damage or deterioration. • If anything is found, repair or replace damaged parts.

SMA211A


EX-4

2009 G37 Coupe

EXHAUST SYSTEM < REMOVAL AND INSTALLATION >


A

EXHAUST SYSTEM Exploded View

INFOID:0000000004251114

EX

C

D

E

F

G

H

I

J

K

L

M

N JPBIA1939GB

1.

Mounting bracket

2.

Mounting rubber

3.

Main muffler

4.

Dynamic damper

5.

Mounting rubber

6.

Gasket

7.

Mounting rubber

8.

Mounting bracket

9.

Center muffler

O

10. Gasket

11. Three way catalyst (bank 1)


13. Collar

14. Grommet

15. Exhaust mounting bracket

16. Grommet


18. Three way catalyst (bank 2)

19. Gasket

20. Dynamic damper

21. Exhaust front tube

22. Gasket Refer to GI-4, "Components" for symbols in the figure.


EX-5

2009 G37 Coupe

P

EXHAUST SYSTEM < REMOVAL AND INSTALLATION >


INFOID:0000000004251115

REMOVAL • Disconnect each joint and mounting using power tool. • Remove heated oxygen sensor 2 as follows: - Using heated oxygen sensor wrench [SST: KV10114400 (J38365)] (C), removal heated oxygen sensor 2. A

: Bank 1

B

: Bank 2 : Vehicle front

CAUTION: Be careful not to damage heated oxygen sensor 2. JPBIA2218ZZ

INSTALLATION Note the following, and install in the reverse order of removal. • Check for deformation of the grommets (14 and 16 of Components). • Insert the collar (13 of Components) vertically. • Temporarily tighten nuts and bolts when installing exhaust pipe assembly. Tighten them to the specified torque when connecting the vehicle rear to the vehicle front. CAUTION: • Always replace exhaust tube gaskets with new ones when reassembling. • Discard any heated oxygen sensor 2 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 (commercial service tool: J-43897-18 or J-43897-12), and apply the antiseize lubricant (commercial service tool). • Never over torque heated oxygen sensor 2. Doing so may cause damage to 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 gases leakage. • Temporarily tighten mounting nuts on the exhaust manifold side and mounting bolts on the vehicle side. 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 and right/left directions.

Inspection

INFOID:0000000004251116

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.


EX-6

2009 G37 Coupe

BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY

SECTION

EXT

EXTERIOR

A

B

C

D

E


Removal and Installation .........................................21

SQUEAK AND RATTLE TROUBLE DIAGNOSES ................................................................ 3

FENDER PROTECTOR .................................... 24

Work Flow ................................................................. 3 Inspection Procedure ................................................ 5 Diagnostic Worksheet ............................................... 7

PRECAUTION ............................................... 9 PRECAUTIONS ................................................... 9 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ................................................................... 9 Precaution Necessary for Steering Wheel Rotation after Battery Disconnect ..................................... 9 Precaution for Battery Service ................................ 10 Precaution for Procedure without Cowl Top Cover.... 10 Precaution for Work ................................................ 10

FENDER PROTECTOR .............................................24 FENDER PROTECTOR : Exploded View ...............24 FENDER PROTECTOR : Removal and Installation ...........................................................................24 REAR WHEEL HOUSE PROTECTOR ......................25 REAR WHEEL HOUSE PROTECTOR : Exploded View .........................................................................25 REAR WHEEL HOUSE PROTECTOR : Removal and Installation ........................................................25

CENTER MUD GUARD ..................................... 27 Exploded View .........................................................27 Removal and Installation .........................................27 Exploded View .........................................................29 Removal and Installation .........................................29

PREPARATION ..................................................11

ROOF SIDE MOLDING ..................................... 31

Special Service Tools .............................................. 11 Commercial Service Tools ..................................... 11



FRONT PILLAR FINISHER ............................... 33

FRONT BUMPER ...............................................12


Exploded View ........................................................ 12 Removal and Installation ......................................... 13

DOOR OUTSIDE MOLDING ............................. 35

REAR BUMPER .................................................16



DOOR PARTING SEAL .................................... 36

FRONT GRILLE .................................................19


COWL TOP .........................................................21 Exploded View ........................................................ 21


G

H

I

J

EXT

FLOOR SIDE FAIRING ..................................... 29

PREPARATION ........................................... 11


F

TRUNK LID FINISHER ...................................... 37 TRUNK LID OUTER FINISHER .................................37 TRUNK LID OUTER FINISHER : Exploded View....37

EXT-1

2009 G37 Coupe

L

M

N

O

P

TRUNK LID OUTER FINISHER : Removal and Installation ................................................................. 37 TRUNK DRIP COVER ............................................... 38 TRUNK DRIP COVER : Exploded View ................. 39


TRUNK DRIP COVER : Removal and Installation... 39

REAR SPOILER ................................................ 41 Exploded View ........................................................ 41 Removal and Installation ......................................... 41

EXT-2

2009 G37 Coupe


SYMPTOM DIAGNOSIS

A

SQUEAK AND RATTLE TROUBLE DIAGNOSES Work Flow

INFOID:0000000004678284

B

C

D

E

F

G SBT842

CUSTOMER INTERVIEW

H Interview the customer if possible, to determine the conditions that exist when the noise occurs. Use the Diagnostic Worksheet during the interview to document the facts and conditions when the noise occurs and any of customer's comments; refer to EXT-7, "Diagnostic Worksheet". This information is necessary to duplicate the I conditions that exist when the noise occurs. • The customer may not be able to provide a detailed description or the location of the noise. Attempt to obtain all the facts and conditions that exist when the noise occurs (or does not occur). • If there is more than one noise in the vehicle, perform a diagnosis and repair the noise that the customer is J concerned about. This can be accomplished by performing a cruise test on the vehicle with the customer. • After identifying the type of noise, isolate the noise in terms of its characteristics. The noise characteristics are provided so the customer, service adviser and technician are all speaking the same language when EXT defining the noise. • Squeak – (Like tennis shoes on a clean floor) Squeak characteristics include the light contact/fast movement/brought on by road conditions/hard surfaces L = higher pitch noise/softer surfaces = lower pitch noises/edge to surface = chirping • Creak – (Like walking on an old wooden floor) Creak characteristics include firm contact/slow movement/twisting with a rotational movement/pitch dependent on materials/often brought on by activity. M • Rattle – (Like shaking a baby rattle) Rattle characteristics include the fast repeated contact/vibration or similar movement/loose parts/missing clip or fastener/incorrect clearance. N • Knock – (Like a knock on a door) Knock characteristics include hollow sounding/sometimes repeating/often brought on by driver action. • Tick – (Like a clock second hand) Tick characteristics include gentle contacting of light materials/loose components/can be caused by driver O action or road conditions. • Thump – (Heavy, muffled knock noise) Thump characteristics include softer knock/dead sound often brought on by activity. P • Buzz – (Like a bumblebee) Buzz characteristics include high frequency rattle/firm contact. • Often the degree of acceptable noise level will vary depending up on the person. A noise that a technician may judge as acceptable may be very irritating to the customer. • Weather conditions, especially humidity and temperature, may have a great effect on noise level.

DUPLICATE THE NOISE AND TEST DRIVE


EXT-3

2009 G37 Coupe

SQUEAK AND RATTLE TROUBLE DIAGNOSES < SYMPTOM DIAGNOSIS > If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information on the Diagnostic Worksheet regarding the conditions or location of the noise. This information can be used to duplicate the same conditions when the repair is reconfirmed. If the noise can be duplicated easily during the test drive, to help identify the source of the noise, try to duplicate the noise with the vehicle stopped by doing one or all of the following: 1) Close a door. 2) Tap or push/pull around the area where the noise appears to be coming from. 3) Rev the engine. 4) Use a floor jack to recreate vehicle “twist”. 5) At idle, apply engine load (electrical load, half-clutch on M/T models, drive position on A/T models). 6) Raise the vehicle on a hoist and hit a tire with a rubber hammer. • Drive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs. • If it is difficult to duplicate the noise, drive the vehicle slowly on an undulating or rough road to stress the vehicle body.

CHECK RELATED SERVICE BULLETINS After verifying the customer concern or symptom, check ASIST for Technical Service Bulletins (TSBs) related to that concern or symptom. If a TSB relates to the symptom, follow the procedure to repair the noise.

LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE 1.

Narrow down the noise to a general area. To help pinpoint the source of the noise, use a listening tool (Chassis ear: J-39570, Engine ear and mechanics stethoscope). 2. Narrow down the noise to a more specific area and identify the cause of the noise by: • Removing the components in the area that is are suspected to be the cause of the noise. Do not use too much force when removing clips and fasteners, otherwise clips and fastener can be broken or lost during the repair, resulting in the creation of new noise. • Tapping or pushing/pulling the component that is are suspected to be the cause of the noise. Do not tap or push/pull the component with excessive force, otherwise the noise will be eliminated only temporarily. • Feeling for a vibration by hand by touching the component(s) that is are suspected to be the cause of the noise. • Placing a piece of paper between components that are suspected to be the cause of the noise. • Looking for loose components and contact marks. Refer to EXT-5, "Inspection Procedure".

REPAIR THE CAUSE • • -

If the cause is a loose component, tighten the component securely. If the cause is insufficient clearance between components: Separate components by repositioning or loosening and retightening the component, if possible. Insulate components with a suitable insulator such as urethane pads, foam blocks, felt cloth tape or urethane tape. A Nissan Squeak and Rattle Kit (J-43980) is available through the authorized Nissan Parts Department. CAUTION: Never use excessive force as many components are constructed of plastic and may be damaged. NOTE: Always check with the Parts Department for the latest parts information. The following materials are contained in the Nissan Squeak and Rattle Kit (J-43980). Each item can be ordered separately as needed. URETHANE PADS [1.5 mm (0.059 in) thick] Insulates connectors, harness, etc. • 76268-9E005: 100 × 135 mm (3.937 × 5.315 in) • 76884-71L01: 60 × 85 mm (2.362 × 3.346 in) • 76884-71L02:15 × 25 mm (0.591 × 0.984 in) INSULATOR (Foam blocks) Insulates components from contact. Can be used to fill space behind a panel. • 73982-9E000: 45 mm (1.772 in) thick, 50 × 50 mm (1.969 × 1.969 in) • 73982-50Y00: 10 mm (0.394 in) thick, 50 × 50 mm (1.969 × 1.969 in) INSULATOR (Light foam block) 80845-71L00: 30 mm (1.18 in) thick, 30 × 50 mm (1.181 × 1.969in) FELT CLOTHTAPE Revision: 2009 October

EXT-4

2009 G37 Coupe

SQUEAK AND RATTLE TROUBLE DIAGNOSES < SYMPTOM DIAGNOSIS > Used to insulate where movement does not occur. Ideal for instrument panel applications. • 68370-4B000: 15 × 25 mm (0.591 × 0.984 in) pad • 68239-13E00: 5 mm (0.197 in) wide tape roll The following materials, not found in the kit, can also be used to repair squeaks and rattles. UHMW (TEFLON) TAPE Insulates where slight movement is present. Ideal for instrument panel applications. SILICONE GREASE Used in place of UHMW tape that is be visible or does not fit. Will only last a few months. SILICONE SPRAY Used when grease cannot be applied. DUCT TAPE Used to eliminate movement.

A

B

C

D

CONFIRM THE REPAIR Confirm that the cause of a noise is repaired by test driving the vehicle. Operate the vehicle under the same conditions as when the noise originally occurred. Refer to the notes on the Diagnostic Worksheet.

Inspection Procedure

E

INFOID:0000000004678285

Refer to Table of Contents for specific component removal and installation information.

F

INSTRUMENT PANEL Most incidents are caused by contact and movement between: G 1. The cluster lid A and instrument panel 2. Acrylic lens and combination meter housing 3. Instrument panel to front pillar garnish H 4. Instrument panel to windshield 5. Instrument panel mounting pins 6. Wiring harnesses behind the combination meter I 7. A/C defroster duct and duct joint These incidents can usually be located by tapping or moving the components to duplicate the noise or by pressing on the components while driving to stop the noise. Most of these incidents can be repaired by J applying felt cloth tape or silicon spray (in hard to reach areas). Urethane pads can be used to insulate wiring harness. CAUTION: Never use silicone spray to isolate a squeak or rattle. If the area is saturated with silicone, the EXT recheck of repair becomes impossible.

CENTER CONSOLE

L

Components to pay attention to include: 1. Shifter assembly cover to finisher 2. A/C control unit and cluster lid C 3. Wiring harnesses behind audio and A/C control unit The instrument panel repair and isolation procedures also apply to the center console.

M

N

DOORS Pay attention to the following: 1. Finisher and inner panel making a slapping noise 2. Inside handle escutcheon to door finisher 3. Wiring harnesses tapping 4. Door striker out of alignment causing a popping noise on starts and stops Tapping or moving the components or pressing on them while driving to duplicate the conditions can isolate many of these incidents. The areas can usually be insulated with felt cloth tape or insulator foam blocks from the Nissan Squeak and Rattle Kit (J-43980) to repair the noise.

TRUNK Trunk noises are often caused by a loose jack or loose items put into the trunk by the customer. In addition look for the following: 1. Trunk lid dumpers out of adjustment Revision: 2009 October

EXT-5

2009 G37 Coupe

O

P

SQUEAK AND RATTLE TROUBLE DIAGNOSES < SYMPTOM DIAGNOSIS > 2. Trunk lid striker out of adjustment 3. The trunk lid torsion bars knocking together 4. A loose license plate or bracket Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) causing the noise.

SUNROOF/HEADLINING Noises in the sunroof/headlining area can often be traced to one of the following: 1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise 2. Sunvisor shaft shaking in the holder 3. Front or rear windshield touching headlining and squeaking Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these incidents. Repairs usually consist of insulating with felt cloth tape.

SEATS When isolating seat noise it's important to note the position the seats in and the load placed on the seat when the noise occurs. These conditions should be duplicated when verifying and isolating the cause of the noise. Cause of seat noise include: 1. Headrest rods and holder 2. A squeak between the seat pad cushion and frame 3. The rear seatback lock and bracket These noises can be isolated by moving or pressing on the suspected components while duplicating the conditions under which the noise occurs.Most of these incidents can be repaired by repositioning the component or applying urethane tape to the contact area.

UNDERHOOD Some interior noise may be caused by components under the hood or on the engine wall. The noise is then transmitted into the passenger compartment. Causes of transmitted underhood noise include: 1. Any component mounted to the engine wall 2. Components that pass through the engine wall 3. Engine wall mounts and connectors 4. Loose radiator mounting pins 5. Hood bumpers out of adjustment 6. Hood striker out of adjustment These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or insulating the component causing the noise.


EXT-6

2009 G37 Coupe


Diagnostic Worksheet

INFOID:0000000004678286

A

B

C

D

E

F

G

H

I

J

EXT

L

M

N

O

PIIB8741E


EXT-7

2009 G37 Coupe

P


PIIB8742E


EXT-8

2009 G37 Coupe


PRECAUTION

A


B

INFOID:0000000004249853



C

D

E

F

G

H

I

J




2. 3. 4.



EXT-9

2009 G37 Coupe

EXT

L

M

N

O

P

PRECAUTIONS < PRECAUTION > 5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock when the push-button ignition switch is turned to LOCK position.) 6. Perform self-diagnosis check of all control units using CONSULT-III.


INFOID:0000000004678292



INFOID:0000000004249855


PIIB3706J

Precaution for Work

INFOID:0000000004249856

• After removing and installing the opening/closing parts, be sure to carry out fitting adjustments to check their operation. • Check the lubrication level, damage, and wear of each part. If necessary, grease or replace it.


EXT-10

2009 G37 Coupe


PREPARATION

A

PREPARATION Special Service Tools

INFOID:0000000004249857

B

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. C

Tool number (Kent-Moore No.) Tool name

Description

D

(J-39570) Chassis ear

E

Locates the noise

F

SIIA0993E

G

(J-43980) NISSAN Squeak and Rattle Kit

Repaires the cause of noise

H SIIA0994E


INFOID:0000000004249858

Tool name

Description

Engine ear

I

J

EXT

Locates the noise

L SIIA0995E

M Remover tool

Removes clips, pawls and metal clips

N JMKIA3050ZZ

O

Power tool

P

PIIB1407E


EXT-11

2009 G37 Coupe

FRONT BUMPER < REMOVAL AND INSTALLATION >

REMOVAL AND INSTALLATION FRONT BUMPER Exploded View

INFOID:0000000004249859

JMKIA1225ZZ

1.

Bumper bracket RH

2.

Hood seal assembly (front)

3.

Bumper side bracket RH

4.

Bumper side stiffener RH

5.

Bumper finisher RH

6.

License plate bracket

7.

Front grille

Bumper side stiffener LH

8.

J-nut

9.

10. Bumper finisher LH

11.

Bumper bracket LH

12. Bumper reinforcement

13. Energy absorber

14.

Bumper fascia assembly (normal)

15. Grommet


EXT-12

2009 G37 Coupe

FRONT BUMPER < REMOVAL AND INSTALLATION > 16. Bumper side bracket LH

17.

Bumper finisher (center)

18. Bumper bracket cover

A

19. Bumper fascia assembly (sports) : Clip : Pawl

B


INFOID:0000000004249860

REMOVAL

C

CAUTION: Bumper fascia is made of resin. Never apply strong force to it, and be careful to prevent contact with oil. 1. Fully open hood assembly. 2. Remove clips (A) of front bumper fascia upper side.

D

E

F

G

JMKIA1226ZZ

3. 4.

Remove radiator core support ornament. Refer to DLK-212, "Removal and Installation". Remove clips (A) of hood seal assembly (side) (LH/RH) with remover tool (B), and then remove hood seal assembly located front portion. Refer to DLK-215, "Removal and Installation".

H

I

J

EXT JMKIA1227ZZ

L

5.

Remove bolts (A), and then remove bumper bracket (1) (LH/ RH). M

N

O JMKIA1228ZZ

P


EXT-13

2009 G37 Coupe

FRONT BUMPER < REMOVAL AND INSTALLATION > 6. Remove bolts (A) of fixing engine lower cover and front fender protector.

JMKIA1229ZZ

7.

Remove fender protector (front) mounting bolts and clips, and then remove screw (A) of fixing bumper fascia left and right side.

JMKIA1230ZZ

8.

Pull the bumper fascia side toward the vehicle side to disengage the fitting of bumper side bracket and bumper fascia side.

JMKIA1231ZZ

9.

Remove bumper fascia assembly. CAUTION: When removing bumper fascia, 2 workers are required so as to prevent it from dropping. 10. Remove the following parts after removing bumper fascia. • Front grille • Hood seal assembly (front) • License plate bracket • Front bumper side bracket (LH/RH) • Front bumper side stiffener (LH/RH) • Front bumper finisher 11. Remove bumper energy absorber. 12. Remove bumper reinforcement mounting nuts and bolts, and then remove bumper reinforcement with power tool.

INSTALLATION Install in the reverse order of removal. NOTE: After installing, perform fitting adjustment. Portion

Clearance

Front bumper – Hood assembly

A–A

2.0 – 4.5 mm (0.079 – 0.177 in)

Front bumper – Front grille

B–B

0.2 – 2.8 mm (0.008 – 0.110 in)


EXT-14

2009 G37 Coupe

FRONT BUMPER < REMOVAL AND INSTALLATION > Portion

Clearance

Front bumper – Headlamp

C–C

0.5 – 3.2 mm (0.020 – 0.126 in)

Front bumper – Front fender

D–D

0.0 – 0.7 mm (0.000 – 0.028 in)

Front bumper – Headlamp

E–E

0.3 – 3.2 mm (0.012 – 0.126 in)


F–F

0.0 – 0.7 mm (0.000 – 0.028 in)


G–G

0.0 – 0.8 mm (0.000 – 0.031 in)

A

B

C

D

E

F

G

H

I

J

EXT

L

M

N

O

P


EXT-15

2009 G37 Coupe

REAR BUMPER < REMOVAL AND INSTALLATION >

REAR BUMPER Exploded View

INFOID:0000000004249861

JMKIA1232ZZ

1.

Bumper side bracket RH

4.

Bumper stay LH

5.

Rivet

6.

Bumper side bracket LH

7.

Bumper energy absorber

8.

Bumper fascia assembly

9.

Rear license plate bracket

10. Grommet

2.

Bumper stay RH

11. License lamp bracket

3.

Bumper lower retainer

12. Bumper reinforcement

: Clip


EXT-16

2009 G37 Coupe

REAR BUMPER < REMOVAL AND INSTALLATION > : Pawl

A



INFOID:0000000004249862

B

REMOVAL CAUTION: Bumper fascia is made of resin. Never apply strong force to it, and be careful to prevent contact with oil. 1. Fully open trunk lid assembly. 2. Remove rear combination lamp (LH/RH). Refer to EXL-203, "Removal and Installation". 3. Remove clips (A) located under rear combination lamp (LH/RH).

C

D

E

F

G JMKIA1233ZZ

4.

Remove bolts (A) of bumper fascia underside (LH/RH).

H

I

J

JMKIA1234ZZ

5.

EXT

Remove screws (A) of bumper fascia front end upper (LH/RH). L

M

N JMKIA0095GB

6.

Remove clips of bumper fascia underside, and then pull out bumper fascia toward rear of vehicle.

O

P


EXT-17

2009 G37 Coupe

REAR BUMPER < REMOVAL AND INSTALLATION > 7. Disconnect license plate lamp connector (A).

JMKIA0096GB

8.

Pull the bumper fascia side toward the vehicle side to disengage the fitting of bumper side bracket and bumper fascia side.

JMKIA1235ZZ

9.

10.

11. 12. 13.

Remove bumper fascia assembly. CAUTION: When removing bumper fascia, 2 workers are required so as to prevent it from dropping. Remove the following parts after removing bumper fascia. • License plate lamp. Refer to EXL-207, "Removal and Installation". • License lamp bracket. • License plate bracket. • Bumper lower retainer. Remove bumper energy absorber. Remove license lamp harness clamps of bumper reinforcement. Remove bumper reinforcement mounting nuts and bolts, and then remove bumper reinforcement with power tool.

INSTALLATION Install in the reverse order of removal. NOTE: After installing, perform fitting adjustment. Portion

Clearance

Rear bumper – Trunk lid

A–A

4.0 – 8.0 mm (0.157 – 0.315 in)

Rear bumper – Rear combination lamp

B–B

0.0 – 3.0 mm (0.000 – 0.118 in)

Rear bumper – Rear fender

C–C

0.0 – 0.8 mm (0.000 – 0.031 in)

Rear bumper – Rear fender

D–D

0.0 – 0.8 mm (0.000 – 0.031 in)


EXT-18

2009 G37 Coupe

FRONT GRILLE < REMOVAL AND INSTALLATION >

FRONT GRILLE

A

Exploded View

INFOID:0000000004249863

B

C

D

E

F

G

H

I

J JMKIA1236ZZ

1.

Front grille

2.

EXT

Front emblem

: Pawl


INFOID:0000000004249864

L

REMOVAL CAUTION: Apply protection tape around outer circumference of front grille (bumper fascia side). 1. Fully open hood assembly. 2. Remove reservoir tank. Refer to CO-14, "Removal and Installation". 3. Remove radiator core support ornament. Refer to DLK-212, "Removal and Installation". 4. Remove front grille mounting nuts (A).

M

N

O

P

JMKIA0097GB


EXT-19

2009 G37 Coupe

FRONT GRILLE < REMOVAL AND INSTALLATION > 5. Disengage pawls (A) of fixing front grille. : Pawl

JMKIA0098GB

6. 7.

Pull front grille out toward vehicle front. Remove the following parts after removing front grille. Front emblem



EXT-20

2009 G37 Coupe

COWL TOP < REMOVAL AND INSTALLATION >

COWL TOP

A

Exploded View

INFOID:0000000004249865

B

C

D

E

F

G

H

I

J

EXT

L

M JMKIA1507ZZ

N 1.

Front fender cover (RH)

2.

Cowl top seal

3.

Front fender cover (LH)

4.

Cowl top cover (RH)

5.

Cowl top cover (LH)

6.

Cowl top cover seal (RH)

7.

Cowl top cover seal (LH)

8.

Battery cover

9.

Brake master cylinder cover

10. Hoodledge cover (RH)

11. Hoodledge cover (LH)

O

12. EPT sealer

: Clip

P

: Pawl Refer to GI-4, "Components" for symbols in the figure.


INFOID:0000000004249866

REMOVAL 1.

Fully open hood assembly.


EXT-21

2009 G37 Coupe

COWL TOP < REMOVAL AND INSTALLATION > 2. Remove front wiper arm (LH/RH) from vehicle. Refer to WW-93, "Removal and Installation". 3. Remove battery cover and brake master cylinder cover. 4. Remove hoodledge cover mounting clips and then remove hoodledge cover (LH/RH) and cowl top cover seal (LH/RH). 5. Remove cowl top seal. 6. Remove cowl top cover mounting clips. 7. Plastic pawl (A) is pull up and cowl top cover RH (2) is removed ahead of vehicles.

JMKIA0099GB

8.

Plastic pawl (B) is push down and cowl top cover LH (1) is removed ahead of vehicles.

JMKIA0100GB

9.

Remove the following parts after removing cowl top cover. • Front fender cover (LH/RH). • EPT sealer.

INSTALLATION Note the following, and install in the reverse order of removal. • Install cowl top cover LH (1) with (C) (pin from front windshield glass) aligned with concave part.

JMKIA0104GB


EXT-22

2009 G37 Coupe

COWL TOP < REMOVAL AND INSTALLATION > • Slide the pawl while aligning with the concave part of (E). • Engage the joint of plastic pawl of (A) with (D), and then assemble cowl top covers LH (1) and RH (2).

A

B

C JMKIA0105GB

D

CAUTION: After installing, perform adjustment of wiper arm. Refer to WW-93, "Adjustment". E

F

G

H

I

J

EXT

L

M

N

O

P


EXT-23

2009 G37 Coupe

FENDER PROTECTOR < REMOVAL AND INSTALLATION >

FENDER PROTECTOR FENDER PROTECTOR FENDER PROTECTOR : Exploded View

INFOID:0000000004249867

JMKIA1237ZZ

1.

Fender protector (front)

2.

Fender protector (rear)

3.

J-nut

4.

Fairing

5.

Splash guard

6.

Front fender

7.

Fender clip

8.

Grommet

FENDER PROTECTOR : Removal and Installation

INFOID:0000000004249868

REMOVAL 1. 2.

Remove bolt (A) of fender protector (rear) rear end. Remove screws (B) of fender protector (rear) located center mud guard and front fender.

JMKIA0106GB

3. 4.

Remove clips of fender protector (rear). Remove fender clip from wheelhouse arches, and then remove fender protector (rear) from wheel house.


EXT-24

2009 G37 Coupe

FENDER PROTECTOR < REMOVAL AND INSTALLATION > 5. Remove bolts (A) of fender protector (front) located engine under cover and front bumper.

A

B

C JMKIA0107GB

D

6. 7. 8.

Remove fender protector (front) mounting clips. Remove fender clip from wheel house arches, and then remove fender protector (front) from wheel house. Remove the following parts after removing front fender protector. • Fairing • Fender clip

INSTALLATION

E

F

Install in the reverse order of removal.

REAR WHEEL HOUSE PROTECTOR REAR WHEEL HOUSE PROTECTOR : Exploded View

G INFOID:0000000004249869

H

I

J

EXT

L

M

N

O

P JMKIA1238ZZ

1.

Rear wheel house protector

REAR WHEEL HOUSE PROTECTOR : Removal and Installation

INFOID:0000000004249870

REMOVAL Revision: 2009 October

EXT-25

2009 G37 Coupe

FENDER PROTECTOR < REMOVAL AND INSTALLATION > 1. Remove bolt (A) of rear wheel house protector rear end.

JMKIA1239ZZ

2.

Remove screw (A) of rear wheel house protector located center mud guard.

JMKIA1240ZZ

3.

Remove rear wheel house protector mounting nuts and then remove rear wheel house protector.



EXT-26

2009 G37 Coupe

CENTER MUD GUARD < REMOVAL AND INSTALLATION >

CENTER MUD GUARD

A

Exploded View

INFOID:0000000004249871

B

C

D

E

F

G

H

I

J

EXT

L JMKIA1241ZZ

1.

Body side outer

4.

Center mud guard

2.

Grommet

3.


Wind deflector

M

INFOID:0000000004613636

N

REMOVAL 1.

Remove wind deflector mounting clip (A) and nuts (B), and then remove wind deflector (1).

O

P

JMKIA1242ZZ


EXT-27

2009 G37 Coupe

CENTER MUD GUARD < REMOVAL AND INSTALLATION > 2. Remove screw (A) and bolt (B) of center mud guard front end.

JMKIA0111GB

3.

Remove screw (A) of center mud guard rear end.

JMKIA1243ZZ

4. 5. 6. 7.

Remove screws of center mud guard underside. Fully open front door. Remove clips from back of center mud guard using remover tool. Remove center mud guard from body side.

INSTALLATION Install in the reverse order of removal. CAUTION: When installing center mud guard, chack that clips are securely fitted in panel holes on body, and then press them in.


EXT-28

2009 G37 Coupe

FLOOR SIDE FAIRING < REMOVAL AND INSTALLATION >

FLOOR SIDE FAIRING

A

Exploded View

INFOID:0000000004249873

B

C

D

E

F

G

H

I

J JMKIA1244ZZ

1.

Engine lower cover

2.

Front under cover

3.

Floor under cover RH

4.

Floor under cover LH

5.

Rear under cover RH

6.

Rear under cover LH


EXT

INFOID:0000000004249874

L

REMOVAL M

ENGINE LOWER COVER

1. 2. 3.

Remove engine lower cover mounting clips. Remove engine lower cover mounting bolts with power tool. Remove engine lower cover.

N

FRONT UNDER COVER

1. 2. 3.

Remove front under cover mounting clips. Remove front under cover mounting bolts with power tool. Remove front under cover.

O

P

FLOOR UNDER COVER (LH/RH)

1. 2. 3.

Remove floor under cover mounting clips. Remove floor under cover mounting bolts and nuts with power tool. Remove floor under cover.

REAR UNDER COVER (LH/RH)

1.

Remove rear under cover mounting bolts.


EXT-29

2009 G37 Coupe

FLOOR SIDE FAIRING < REMOVAL AND INSTALLATION > 2. Remove rear under cover.



EXT-30

2009 G37 Coupe

ROOF SIDE MOLDING < REMOVAL AND INSTALLATION >

ROOF SIDE MOLDING

A

Exploded View

INFOID:0000000004249875

B

C

D

E

F

G

H

I

J JMKIA1774ZZ

1.

Roof side molding

4.

Roof panel

2.

Roof side molding clip

3.

EXT

Body side panel


INFOID:0000000004249876

L

REMOVAL Disengage roof side molding (1) fixing clips with remover tool (A). CAUTION: Wrap the tip of remover tool (A) with a cloth (B).

M

N

: Clip

O

JMKIA1246ZZ

INSTALLATION Install from roof side molding rear end to front end in this order after temporarily holding.

REMOVAL AND INSTALLATION OF ROOF SIDE MOLDING CLIP Removal

1.

Remove roof side molding.


EXT-31

2009 G37 Coupe

P

ROOF SIDE MOLDING < REMOVAL AND INSTALLATION > 2. Heat adhesive tape interface using a dryer, and then peel roof side molding clips (body side) using longnose pliers. CAUTION: Be careful not to damage the body. Installation

1. 2.

Clean tape removed surface with a shop cloth soaked in white gasoline or IPA. Use two-part epoxy adhesive. Adhesive

3.

Apply adhesive evenly to clip tape surface. Thickness

4.

: 3M–weld DP-100 or equivalent

: Approximately 0.5 mm (0.020 in)

Position applied parts to the proper location, and then sufficiently press-fit until the adhesive protrudes to tape side. Press-fit limit : 19.6 N × 2 seconds

5.

Tape clips after press fit, and temporarily hold it for specified time based on the following. 5 to 10°C (41 to 50°F) 11 to 23°C (52 to 73°F) 24°C or more (75°F or more)

: 1 hour or more : 30 minutes or more : 15 minutes or more

6. Install from roof side molding rear end to front end in this order after temporarily holding. CAUTION: • Use double-faced adhesive tape after hardening for clips. • Securely insert molding rear end cap onto roof rear end cutout (installation standard). • When installing roof side molding of windshield portion, check that molding fastener is securely inserted and then press in. • Never wash the vehicle with in 24 hours so as to keep adhesive.


EXT-32

2009 G37 Coupe

FRONT PILLAR FINISHER < REMOVAL AND INSTALLATION >

FRONT PILLAR FINISHER

A

Exploded View

INFOID:0000000004249877

B

C

D

E

F

G

H

I

J JMKIA1509ZZ

1.

Front pillar finisher

2.

Body side weather-strip retainer

4.

Grommet

5.

Body side outer

3.

EXT

Body side weather-strip

: Clip

L



INFOID:0000000004249878

M

Removal 1. 2. 3.

Remove clip and double faced adhesive tapes of body side weather-strip. Remove body side weather-strip. Remove body side weather-strip retainer (1) mounting screws (A) and clip (B), and then remove body side weather-strip retainer (1).

N

O

P

JMKIA1248ZZ


EXT-33

2009 G37 Coupe

FRONT PILLAR FINISHER < REMOVAL AND INSTALLATION > 4. Remove front pillar finisher (1) fixing clips with remover tool (A). : Clip

JMKIA1249ZZ

5.

Remove front pillar finisher.

Installation Install in the reverse order of removal.


EXT-34

2009 G37 Coupe

DOOR OUTSIDE MOLDING < REMOVAL AND INSTALLATION >

DOOR OUTSIDE MOLDING

A

Exploded View

INFOID:0000000004249879

B

C

D

E

F

G

H

I

J JMKIA1250ZZ

1.

Door outside molding

2.

EXT

Door panel assembly



INFOID:0000000004249880

L

Remove door finisher. Refer to INT-11, "Removal and Installation". Remove door mirror assembly. Refer to MIR-18, "DOOR MIRROR ASSEMBLY : Removal and Installation". Twists and pull up to upper side, and then remove front door outside molding (1).

M

REMOVAL 1. 2. 3.

N

O

P

JMKIA0116GB

INSTALLATION Install in the reverse order of removal. Revision: 2009 October

EXT-35

2009 G37 Coupe

DOOR PARTING SEAL < REMOVAL AND INSTALLATION >

DOOR PARTING SEAL Exploded View

INFOID:0000000004249881

JMKIA1251ZZ

1.

Door parting seal

2.

Door panel assembly

: Clip


INFOID:0000000004249882

REMOVAL 1. 2. 3.

Fully open door. Remove door parting seal mounting plastic clips with remover tool. Remove door parting seal.



EXT-36

2009 G37 Coupe

TRUNK LID FINISHER < REMOVAL AND INSTALLATION >

TRUNK LID FINISHER

A

TRUNK LID OUTER FINISHER TRUNK LID OUTER FINISHER : Exploded View

INFOID:0000000004249883

B

C

D

E

F

G

H

I

J

JMKIA1252ZZ

1.

Trunk lid finisher outer

2.

Trunk lid panel assembly

3.

Rivet

4.

Trunk drip cover RH

5.

Trunk drip cover LH

6.

Double-faced adhesive tape [t: 4.0 mm (0.157 in)]

7.


EXT

L

M

: Clip : Metal clip Refer to GI-4, "Components" for symbols in the figure.

N

TRUNK LID OUTER FINISHER : Removal and Installation

INFOID:0000000004249884

O

REMOVAL 1. 2.

Fully open trunk lid. Remove trunk lid trim. Refer to INT-29, "Removal and Installation".


EXT-37

P

2009 G37 Coupe

TRUNK LID FINISHER < REMOVAL AND INSTALLATION > 3. Remove trunk lid finisher outer mounting nuts (A).

JMKIA1253ZZ

4. 5.

Apply protection tape (A) around outer circumference of trunk lid finisher outer (1). Remove trunk lid finisher outer, using remover tool (B). : Clip

CAUTION: Be careful not to damage the body.

JMKIA1254ZZ

INSTALLATION Install in the reverse order of removal. CAUTION: • Install after cleaning adhesive parts of body side and back of finisher outer. • When installing door finisher, check that clips are securely fitted in panel holes on body, and thenpress them in.

TRUNK DRIP COVER


EXT-38

2009 G37 Coupe

TRUNK LID FINISHER < REMOVAL AND INSTALLATION >

TRUNK DRIP COVER : Exploded View

INFOID:0000000004249885

A

B

C

D

E

F

G

H

I

JMKIA1252ZZ

1.

Trunk lid finisher outer

2.


3.

Rivet

4.

Trunk drip cover RH

5.

Trunk drip cover LH

6.


7.


J

EXT

L

: Clip : Metal clip Refer to GI-4, "Components" for symbols in the figure.

M

TRUNK DRIP COVER : Removal and Installation

INFOID:0000000004249886

N

REMOVAL 1. 2.

Fully open trunk lid. Remove double-faced adhesive tape (A) of trunk drip cover (1) with remover tool (B).

O

P

JMKIA1258ZZ


EXT-39

2009 G37 Coupe

TRUNK LID FINISHER < REMOVAL AND INSTALLATION > 3. Disengage trunk drip cover (1) fixing clip using remover tool (A). : Clip

JMKIA1262ZZ

4.

Disengage trunk drip cover (1) fixing metal clip using remover tool (A). : Metal clip

JMKIA1263ZZ

5.

Slide forward then remove drip cover (1).

JMKIA1264ZZ

INSTALLATION Install in the reverse order of removal. CAUTION: • Double-faced adhesive tape is not reusable, always use new double-faced adhesive tape. • Never wash vehicle with in 24 hours after installation.


EXT-40

2009 G37 Coupe

REAR SPOILER < REMOVAL AND INSTALLATION >

REAR SPOILER

A

Exploded View

INFOID:0000000004249887

B

C

D

E

F

G

H

I

J

EXT

L

M JMKIA1259ZZ

N 1.

Rear spoiler assembly

2.


3.

Grommet

4.

Rear view camera assembly

5.

High-mounted stop lamp

6.

Double-faced adhesive tape [t: 2.0mm (0.079 in)]

O

: Clip Refer to GI-4, "Components" for symbols in the figure.

P


INFOID:0000000004249888

REMOVAL 1.

Remove trunk lid trim. Refer to INT-29, "Removal and Installation".


EXT-41

2009 G37 Coupe

REAR SPOILER < REMOVAL AND INSTALLATION > 2. Disconnect harness connector (A) of high-mounted stop lamp. 3. Disconnect harness connector (B) of rear view camera. 4. Remove bolt (C).

JMKIA1261ZZ

5.

Remove rear spoiler mounting nuts (A).

JMKIA1260ZZ

6. 7. 8. 9.

Release rear spoiler connection between trunk lid panel and rear spoiler, using a remover tool, and take off double-faced adhesive tape. Disengage rear spoiler mounting clip, and then disconnect grommets of high-mounted stop lamp harness and rear view camera harness. Remove rear spoiler. Remove following parts after removing rear spoiler. • High-mounted stop lamp. Refer to EXL-205, "WITH REAR SPOILER : Removal and Installation". • Rear view camera. Refer to AV-638, "Removal and Installation". • Rear spoiler clip and grommet.

INSTALLATION Install in the reverse order of removal. CAUTION: • Be careful not to damage the body. • Never let air between contact surfaces when installing. • Never wash vehicle within 24 hours after installation.


EXT-42

2009 G37 Coupe

TRANSMISSION & DRIVELINE

SECTION

FAX

FRONT AXLE

A

B

C

FAX

E

CONTENTS 2WD

NVH Troubleshooting Chart ...................................... 3

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" .................................................................10 Precaution Necessary for Steering Wheel Rotation after Battery Disconnect ...................................10 Precaution for Procedure without Cowl Top Cover....11 Precautions for Drive Shaft ......................................11

PREPARATION ............................................ 4

PREPARATION ........................................... 12

PREPARATION ................................................... 4

PREPARATION ................................................. 12

Commercial Service Tool .......................................... 4

Special Service Tool ................................................12 Commercial Service Tool ........................................13

SYMPTOM DIAGNOSIS ............................... 3 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ............................. 3

PERIODIC MAINTENANCE .......................... 5 FRONT WHEEL HUB AND KNUCKLE .............. 5 Inspection .................................................................. 5

REMOVAL AND INSTALLATION ................ 6 FRONT WHEEL HUB AND KNUCKLE .............. 6 Exploded View .......................................................... 6 Removal and Installation ........................................... 6 Inspection .................................................................. 7

SERVICE DATA AND SPECIFICATIONS (SDS) ............................................................. 8

PERIODIC MAINTENANCE ........................ 14 Inspection ................................................................14

PRECAUTION .............................................. 10

K

L

FRONT WHEEL HUB AND KNUCKLE ............ 16 Exploded View .........................................................16 Removal and Installation .........................................16 Inspection ................................................................17

M

N

O

FRONT DRIVE SHAFT ..................................... 22 Exploded View .........................................................22 Removal and Installation .........................................23 Disassembly and Assembly .....................................23 Inspection ................................................................26

SERVICE DATA AND SPECIFICATIONS (SDS) ............................................................ 28

PRECAUTIONS ..................................................10


J


Exploded View .........................................................18 Replacement ...........................................................18

NVH Troubleshooting Chart ...................................... 9

I

Inspection ................................................................15

Wheel Bearing ........................................................... 8

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ............................. 9

H

FRONT DRIVE SHAFT ..................................... 15

FRONT DRIVE SHAFT BOOT .......................... 18

SYMPTOM DIAGNOSIS ............................... 9

G

FRONT WHEEL HUB AND KNUCKLE ............ 14

SERVICE DATA AND SPECIFICATIONS (SDS) ................................................................... 8

AWD

F

FAX-1

2009 G37 Coupe

P

SERVICE DATA AND SPECIFICATIONS (SDS) .................................................................. 28


Wheel Bearing ........................................................ 28 Drive Shaft .............................................................. 28

FAX-2

2009 G37 Coupe

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING [2WD]


SYMPTOM DIAGNOSIS

A

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart

INFOID:0000000004670017

B

NVH in ST section

NVH in BR section

NVH in WT section

NVH in WT section

FRONT AXLE AND FRONT SUSPENSION

TIRE

ROAD WHEEL

BRAKE

STEERING

NVH in FAX and FSU sections

Wheel bearing damage

FAX-5

Parts interference

FRONT AXLE

×

×

×

×

×

×

×

×

Shake

×

×

×

×

×

×

×

×

Vibration

×

×

×

×

×

Shimmy

×

×

×

×

×

×

×

Judder

×

×

×

×

×

×

Poor quality ride or handling

×

×

×

×

×

FAX

E

F

Noise

Possible cause and SUSPECTED PARTS

Symptom

C

Improper installation, looseness

Reference page

—

FAX-6

Use chart below to find the cause of the symptom. If necessary, repair or replace these parts.

G

H

I

J

K

×

×: Applicable

L

M

N

O

P


FAX-3

2009 G37 Coupe

PREPARATION [2WD]

< PREPARATION >

PREPARATION PREPARATION Commercial Service Tool

INFOID:0000000004670018

Tool name

Description

Power tool


PBIC0190E


FAX-4

2009 G37 Coupe

FRONT WHEEL HUB AND KNUCKLE [2WD]

< PERIODIC MAINTENANCE >


A

FRONT WHEEL HUB AND KNUCKLE Inspection

INFOID:0000000004670019

B

Make sure that the mounting conditions (looseness, backlash) of each component and component conditions (wear, damage) are normal.

C

MOUNTING INSPECTION

WHEEL BEARING INSPECTION • Move wheel hub and bearing assembly in the axial direction by hand. Make sure there is no looseness of FAX wheel bearing. Standard Axial end play

E

: Refer to FAX-8, "Wheel Bearing".

• Rotate wheel hub and bearing assembly and make sure that is no unusual noise or other irregular conditions. If there is any of irregular conditions, replace wheel hub and bearing assembly.

F

G

H

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K

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M

N

O

P


FAX-5

2009 G37 Coupe

FRONT WHEEL HUB AND KNUCKLE [2WD]


REMOVAL AND INSTALLATION FRONT WHEEL HUB AND KNUCKLE Exploded View

INFOID:0000000004670020

JPDIF0166GB

1.

Steering knuckle

2.

Ball seat

3.

4.

Splash guard

5.

Wheel hub and bearing assembly

Cotter pin



INFOID:0000000004670021

REMOVAL Wheel Hub and Bearing Assembly

1. 2.

3.

4.

5.

Remove tires from vehicle with power tool. Remove wheel sensor from steering knuckle. Refer to BRC-100, "Exploded View". CAUTION: Never pull on wheel sensor harness. Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work. Refer to BR-45, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : Exploded View" (1 piston type), BR-53, "BRAKE CALIPER ASSEMBLY (4 PISTON TYPE) : Exploded View" (4 piston type). CAUTION: Never depress brake pedal while brake caliper is removed. Remove disc rotor. Refer to BR-46, "BRAKE CALIPER ASSEMBLY (1 PISTON TYPE) : Removal and Installation" (1 piston type), BR-54, "BRAKE CALIPER ASSEMBLY (4 PISTON TYPE) : Removal and Installation" (4 piston type). Remove wheel hub and bearing assembly mounting bolts, and then remove splash guard and wheel hub and bearing assembly from steering knuckle.

Steering Knuckle

1. 2.

Remove wheel hub and bearing assembly, and then remove splash guard. Remove brake hose bracket. Refer to BR-21, "FRONT : Exploded View".


FAX-6

2009 G37 Coupe

FRONT WHEEL HUB AND KNUCKLE [2WD] < REMOVAL AND INSTALLATION > 3. Remove cotter pin (1) of steering outer socket, and then loosen the nut. A 4. Remove steering outer socket (2) from steering knuckle (3) so as not to damage ball joint boot (4) using the ball joint remover. CAUTION: B Temporarily tighten the nut to prevent damage to threads and to prevent the ball joint remover from suddenly coming off. C 5. Remove cotter pin of transverse link and steering knuckle, and then loosen nut. SGIA1183E 6. Separate upper link from steering knuckle. FAX 7. Separate transverse link from steering knuckle so as not to damage ball joint boot using the ball joint remover. CAUTION: Temporarily tighten the nut to prevent damage to threads and to prevent the ball joint remover E from suddenly coming off. 8. Remove steering knuckle form vehicle. F

INSTALLATION Note the following, and install in the reverse order of the removal. • Perform the final tightening of each of parts under conditions, which were removed when removing wheel hub and bearing assembly and steering knuckle. • Never reuse cotter pin.

Inspection

INFOID:0000000004670022

G

H

INSPECTION AFTER REMOVAL Check components for deformation, cracks, and other damage. Replace if necessary.

I

Ball Joint Inspection Check boots of transverse link and steering outer socket ball joint for breakage, axial play, and torque. Refer to FSU-7, "Inspection" and ST-36, "2WD : Inspection".

J

INSPECTION AFTER INSTALLATION • Check wheel sensor harness for proper connection. Refer to BRC-100, "Exploded View". • Check wheel alignment. Refer to FSU-8, "Inspection". • Adjust neutral position of steering angle sensor. Refer to BRC-8, "ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Special Repair Requirement".

K

L

M

N

O

P


FAX-7

2009 G37 Coupe

SERVICE DATA AND SPECIFICATIONS (SDS) [2WD]

< SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Wheel Bearing

INFOID:0000000004670023

Item

Standard

Axial end play


0.05 mm (0.002 in) or less

FAX-8

2009 G37 Coupe

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING [AWD]


SYMPTOM DIAGNOSIS

A


INFOID:0000000004670024

B

Symptom FRONT AXLE

NVH in ST section

NVH in BR section BRAKE

STEERING

Refer to DRIVE SHAFT in this chart.

NVH in WT section ROAD WHEEL

NVH in WT section

Refer to Front axle in this chart.

NVH in FAX and FSU sections

FAX-14 ×

×

×

×

×

×

×

×

×

×

×

×

×

×

H

I

Noise

×

×

×

×

×

×

×

×

×

Shake

×

×

×

×

×

×

×

×

×

Vibration

×

×

×

×

×

Shimmy

×

×

×

×

×

×

×

Judder

×

×

×

×

×

×


×

×

×

×

×

E

G

DRIVE SHAFT

—

FAX-16

— ×

TIRE

×

FRONT AXLE

Shake

FAX

F


×

Parts interference

×

C

Wheel bearing damage

DRIVE SHAFT


Joint sliding resistance

Noise


Imbalance

Excessive joint angle

Reference page

FAX-26

—


×

J

K

L

×

×: Applicable

M

N

O

P


FAX-9

2009 G37 Coupe

PRECAUTIONS [AWD]

< PRECAUTION >


INFOID:0000000004679102






2. 3. 4.



FAX-10

2009 G37 Coupe

PRECAUTIONS [AWD] < PRECAUTION > 5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock when the push-button ignition switch is turned to LOCK position.) 6. Perform self-diagnosis check of all control units using CONSULT-III.

A


B

INFOID:0000000004679106


C

FAX

E PIIB3706J

F

Precautions for Drive Shaft

INFOID:0000000004670028

• • • • • •

Observe the following precautions when disassembling and assembling drive shaft. Never disassemble joint sub-assembly because it is non-overhaul parts. Perform work in a location which is as dust-free as possible. Clean the parts, before disassembling and assembling. Prevent the entry of foreign objects during disassembly of the service location. Reassemble disassembled parts carefully in the correct order. If work is interrupted, a clean cover must be placed over parts. • Use paper waste. Fabric shop cloths must not be used because of the danger of lint adhering to parts. • Clean disassembled parts (except for rubber parts) with kerosene which shall be removed by blowing with air or wiping with paper waste.

G

H

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K

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M

N

O

P


FAX-11

2009 G37 Coupe

PREPARATION [AWD]

< PREPARATION >


INFOID:0000000004670029


Description Installing boot band

KV40107300 ( − ) Boot band crimping tool

ZZA1229D

Removing drive shaft

KV40107500 ( − ) Drive shaft attachment

ZZA1230D

Installing drive shaft

KV38107900 ( − ) Protector a: 32 mm (1.26 in) dia.

PDIA1183J

Installing drive shaft plug

KV38100500 ( − ) Drift a: 80 mm (3.15 in) dia. b: 60 mm (2.36 in) dia.

ZZA0701D

Installing drive shaft plug

KV38102200 ( − ) Drift a: 90 mm (3.54 in) dia. b: 31 mm (1.22 in) dia.

ZZA0920D


FAX-12

2009 G37 Coupe

PREPARATION [AWD]

< PREPARATION >


INFOID:0000000004670030

A Tool name

Description

Power tool


B

C

FAX

PBIC0190E

E

F

G

H

I

J

K

L

M

N

O

P


FAX-13

2009 G37 Coupe

FRONT WHEEL HUB AND KNUCKLE [AWD]


PERIODIC MAINTENANCE FRONT WHEEL HUB AND KNUCKLE Inspection

INFOID:0000000004670031

MOUNTING INSPECTION Make sure that the mounting conditions (looseness, backlash) of each component and component conditions (wear, damage) are normal.

WHEEL BEARING INSPECTION • Move wheel hub and bearing assembly in the axial direction by hand. Make sure there is no looseness of wheel bearing. Standard Axial end play

: Refer to FAX-28, "Wheel Bearing".

• Rotate wheel hub and bearing assembly and make sure that is no unusual noise or other irregular conditions. If there is any of irregular conditions, replace wheel hub and bearing assembly.


FAX-14

2009 G37 Coupe

FRONT DRIVE SHAFT [AWD]


FRONT DRIVE SHAFT

A

Inspection

INFOID:0000000004670032

• Check drive shaft mounting point and joint for looseness and other damage. • Check boot for cracks and other damage. CAUTION: Replace entire drive shaft assembly when noise or vibration occurs from drive shaft.

B

C

FAX

E

F

G

H

I

J

K

L

M

N

O

P


FAX-15

2009 G37 Coupe

FRONT WHEEL HUB AND KNUCKLE [AWD]


REMOVAL AND INSTALLATION FRONT WHEEL HUB AND KNUCKLE Exploded View

INFOID:0000000004670033

JPDIF0221GB

1.

Steering knuckle

2.

Ball seat

3.

Cotter pin

4.

Splash guard

5.

Wheel hub and bearing assembly

6.

Wheel hub lock nut



INFOID:0000000004670034

REMOVAL Wheel Hub and Bearing Assembly

1. 2.

3.

4. 5. 6.

7.

Remove tires with power tool. Remove wheel sensor from steering knuckle. Refer to BRC-100, "Exploded View". CAUTION: Never pull on wheel sensor harness. Remove caliper assembly. Hang caliper assembly in a place where it will not interfere with work. Refer to BR-49, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Exploded View". CAUTION: Never depress brake pedal while brake caliper is removed. Remove disc rotor. Refer to BR-50, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Removal and Installation". Remove cotter pin, then loosen wheel hub lock nut with power tool. Patch wheel hub lock nut with a piece of wood. Hammer the wood to disengage wheel hub and bearing assembly from drive shaft. Take out the wheel hub lock nut. CAUTION: • Never place drive shaft joint at an extreme angle. Also be careful not to overextend slide joint. • Never allow drive shaft to hang down without support for housing (or joint sub-assembly), shaft and the other parts. NOTE: Use a suitable puller, if wheel hub and bearing assembly and drive shaft cannot be separated even after performing the above procedure. Remove wheel hub and bearing assembly mounting bolts, and then remove splash guard and wheel hub and bearing assembly from steering knuckle.

Steering Knuckle


FAX-16

2009 G37 Coupe

FRONT WHEEL HUB AND KNUCKLE [AWD] < REMOVAL AND INSTALLATION > 1. Remove wheel hub and bearing assembly, and then remove splash guard. A 2. Remove brake hose bracket. Refer to BR-21, "FRONT : Exploded View". 3. Remove cotter pin (1) of steering outer socket, and then loosen the nut. B 4. Remove steering outer socket (2) from steering knuckle (3) so as not to damage ball joint boot (4) using the ball joint remover. CAUTION: Temporarily tighten the nut to prevent damage to threads C and to prevent the ball joint remover from suddenly coming off. 5. Remove cotter pin of transverse link and steering knuckle, and FAX then loosen nut. SGIA1183E 6. Separate upper link from steering knuckle. 7. Separate transverse link from steering knuckle so as not to damage ball joint boot using the ball joint E remover. CAUTION: Temporarily tighten the nut to prevent damage to threads and to prevent the ball joint remover F from suddenly coming off. 8. Remove steering knuckle form vehicle.

INSTALLATION Note the following, and install in the reverse order of the removal. • Perform the final tightening of each of parts under unladen conditions, which were removed when removing wheel hub and bearing assembly and steering knuckle. • Never reuse cotter pin.

Inspection

G

H

INFOID:0000000004670035

I

INSPECTION AFTER REMOVAL Check components for deformation, cracks, and other damage. Replace if necessary. Ball Joint Inspection Check boots of transverse link and steering outer socket ball joint for breakage, axial play, and torque. Refer to FSU-37, "Inspection" and ST-46, "AWD : Inspection".

J

INSPECTION AFTER INSTALLATION

K

1. 2. 3.

Check the wheel sensor harness for proper connection. Refer to BRC-100, "Exploded View". Check the wheel alignment. Refer to FSU-30, "Inspection". Adjust neutral position of steering angle sensor. Refer to BRC-8, "ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Special Repair Requirement".

L

M

N

O

P


FAX-17

2009 G37 Coupe

FRONT DRIVE SHAFT BOOT [AWD]


FRONT DRIVE SHAFT BOOT Exploded View

INFOID:0000000004670036

JPDIF0021ZZ

1.

Joint sub-assembly

2.

Circular clip

3.

Boot band

4.

Boot

5.

Shaft

6.

Spider assembly

7.

Snap ring

8.

Housing

9.

Plug

B.

Right side

10. Dust shield A.

Left side : Wheel side

: NISSAN genuine grease or an equivalent. Refer to GI-4, "Components" for symbols not described on the above.

Replacement

INFOID:0000000004670037

WHEEL SIDE 1. 2.

3. 4.

5. 6. 7.

Remove tires with power tool. Remove wheel sensor from steering knuckle. Refer to BRC-100, "Exploded View". CAUTION: Never pull on wheel sensor harness. Remove brake hose bracket. Refer to BR-21, "FRONT : Exploded View". Remove caliper assembly. Hang caliper assembly a place where it will not interfere with work. Refer to BR-49, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Exploded View". CAUTION: Never depress brake pedal while brake caliper is removed. Remove disc rotor. Refer to BR-50, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Removal and Installation". Remove cotter pin, then loosen wheel hub lock nut with a power tool. Patch wheel hub lock nut with a piece of wood. Hammer the wood to disengage wheel hub and bearing assembly from drive shaft. Take out the wheel hub lock nut. CAUTION: • Never place drive shaft joint at an extreme angle. Also be careful not to overextend slide joint. • Never allow drive shaft to hang down without support for housing (or joint sub-assembly), shaft and the other parts. NOTE: Use a suitable puller if wheel hub and bearing assembly and drive shaft cannot be separated even after performing the above procedure.


FAX-18

2009 G37 Coupe

FRONT DRIVE SHAFT BOOT [AWD] < REMOVAL AND INSTALLATION > 8. Remove cotter pin (1) of steering outer socket, and then loosen the nut. A 9. Remove steering outer socket (2) from steering knuckle (3) so as not to damage ball joint boot (4) using the ball joint remover. CAUTION: B Temporarily tighten the nut to prevent damage to threads and to prevent the ball joint remover from suddenly coming off. C 10. Remove cotter pin of transverse link and steering knuckle, and then loosen nut. SGIA1183E 11. Separate transverse link from steering knuckle so as not to damFAX age ball joint boot using the ball joint remover. CAUTION: Temporarily tighten the nut to prevent damage to threads and to prevent the ball joint remover from suddenly coming off. E 12. Remove drive shaft from wheel hub and bearing assembly. 13. Remove boot bands, and then remove boot from joint sub-assembly. F 14. Screw a drive shaft puller (A) into joint sub-assembly screw part to a length of 30 mm (1.18 in) or more. Support drive shaft with one hand and pull out joint sub-assembly with a sliding hammer (B) from shaft. G CAUTION: • Align a sliding hammer and drive shaft and remove them by pulling firmly and uniformly. H • If joint sub-assembly cannot be pulled out, try after removing drive shaft from vehicle. JPDIF0022ZZ

15. 16. 17. 18.

19.

20. 21.

22.

Remove the circular clip (1) from shaft. Remove boot from shaft. Clean the old grease on joint sub-assembly with paper waste. Fill serration slot joint sub-assembly with NISSAN genuine grease or equivalent until the serration slot and ball groove become full to the brim. CAUTION: After applying grease, use a paper waste to wipe off old grease that has oozed out. Install boot and boot bands to shaft. JPDIF0007ZZ CAUTION: • Wrap serration on shaft with tape to protect the boot from damage. • Never reuse boot and boot band. Remove the tape wrapped around the serration on shaft. Position circular clip on groove at the shaft edge. CAUTION: Never reuse circular clip. NOTE: Drive joint inserter is recommended when installing circular clip. Align both center axles of the shaft edge and joint sub-assembly. Then assemble shaft with circular clip joint sub-assembly.


FAX-19

2009 G37 Coupe

I

J

K

L

M

N

O

P

FRONT DRIVE SHAFT BOOT [AWD]

< REMOVAL AND INSTALLATION > 23. Install joint sub-assembly (1) to shaft using plastic hammer. CAUTION: Confirm that joint sub-assembly is correctly engaged while rotating drive shaft. 24. Apply the balance of the specified amount of grease into the boot inside from large diameter side of boot. Standard Grease amount

: Refer to FAX-28, "Drive Shaft". JPDIF0011ZZ

25. Install the boot securely into grooves (indicated by “*” marks) shown in the figure. CAUTION: If grease adheres to the boot mounting surface (with “*” mark) on the shaft or joint sub-assembly, boot may come off. Remove all grease from the surface. 26. To prevent the deformation of the boot, adjust the boot installation length (L) to the specified value shown below by inserting the suitable tool into inside of the boot from the large diameter side of the boot and discharging the inside air. JPDIF0222ZZ

Standard Boots installed length (L)

: Refer to FAX-28, "Drive Shaft".

CAUTION: • If the boot installation length is outside the standard, it may cause breakage of boot. • Be careful not to touch the inside of the boot with a tip of tool. 27. Secure the large and small ends of the boot with boot bands using the boot band crimping tool (A) [SST: KV40107300 ( − )].

JPDIF0012ZZ

NOTE: Secure boot band so that dimension (M) meets the specification as shown in the figure. Dimension (M)

: 2.0 – 3.0 mm (0.079 – 0.118 in)

28. Secure joint sub-assembly and shaft, and then make sure that they are in the correct position when rotating boot. Install them with boot band when boot installation positions become incorrect. 29. Insert drive shaft to wheel hub and bearing assembly, and then temporarily tighten wheel hub lock nut. DSF0047D CAUTION: • The drive shaft is press-fit. When assembling the shaft, never press it, but pull it until fully seated by tightening the wheel hub lock nut. • Check that anticorrosive oil is applied to the thread of the drive shaft. If not, apply appropriate oil such as engine oil. Revision: 2009 October

FAX-20

2009 G37 Coupe

FRONT DRIVE SHAFT BOOT [AWD] < REMOVAL AND INSTALLATION > • If sufficient oil is not applied to the thread of the drive shaft, the wheel hub lock nut may be seized and the tightening torque reaches the specified limit prematurely. It may cause looseness A or abnormal noises. 30. Install transverse link to steering knuckle. Refer to FAX-16, "Exploded View". 31. Install steering outer socket to steering knuckle. Refer to ST-37, "AWD : Exploded View". B 32. Install disc rotor. Refer to BR-50, "BRAKE CALIPER ASSEMBLY (2 PISTON TYPE) : Removal and Installation". 33. Install caliper assembly to steering knuckle. Refer to BR-49, "BRAKE CALIPER ASSEMBLY (2 PISTON C TYPE) : Exploded View". 34. Install brake hose bracket to steering knuckle. Refer to BR-21, "FRONT : Exploded View". FAX 35. Install wheel sensor to steering knuckle. Refer to BRC-100, "Exploded View". 36. Tighten the wheel hub lock nut to the specified torque. Refer to FAX-16, "Exploded View". 37. Install cotter pin. E CAUTION: • Never reuse cotter pin. • Bend it at the root sufficiently to prevent any looseness. F

G

H

I

J

K

L

M

N

O

P


FAX-21

2009 G37 Coupe



FRONT DRIVE SHAFT Exploded View

INFOID:0000000004670038

REMOVAL

SDIA3042J

1.

Drive shaft (right side)

2.

Drive shaft (left side)

3.

Cotter pin

Refer to GI section for symbols in the figure.

DISASSEMBLY

JPDIF0021ZZ

1.

Joint sub-assembly

2.

Circular clip

3.

4.

Boot

5.

Shaft

6.

Boot band Spider assembly

7.

Snap ring

8.

Housing

9.

Plug

B.

Right side

10. Dust shield A.

Left side : Wheel side

: NISSAN genuine grease or an equivalent. Refer to GI-4, "Components" for symbols not described on the above.


FAX-22

2009 G37 Coupe




INFOID:0000000004670039

A

REMOVAL Left Side

1. 2. 3.

B

Refer to the procedure from 1 to 12 in FAX-18, "Replacement". Remove shock absorber from transverse link with power tool. Refer to FSU-31, "Exploded View". Remove fixing bolts and nuts, and then remove drive shaft from vehicle.

C

Right Side

1. 2. 3.

Refer to the procedure from 1 to 12 in FAX-18, "Replacement". Remove shock absorber from transverse link with power tool. Refer to FSU-31, "Exploded View". Remove drive shaft from front final drive. • Remove drive shaft from front final drive using the drive shaft attachment (A) [SST:KV40107500 ( − )] and a sliding hammer (B) while inserting tip of the drive shaft attachment between housing and front final drive. CAUTION: Never place drive shaft joint at an extreme angle when removing drive shaft. Also be careful not to overextend slide joint.

FAX

E

F

G JPDIF0004ZZ

INSTALLATION

H

Left Side Install in the reverse order of removal. Right Side Note the following, and install in the reverse order of removal. CAUTION: Always replace front final drive oil seal with new one when installing drive shaft. Refer to DLN-117, "RIGHT SIDE : Exploded View". • Place the protector (A) [SST:KV38107900 ( − )] onto front final drive to prevent damage to the oil seal while inserting drive shaft. Slide drive shaft sliding joint and tap with a hammer to install securely.

I

J

K

L

M JPDIF0023ZZ

N


INFOID:0000000004670040

DISASSEMBLY

O

Front Final Drive Side

1.

2. 3.

Fix shaft with a vise. CAUTION: Protect shaft when fixing with a vise using aluminum or copper plates. Remove boot bands, and then remove boot from housing. Put matching marks on housing and shaft, and then pull out housing from shaft. CAUTION: Use paint or similar substance for matching marks. Never scratch the surfaces.


FAX-23

P

2009 G37 Coupe

FRONT DRIVE SHAFT < REMOVAL AND INSTALLATION > 4. Put matching marks (A) on the spider assembly and shaft. CAUTION: Use paint or similar substance for matching marks. Never scratch the surfaces.

[AWD]

JPDIF0006ZZ

5. 6. 7. 8.

Remove snap ring (1), and then remove spider assembly from the shaft. Remove boot from the shaft. Remove dust shield from housing. (right side) If plug needs to be removed, move boot to wheel side, and take it out with a plastic hammer. (left side)

JPDIF0014ZZ

Wheel Side

1.

2. 3.

4. 5. 6.

Fix shaft with a vise. CAUTION: Protect shaft when fixing with a vise using aluminum or copper plates. Remove boot bands, and then remove boot from joint sub-assembly. Screw the drive shaft puller (A) 30 mm (1.18 in) or more into the thread of joint sub-assembly, and pull joint sub-assembly with a sliding hammer (B) from shaft. CAUTION: • If joint sub-assembly cannot be removed after five or more unsuccessful attempts, replace shaft and joint sub assembly as a set. • Align sliding hammer and drive shaft and remove them by pulling directory. Remove circular clip from shaft. Remove boot from shaft. Clean old grease on joint sub-assembly with paper waste while rotating ball cage.

JPDIF0015ZZ

ASSEMBLY Front Final Drive Side

1. 2.

3.

Clean old grease on housing with paper waste. If plug (1) has been removed, use a drift to press in a new one. (left side) : Press A: Drift [SST: KV38100500 (

−

)]

B: Drift [SST: KV38102200 (

−

)]

Install new boot and boot bands to shaft. CAUTION: • Wrap serration on shaft with tape to protect boot from damage.


FAX-24

JPDIF0016ZZ

2009 G37 Coupe


< REMOVAL AND INSTALLATION > • Never reuse boot and boot band. 4. Remove the tape wrapped around the serration on shaft. 5. To install the spider assembly (1), align it with the matching marks (A) on the shaft (2) during the removal, and direct the serration mounting surface (B) to the shaft.

A

B

C

FAX JPDIF0017ZZ

6. 7. 8.

E

Secure spider assembly onto shaft with snap ring (1). Apply the appropriate amount of grease to spider assembly and sliding surface. Assemble the housing onto spider assembly, and apply the balance of the specified amount grease. Standard Grease amount

F

G


9. Align matching marks painted when housing was removed. JPDIF0014ZZ 10. Install boot securely into grooves (indicated by “*” marks) shown in the figure. CAUTION: If grease adheres to the boot mounting surface (with “*” mark) on shaft or housing, boot may come off. Remove all grease from the surface. Right side

H

I

J

Left side

K

L

M JPDIF0224ZZ

JPDIF0223ZZ

11. To prevent the deformation of the boot, adjust the boot installation length (L) to the value shown below by inserting the suitable tool into the inside of boot from the large diameter side of boot and discharging inside air.

N

O

Standard Boots installed length (L)


CAUTION: • If the boot installation length is outside the standard, it may cause breakage of boot. • Be careful not to touch the inside of the boot with the tip of tool. 12. Install new larger and smaller boot bands securely.


FAX-25

2009 G37 Coupe

P

FRONT DRIVE SHAFT < REMOVAL AND INSTALLATION > a. For one-touch clamp band i. Secure the large and small ends of a boot with new boot bands as shown in the figure.

[AWD]

PDIA1188J

b. i.

For low profile type band Put boot band in the groove on drive shaft boot. Then fit pawls ( ) into holes to temporary installation. NOTE: For the large diameter side, fit projection (A) and guide slit (B) at first.

SDIA3557E

ii. Pinch projection on the band with suitable pliers to tighten band. iii. Insert tip of band below end of the pawl. 13. Secure housing and shaft, and then make sure that they are in the correct position when rotating boot. Install them with new boot band when the mounting positions become incorrect. 14. Install dust cover to housing. (right side) CAUTION: Never reuse dust cover. SDIA3558E

Wheel Side For further details on the installation procedure, refer to the installation procedure of “Replacement” for the drive shaft boot.

Inspection

INFOID:0000000004670041

INSPECTION AFTER REMOVAL • Move joint up/down, left/right, and in the axial directions. Check for motion that is not smooth and for significant looseness. • Check boot for cracks, damage, and leakage of grease. • Disassemble drive shaft and exchange malfunctioning part if there is a non-standard condition.

SDIA1163J

INSPECTION AFTER DISASSEMBLY Revision: 2009 October

FAX-26

2009 G37 Coupe


< REMOVAL AND INSTALLATION > Shaft Check shaft for runout, cracks, or other damage. Replace if necessary.

A

Joint Sub-Assembly (Wheel Side) Check the following: • Joint sub-assembly for rough rotation and excessive axial looseness. • The inside of the joint sub-assembly for entry of foreign material. • Joint sub-assembly for compression scars, cracks, and fractures inside of joint sub-assembly. Replace joint sub-assembly if there are any non-standard conditions of components.

B

C

Housing and Spider assembly (Front Final Drive side) Replace housing and spider assembly if there is scratching or wear of housing roller contact surface or spider roller contact surface. FAX NOTE: Housing and spider assembly are used in a set. E

F

G

H

I

J

K

L

M

N

O

P


FAX-27

2009 G37 Coupe

SERVICE DATA AND SPECIFICATIONS (SDS) [AWD]


SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Wheel Bearing

INFOID:0000000004670042

Item

Standard

Axial end play

0.05 mm (0.002 in) or less

Drive Shaft

INFOID:0000000004670043

Item

Standard

Joint Grease quantity

Boots installed length

Wheel side Left side Right side Left side Right side


77 – 97 g (2.72 – 3.42 oz)

136 mm (5.35 in)

FAX-28

Front final drive side 95 – 105 g (3.36 – 3.70 oz) 113 – 123 g (3.99 – 4.33 oz) 152 mm (5.98 in) 158.6 mm (6.24 in)

2009 G37 Coupe

ENGINE

SECTION

FL

FUEL SYSTEM

A

FL

C

D

E

CONTENTS PRECAUTION ............................................... 2

Inspection ................................................................. 9

PRECAUTIONS ................................................... 2

FUEL TANK ...................................................... 10

Precaution for Battery Service .................................. 2 General Precautions ................................................. 2


PREPARATION ............................................ 3 PREPARATION ................................................... 3 Commercial Service Tools ........................................ 3

PERIODIC MAINTENANCE .......................... 4

UNIT DISASSEMBLY AND ASSEMBLY ... 13 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY ........................ 13 Exploded View .........................................................13 Disassembly ............................................................13 Assembly .................................................................13

FUEL SYSTEM .................................................... 4 Inspection .................................................................. 4 Quick Connector ....................................................... 4

REMOVAL AND INSTALLATION ................ 5 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY .......................... 5

F

G

H

I

J

SERVICE DATA AND SPECIFICATIONS (SDS) ............................................................ 15 SERVICE DATA AND SPECIFICATIONS (SDS) ................................................................. 15

Exploded View .......................................................... 5 Removal and Installation ........................................... 5

Fuel Tank .................................................................15

K

L

M

N

O

P


FL-1

2009 G37 Coupe


PRECAUTION PRECAUTIONS Precaution for Battery Service

INFOID:0000000004704595


General Precautions

INFOID:0000000004251096

WARNING: When replacing fuel line parts, be sure to observe the following. • Put a “CAUTION: FLAMMABLE” sign in the workshop. • Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher. • Never smoke while servicing fuel system. Keep open flames and sparks away from the work area. CAUTION: • Use gasoline required by the regulations for octane number. Refer to GI-31, "Fuel". • Before removing fuel line parts, perform out the following procedures: - Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in safe area. - Release fuel pressure from the fuel lines. Refer to EC-614, "Inspection". - Disconnect the battery cable from the negative terminal. • Always replace O-ring and clamps with new ones. • Never kink or twist tubes when they are being installed. • Never tighten hose clamps excessively to avoid damaging hoses. • After installing tubes, check there is no fuel leakage at connections in the following steps. - Apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine stopped). Then check for fuel leakage at connections. - Start engine and rev it up and check for fuel leakage at connections. • Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the “MIL” may come on. • For servicing “Evaporative Emission System” parts, refer to EC-86, "Component Parts Location". • For servicing “On Board Refueling Vapor Recovery (ORVR)” parts, refer to EC-513, "Description".


FL-2

2009 G37 Coupe


PREPARATION

A

PREPARATION Commercial Service Tools

INFOID:0000000004251097

Tool name

Description

Power tool

Loosening nuts and bolts

FL

C

D

E PBIC0190E

F

G

H

I

J

K

L

M

N

O

P


FL-3

2009 G37 Coupe

FUEL SYSTEM < PERIODIC MAINTENANCE >

PERIODIC MAINTENANCE FUEL SYSTEM Inspection

INFOID:0000000004251098

Inspect fuel lines, fuel filler cap and fuel tank for improper attachment, leakage, cracks, damage, loose connections, chafing or deterioration. A

: Engine

B

: Fuel line

C

: Fuel tank

If necessary, repair or replace damaged parts. JPBIA0129ZZ

Quick Connector

INFOID:0000000004251099

CAUTION: • After connecting fuel tube quick connectors, check quick connectors are secure. 1

: Quick connector

2

: Retainer

A

: Hard tube (or the equivalent)

B

: Connection (cross-section)

C

: Resin tube

D

: To under floor fuel line

E

: To fuel tank

F

: Tab

G

: Disconnection

• Ensure that connector and resin tube never contact any adjacent parts.

JPBIA0130ZZ


FL-4

2009 G37 Coupe

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY < REMOVAL AND INSTALLATION >


A

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY Exploded View

INFOID:0000000004251100

FL

C

D

E

F

G

H

I

J

JPBIA1835GB

1.

Retainer

4.

Sub fuel level sensor unit

A.

Right side

2.

B.

Main fuel level sensor unit, fuel filter and fuel pump assembly

3.

O-ring

K

Left side


L


INFOID:0000000004251101

WARNING: Read “General Precautions” when working on the fuel system. Refer to GI-28, "General Precautions".

M

REMOVAL 1.

Check fuel level on fuel gauge. If fuel gauge indicates more than the level as shown in the figure (full or almost full), drain fuel from fuel tank until fuel gauge indicates level as shown in the figure or below. NOTE: Because fuel will be spilled when removing main and sub fuel level sensor units for the top of the fuel is above the main and sub fuel level sensor units installation surface. • As a guide, fuel level becomes the position as shown in the figure or below when approximately 20 (5-1/4 US gal, 4-3/8 Imp gal) of fuel are drained from fuel tank. • In a case that fuel pump does not operate, perform the following procedure.


FL-5

N

O

P

JPBIA2481ZZ

2009 G37 Coupe

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY < REMOVAL AND INSTALLATION > a. Insert hose of less than 22 mm (0.87 in) in diameter into fuel filler tube through fuel filler opening to draw fuel from fuel filler tube. b. Disconnect fuel filler hose from fuel filler tube. Refer to FL-10, "Exploded View". c. Insert fuel tube into fuel tank through fuel filler hose to draw fuel from fuel tank. 2. Release the fuel pressure from the fuel lines. Refer to EC-614, "Inspection". 3. Open fuel filler lid. 4. Open filler cap and release the pressure inside fuel tank. 5. Remove rear seat cushion. Refer to SE-192, "Exploded View". 6. Peel off floor carpet, then remove inspection hole cover (1) units by turning clips (2) clockwise by 90 degrees. A b

: Direction mark : 90° : Vehicle front

Right side Left side 7.

: Main fuel level sensor unit, fuel filter and fuel pump assembly : Sub fuel level sensor unit

JPBIA0132ZZ

Disconnect harness connector (3) and fuel feed tube (2). 1

: Quick connector : Vehicle front

JPBIA0133ZZ

Disconnect quick connector as follows:

• Hold the sides of connector, push in tabs and pull out fuel feed tube. A

: Pull

B

: Push in tabs

• If quick connector sticks to tube of main fuel level sensor unit, push and pull quick connector several times until they start to move.Then disconnect them by pulling.

JPBIA0134ZZ

CAUTION:


FL-6

2009 G37 Coupe

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY < REMOVAL AND INSTALLATION > • Quick connector (1) can be disconnected when the tabs (F) are completely depressed. Never twist it more than necessary. B

: Connection (Cross-section)

D

: To under floor fuel line

E

: To fuel tank

G

: Disconnection

A

FL

C

• Never use any tools to disconnected quick connector. • Keep resin tube (C) away from heat. Be especially careful when welding near the resin tube. • Prevent acid liquid such as battery electrolyte, etc. from getting on resin tube. • Never bend or twist resin tube during installation and disconnection. • Never remove the remaining retainer (2) on hard tube (or the equivalent) (A) except when resin tube or retainer is replaced. • When resin tube or hard tube (or the equivalent) is replaced, also replace retainer with new one. Retainer color

D

E

F

G

: Natural

JPBIA0130ZZ

• To keep the connecting portion clean and to avoid damage and foreign materials, cover them completely with plastic bags (A) or something similar.

H

I

J

JPBIA0135ZZ

8.

a. i. ii.

b. i. ii.

Remove main fuel level sensor unit, fuel filter and fuel pump assembly, and sub fuel level sensor unit as follows: CAUTION: • Never bend float arm during removal. • Avoid impacts such as falling when handling components. Removal of main fuel level sensor unit, fuel filter and fuel pump assembly: Remove retainer. Raise main fuel level sensor unit, fuel filter and fuel pump assembly, and disconnect quick connector as follows: • Push in tabs (1) and pull out fuel tube (2). Removal of sub fuel level sensor unit: Remove retainer. Raise and release sub fuel level sensor unit to remove.

K

L

M

N

O

P

JPBIA1836ZZ

INSTALLATION Note the following, and install in the reverse order of removal. Revision: 2009 October

FL-7

2009 G37 Coupe

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY < REMOVAL AND INSTALLATION > Fuel hose

• When installing fuel hose connector (1), refer to “Quick Connector”. 2

: Retainer

JPBIA1992ZZ

Main and Sub Fuel Level Sensor Unit

• Face main and sub fuel level sensor units as shown in the figure, and install them with the knock pin (C) on back aligned with pin hole on fuel tank. A

: Right side

B

: Left side : Vehicle front

JPBIA2038ZZ

• Install retainer so that its notch becomes parallel with the notch on fuel tank. A

: Align notches : Vehicle front

• Tighten retainer mounting bolts evenly.

JPBIA2039ZZ

Quick Connector

• Connect quick connector as follows: 1. Check the connection for damage or any foreign materials. 2. Align the connector with the tube, then insert the connector straight into the tube until a click sound is heard. 3. After connecting, check that the connection is secure by following method. • Pull the tube and the connector to check they are securely connected. A

: Pull

• Visually confirm that the two retainer tabs are connected to the connector.

JPBIA0140ZZ


FL-8

2009 G37 Coupe

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY < REMOVAL AND INSTALLATION >

Inspection

INFOID:0000000004251102

A

INSPECTION AFTER INSTALLATION Use the following procedure to check for fuel leakage. 1. Turn ignition switch “ON” (with engine stopped), then check connections for leakage by applying fuel pres- FL sure to fuel piping. 2. Start engine and let it idle and check there are no fuel leakage at the fuel system connections. C

D

E

F

G

H

I

J

K

L

M

N

O

P


FL-9

2009 G37 Coupe

FUEL TANK < REMOVAL AND INSTALLATION >

FUEL TANK Exploded View

INFOID:0000000004251103

JPBIA0155GB

1.

Fuel filler cap

2.

Grommet

3.

Fuel filler tube

4.

Clamp

7.

Vent hose

5.

Vent hose

6.

Vent tube

8.

EVAP hose

9.

Clamp

10. Clamp

11.

Fuel filler hose

12. Fuel tank mounting band

13. Fuel tank protector

14.

Insulator

15. Fuel tank

Refer to GI-4, "Components" for to symbols in the figure.


INFOID:0000000004251104

WARNING: Be sure to read “General Precautions” when working on the fuel system. Refer to GI-28, "General Precautions".

REMOVAL • Drain fuel from fuel tank if necessary. Refer to FL-10, "Exploded View". • Perform work on level place. 1. Perform steps 2 to 7 of “REMOVAL” in “ FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY” on main and sub fuel level sensor units. Refer to FL-5, "Exploded View". 2. Remove exhaust front tube, center muffler, and main muffler. Refer to EX-5, "Exploded View". 3. Remove propeller shaft. Refer to DLN-90, "Exploded View" (M/T models) or DLN-97, "Exploded View" (A/ T models). 4. Remove parking rear brake cables. Refer to PB-6, "PEDAL TYPE : Exploded View" (PEDAL TYPE) or PB-7, "LEVER TYPE : Exploded View" (LEVER TYPE). Revision: 2009 October

FL-10

2009 G37 Coupe

FUEL TANK < REMOVAL AND INSTALLATION > 5. Remove rear suspension assembly. Refer to RSU-23, "Exploded View". NOTE: A For this service, drive shaft, final drive, and rear suspension member are required not to be separate one another during removal. 6. Disconnect fuel filler hose (1), vent hose (2), and EVAP hoses FL (3) at fuel tank side. 4

: Fuel tank protector

C

: Vehicle front

D

JPBIA0144ZZ

7. 8.

Remove fuel tank protector. Support the lower part of fuel tank (1) with transmission jack (A). CAUTION: Support the position that fuel tank mounting bands never engage.

E

F

G

H

JPBIA0145ZZ

9. Remove fuel tank mounting bands. 10. Supporting with hands, descend transmission jack carefully, and remove fuel tank. CAUTION: • Check that all connection points have been disconnected. • Confirm there is no interference with vehicle. 11. Remove fuel filler tube if necessary.

I

J

K

INSTALLATION Note the following, and install in the reverse order of removal. • Surely clamp fuel hoses and insert hose to the length below. Fuel filler hose The other hoses

L

: 35 mm (1.38 in) : 25 mm (0.98 in)

M

• Be sure hose clamp is not placed on swelled area of fuel tube. • Tighten the clamp hand with the top mark (A) until the mark is on the bolt head flange.

N

O

P

JPBIA0146ZZ

• To connect quick connector, refer to FL-4, "Quick Connector".


FL-11

2009 G37 Coupe

FUEL TANK < REMOVAL AND INSTALLATION >

Inspection

INFOID:0000000004251105

INSPECTION AFTER INSTALLATION Use the following procedure to check for fuel leakage. 1. Turn ignition switch “ON” (with engine stopped), and check connections for leakage by applying fuel pressure to fuel piping. 2. Start engine and rev it up and check there are no fuel leakage at the fuel system tube and hose connections. • After removing/installing rear suspension assembly, check to adjust wheel alignment and then, adjust neutral position of steering angle sensor. Refer to RSU-6, "Inspection" and STC-28, "4WAS FRONT ACTUATOR NEUTRAL POSITION ADJUSTMENT : Description".


FL-12

2009 G37 Coupe

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY < UNIT DISASSEMBLY AND ASSEMBLY >

UNIT DISASSEMBLY AND ASSEMBLY

A

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY Exploded View

INFOID:0000000004496642

FL

C

D

E JPBIA2585ZZ

1.

Fuel filter and fuel pump assembly

A.

Fuel temp sensor

2.

F

Main fuel level sensor unit

Disassembly

INFOID:0000000004496643

CAUTION: Sub fuel level sensor unit cannot be disassembled and should be replaced as a unit. Remove main fuel level sensor unit as follows: 1. Disconnect harness connector (A). a. Hold connector by fingers and push stopper release tab. b. Pull it out connector.

G

H

I

J

K JPBIA2586ZZ

2. a. b.

L

Remove main fuel level sensor unit (1) from fuel filter and fuel pump assembly (2) as follows: Push in tab (A) to release the lock. After fixing tabs are disengaged, slide main fuel level sensor unit out in direction shown by the arrow (B). CAUTION: • Be careful not to damage the main fuel level sensor unit. • Never disassemble fuel filter and fuel pump assembly.

M

N

O JPBIA2587ZZ

Assembly

INFOID:0000000004496644

CAUTION: Sub fuel level sensor unit cannot be disassembled and should be replaced as a unit. 1. Check for damage of main fuel level sensor unit installation position on the side of fuel filter and fuel pump assembly. 2. Slide main fuel level sensor unit until it aligns to installation groove, then insert it until it stops. • After inserting, apply force in reverse direction (removal direction) to ensure it cannot be pulled out.


FL-13

2009 G37 Coupe

P

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY < UNIT DISASSEMBLY AND ASSEMBLY > 3. Connect the white (A), black (B), and red (C) harnesses so that they are in the positions shown in the figure. • Securely insert harness connector until it stops.

JPBIA2588ZZ


FL-14

2009 G37 Coupe


SERVICE DATA AND SPECIFICATIONS (SDS)

A

SERVICE DATA AND SPECIFICATIONS (SDS) Fuel Tank

INFOID:0000000004251109

FL

Standard and Limit C Fuel tank capacity

Approx. 75.6

Fuel recommendation

(20 US gal, 16-5/8 Imp gal) Refer to GI-31

D

E

F

G

H

I

J

K

L

M

N

O

P


FL-15

2009 G37 Coupe

SUSPENSION

SECTION

FSU

FRONT SUSPENSION

A

B

C

D

FSU

CONTENTS 2WD SYMPTOM DIAGNOSIS ............................... 3 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ............................. 3 NVH Troubleshooting Chart ...................................... 3

TRANSVERSE LINK ......................................... 14

F


G

UPPER LINK ..................................................... 17 H

PRECAUTION ............................................... 4


PRECAUTIONS ................................................... 4

FRONT STABILIZER ........................................ 19

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ................................................................... 4 Precaution Necessary for Steering Wheel Rotation after Battery Disconnect ..................................... 4 Precaution for Procedure without Cowl Top Cover...... 5 Precautions for Suspension ...................................... 5


I

PREPARATION ............................................ 6 PREPARATION ................................................... 6

UNIT REMOVAL AND INSTALLATION ...... 21 FRONT SUSPENSION MEMBER ..................... 21 Exploded View .........................................................21 Removal and Installation .........................................22 Inspection ................................................................22

Special Service Tool ................................................. 6 Commercial Service Tool .......................................... 6

SERVICE DATA AND SPECIFICATIONS (SDS) ............................................................ 23

PERIODIC MAINTENANCE .......................... 7

SERVICE DATA AND SPECIFICATIONS (SDS) ................................................................. 23

FRONT SUSPENSION ASSEMBLY ................... 7 Inspection .................................................................. 7

WHEEL ALIGNMENT .......................................... 8

K

L

M

Wheel Alignment .....................................................23 Ball Joint ..................................................................23 Wheelarch Height ....................................................23

AWD

Inspection .................................................................. 8

REMOVAL AND INSTALLATION ................ 9 FRONT COIL SPRING AND SHOCK ABSORBER .............................................................. 9

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ........................... 25

Exploded View .......................................................... 9 Removal and Installation ......................................... 10 Disassembly and Assembly .................................... 10 Inspection ................................................................ 12

NVH Troubleshooting Chart ....................................25

PRECAUTION .............................................. 26 PRECAUTIONS ................................................. 26

FSU-1

N

O

SYMPTOM DIAGNOSIS .............................. 25


J

2009 G37 Coupe

P

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ................................................................. 26 Precaution Necessary for Steering Wheel Rotation after Battery Disconnect .................................. 26 Precaution for Procedure without Cowl Top Cover... 27 Precautions for Suspension .................................... 27

TRANSVERSE LINK ......................................... 36 Exploded View ........................................................ 36 Removal and Installation ......................................... 37 Inspection ................................................................ 37

UPPER LINK ..................................................... 39

PREPARATION ........................................... 28

Exploded View ........................................................ 39 Removal and Installation ......................................... 40 Inspection ................................................................ 40

PREPARATION ................................................. 28

FRONT STABILIZER ......................................... 41

Special Service Tool ............................................... 28 Commercial Service Tool ....................................... 28


PERIODIC MAINTENANCE ........................ 29 FRONT SUSPENSION ASSEMBLY ................. 29

UNIT REMOVAL AND INSTALLATION .... 43

Inspection ............................................................... 29

FRONT SUSPENSION MEMBER ..................... 43

WHEEL ALIGNMENT ........................................ 30


Inspection ............................................................... 30

REMOVAL AND INSTALLATION ............... 31 FRONT COIL SPRING AND SHOCK ABSORBER ............................................................ 31 Exploded View ........................................................ 31 Removal and Installation ........................................ 32 Disassembly and Assembly .................................... 32 Inspection ............................................................... 34


SERVICE DATA AND SPECIFICATIONS (SDS) .......................................................... 45 SERVICE DATA AND SPECIFICATIONS (SDS) ................................................................. 45 Wheel Alignment ..................................................... 45 Ball Joint ................................................................. 45 Wheelarch Height ................................................... 45

FSU-2

2009 G37 Coupe

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING [2WD]


SYMPTOM DIAGNOSIS

A


INFOID:0000000004670198

B

×

Vibration

×

×

×

×

Shimmy

×

×

×

×

Judder

×

×

×


×

×

×

×

NVH in ST section

NVH in BR section

NVH in WT section

NVH in FAX and FSU section

NVH in DLN section

FSU-20

FSU-8

FSU-9, FSU-14, FSU-17, FSU-19, FSU-21

—

STEERING

×

BRAKE

×

ROAD WHEEL

×

H


Shake

F

PROPELLER SHAFT

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

×

Stabilizer bar fatigue

×

× × ×

FSU

G

Incorrect wheel alignment

×

D

Suspension looseness

Parts interference

×

C

Spring fatigue

Bushing or mounting deterioration

FRONT SUSPENSION

—

Shock absorber deformation, damage or deflection

Noise


Symptom

—


Reference page

FSU-12



×

×

I

J

×

×

×

×

×

×

×

×

×

×

×

K

L

M

N

×: Applicable

O

P


FSU-3

2009 G37 Coupe

PRECAUTIONS [2WD]

< PRECAUTION >


INFOID:0000000004679096






2. 3. 4.



FSU-4

2009 G37 Coupe

PRECAUTIONS [2WD] < PRECAUTION > 5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock when the push-button ignition switch is turned to LOCK position.) 6. Perform self-diagnosis check of all control units using CONSULT-III.

A


B

INFOID:0000000004679101


C

D

FSU PIIB3706J

F

Precautions for Suspension

INFOID:0000000004670202

• When installing rubber bushings, the final tightening must be carried out under unladen conditions with tires on ground. Spilled oil might shorten the life of rubber bushings. Be sure to wipe off any spilled oil. - Unladen conditions mean that fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in designated positions. • After servicing suspension parts, be sure to check wheel alignment. • Self-lock nuts are not reusable. Always use new ones when installing. Since new self-lock nuts are pre-oiled, tighten as they are.

G

H

I

J

K

L

M

N

O

P


FSU-5

2009 G37 Coupe

PREPARATION [2WD]

< PREPARATION >


INFOID:0000000004670203


Description Disassembling and assembling shock absorber

ST35652000 ( – ) Shock absorber attachment

ZZA0807D

Measuring rotating torque of ball joint

ST3127S000 (J-25765-A) Preload gauge

ZZA0806D


INFOID:0000000004670204

Tool name

Description

Power tool


PBIC0190E

Spring compressor

Removing and installing coil spring

S-NT717


FSU-6

2009 G37 Coupe

FRONT SUSPENSION ASSEMBLY [2WD]



A

FRONT SUSPENSION ASSEMBLY Inspection

INFOID:0000000004670205

B

Make sure the mounting conditions (looseness, backlash) of each component and component conditions (wear, damage) are normal.

C

MOUNTING INSPECTION

BALL JOINT AXIAL END PLAY 1.

2. 3.

Set front wheels in a straight-ahead position. CAUTION: Never depress brake pedal. Place an iron bar or equivalent between transverse link or upper link and steering knuckle. Measure axial end play by prying it up and down. Standard Axial end play

D

FSU

F

: Refer to FSU-23, "Ball Joint".

CAUTION: Be careful not to damage ball joint boot. never damage the installation position by applying excessive force.

SHOCK ABSORBER

G

H

Check for oil leakage, damage and replace if malfunction is detected.

I

J

K

L

M

N

O

P


FSU-7

2009 G37 Coupe

WHEEL ALIGNMENT [2WD]


WHEEL ALIGNMENT Inspection

INFOID:0000000004670206

DESCRIPTION CAUTION: • Camber, caster, kingpin inclination angles cannot be adjusted. • If camber, caster, or kingpin inclination angle is outside the standard, check front suspension parts for wear and damage. Replace suspect parts if a malfunction is detected. • Kingpin inclination angle is reference value, no inspection is required. • Measure wheel alignment under unladen conditions. NOTE: “Unladen conditions” means that fuel, engine coolant, and lubricant are full. Spare tire, jack, hand tools and mats are in designated positions.

GENENRAL INFORMATION AND RECOMMENDATIONS • A four-wheel thrust alignment should be performed. - This type of alignment is recommended for any NISSAN/INFINITI vehicle. - The four-wheel “thrust” process helps ensure that the vehicle is properly aligned and the steering wheel is centered. - The alignment rack itself should be capable of accepting any NISSAN/INFINITI vehicle. - The rack should be checked to ensure that it is level. • Make sure the machine is properly calibrated. - Your alignment equipment should be regularly calibrated in order to give correct information. - Check with the manufacturer of your specific equipment for their recommended Service/Calibration Schedule.

ALIGNMENT PROCESS IMPORTANT: Use only the alignment specifications listed in this Service Manual. • When displaying the alignment settings, many alignment machines use “indicators”: (Green/red, plus or minus, Go/No Go). Never use these indicators. - The alignment specifications programmed into your machine that operate these indicators may not be correct. - This may result in an ERROR. • Some newer alignment machines are equipped with an “optional Rolling Compensation” method to “compensate” the sensors (alignment targets or head units). Never use this “Rolling Compensation” method. - Use the “Jacking Compensation Method”. After installing the alignment targets or head units, raise the vehicle and rotate the wheels 1/2 turn both ways. - See Instructions in the alignment machine you're using for more information on this.

PRELIMINARY CHECK Check the following: • Tires for improper air pressure and wear. • Road wheels for runout. Refer to WT-95, "Inspection". • Wheel bearing axial end play. Refer to FAX-5, "Inspection". • Transverse link or upper link ball joint axial end play. Refer to FSU-23, "Ball Joint", FSU-18, "Inspection". • Shock absorber operation. • Each mounting part of axle and suspension for looseness and deformation. • Each of suspension member, shock absorber, upper link and transverse link for cracks, deformation and other damage. • Vehicle height (posture).


FSU-8

2009 G37 Coupe

FRONT COIL SPRING AND SHOCK ABSORBER [2WD]



A

FRONT COIL SPRING AND SHOCK ABSORBER Exploded View

INFOID:0000000004670207

B

C

D

FSU

F

G

H

I

J

K

L

M

N

O

P

JPEIA0174GB


FSU-9

2009 G37 Coupe

FRONT COIL SPRING AND SHOCK ABSORBER [2WD]

< REMOVAL AND INSTALLATION > 1.

Piston rod lock nut

2.

Mounting seal

3.

Shock absorber mounting bracket

4.

Bound bumper

5.

Rubber seat

6.

Coil spring

7.

Transverse link

8.

Front suspension member

9.

Suspension member stay

10. Stabilizer clamp

11. Stabilizer bushing

12. Stabilizer connecting rod

13. Stabilizer bar

14. Cotter pin

15. Steering knuckle

16. Upper link

17. Stopper rubber

18. Shock absorber



INFOID:0000000004670208

REMOVAL 1. 2.

3. 4. 5. 6. 7.

Remove tires with power tool. Remove harness of the wheel sensor from shock absorber. Refer to BRC-100, "Exploded View". CAUTION: Never pull on wheel sensor harness. Remove brake hose bracket. Refer to BR-21, "FRONT : Exploded View". Remove stabilizer connecting rod mounting nuts (lower side) with power tool. Remove stabilizer connecting rod mounting nuts (upper side) with power tool, and then remove stabilizer connecting rod from transverse link. Separate upper link from steering knuckle. Remove mounting nuts of shock absorber mounting bracket, then remove shock absorber assembly.

INSTALLATION Note the following, and install in the reverse order of removal. • Never tap on the ball joint cap of the stabilizer connecting rod with a hammer or a similar item when inserting the stabilizer connecting rod into the transverse link. • Perform final tightening of bolts and nuts at the shock absorber lower side (rubber bushing), under unladen conditions with tires on level ground.


INFOID:0000000004670209

DISASSEMBLY CAUTION: Never damage shock absorber piston rod when removing components from shock absorber. 1. Install shock absorber attachment (A) [SST: ST35652000 ( – )] to shock absorber and secure it in a vise. CAUTION: When installing the shock absorber attachment to shock absorber, wrap a shop cloth around shock absorber to protect it from damage.

JPEIA0006ZZ


FSU-10

2009 G37 Coupe

FRONT COIL SPRING AND SHOCK ABSORBER < REMOVAL AND INSTALLATION > 2. Using a spring compressor (A) (commercial service tool), compress coil spring between rubber seat and shock absorber until coil spring with a spring compressor is free. CAUTION: Be sure a spring compressor is securely attached coil spring. Compress coil spring. 3. Make sure coil spring with a spring compressor between rubber seat and shock absorber is free and then remove piston rod lock nut while securing the piston rod tip so that piston rod does not turn. 4. Remove mounting seal, shock absorber mounting bracket, rubber seat, bound bumper from shock absorber. 5. Remove coil spring with a spring compressor, and then gradually release a spring compressor. CAUTION: Loosen while making sure coil spring attachment position does not move. 6. Remove the shock absorber attachment from shock absorber.

[2WD] A

B

C JPEIA0168ZZ

D

FSU

ASSEMBLY 1.

2.

Install shock absorber attachment (A) [SST: ST35652000 ( – )] to shock absorber and secure it in a vise. CAUTION: When installing the shock absorber attachment to shock absorber, wrap a shop cloth around shock absorber to protect it from damage. Compress coil spring using a spring compressor (commercial service tool), and install it onto shock absorber. CAUTION: • Install with the large-diameter side (A) facing up and the small-diameter side (B) facing down. • Be sure a spring compress or is securely attached to coil spring. Compress coil spring.

F

G

H

I

J

K

PEIA0108E

3.

4.

Install the shock absorber mounting bracket and rubber seat. CAUTION: Align the paint mark (A) to the stud bolt (1) position when assembling. Apply soapy water to bound bumper. CAUTION: Never use machine oil.

L

M

N

O JPEIA0009ZZ

P


FSU-11

2009 G37 Coupe

FRONT COIL SPRING AND SHOCK ABSORBER [2WD] < REMOVAL AND INSTALLATION > 5. Insert bound bumper into shock absorber mounting bracket, and then install it to shock absorber together with rubber seat.

JPEIA0016ZZ

1.


A.

Right side

B.

Left side

C.

Coil spring lower end position

: Vehicle front

• Install the shock absorber mounting bracket as shown in the figure. Angle (a) 6. 7.

8. 9.

: 35.4°

• Check that the lower end of the coil spring is positioned at the spring lower seat of the shock absorber. Secure piston rod tip so that piston rod does not turn, then tighten piston rod lock nut with specified torque. Gradually release a spring compressor, and remove coil spring. CAUTION: Loosen while making sure coil spring attachment position does not move. Remove the shock absorber attachment from shock absorber. Install the mounting seal to shock absorber mounting bracket.

Inspection

INFOID:0000000004670210

INSPECTION AFTER DISASSEMBLY Shock Absorber Check the following items, and replace the part if necessary. • Shock absorber for deformation, cracks or damage. • Piston rod for damage, uneven wear or distortion. • Oil leakage. Shock Absorber Mounting Bracket and Rubber Parts Inspection Check shock absorber mounting bracket for cracks and rubber parts for wear. Replace it if necessary. Coil Spring Check coil spring for cracks, wear or damage, and replace it if necessary.


FSU-12

2009 G37 Coupe

FRONT COIL SPRING AND SHOCK ABSORBER [2WD] < REMOVAL AND INSTALLATION > INSPECTION AFTER INSTALLATION • Check wheel sensor harness for proper connection. Refer to BRC-100, "Exploded View". • Check wheel alignment. Refer to FSU-8, "Inspection". • Adjust neutral position of steering angle sensor. Refer to BRC-8, "ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Special Repair Requirement".

A

B

C

D

FSU

F

G

H

I

J

K

L

M

N

O

P


FSU-13

2009 G37 Coupe

TRANSVERSE LINK [2WD]


TRANSVERSE LINK Exploded View

INFOID:0000000004670211

JPEIA0174GB

1.

Piston rod lock nut

2.

Mounting seal

3.

4.

Bound bumper

5.

Rubber seat

6.

Coil spring

7.

Transverse link

8.


9.



FSU-14


2009 G37 Coupe

TRANSVERSE LINK [2WD]

< REMOVAL AND INSTALLATION > 10. Stabilizer clamp



13. Stabilizer bar

14. Cotter pin


16. Upper link

17. Stopper rubber

18. Shock absorber

A


B


INFOID:0000000004670212

REMOVAL 1. 2. 3. 4. 5. 6. 7.

C

Remove tires with power tool. Remove under cover with power tool. Remove shock absorber. Refer to FSU-9, "Exploded View". Remove steering outer socket from steering knuckle. Refer to ST-30, "2WD : Exploded View". Remove transverse link from steering knuckle. Set suitable jack under transverse link. Remove mounting bolts and nuts, and then remove transverse link.

D

FSU

INSTALLATION

F

Note the following, and install in the reverse order of removal. • Never tap on the ball joint cap of the stabilizer connecting rod with a hammer or a similar item when inserting the stabilizer connecting rod into the transverse link. • Perform final tightening of bolts and nuts at the front suspension member installation and shock absorber lower side (rubber bushing), under unladen conditions with tires on level ground. • Never reuse cotter pin.

G

Inspection INSPECTION AFTER REMOVAL

I

Appearance Check the following items, and replace the part if necessary. • Transverse link and bushing for deformation, cracks or damage. • Ball joint boot for cracks or other damage, and also for grease leakage.

J

Ball Joint Inspection Manually move ball stud to confirm it moves smoothly with no binding.

K

Swing Torque Inspection NOTE: Before measurement, move ball stud at least ten times by hand to check for smooth movement. • Hook a spring balance (A) at cotter pin mounting hole. Confirm spring balance measurement value is within specifications when ball stud begins moving.

Standard Swing toque

H

INFOID:0000000004670213

L

M


N

- If it is outside the specified range, replace transverse link assembly.

O JPEIA0005ZZ

Rotating Torque Inspection


P

FSU-15

2009 G37 Coupe

TRANSVERSE LINK < REMOVAL AND INSTALLATION > • Attach mounting nut to ball stud. Make sure that rotating torque is within specifications with a preload gauge (A) [SST: ST3127S000 (J-25765-A)]. Standard Rotating toque

[2WD]


- If it is outside the specified range, replace transverse link assembly. PDIA1258E

Axial End Play Inspection • Move tip of ball stud in axial direction to check for looseness.

Standard Axial end play



INSPECTION AFTER INSTALLATION • Check wheel sensor harness for proper connection. Refer to BR-21, "FRONT : Exploded View". • Check wheel alignment. Refer to FSU-8, "Inspection". • Adjust neutral position of steering angle sensor. Refer to BRC-8, "ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Special Repair Requirement".


FSU-16

2009 G37 Coupe

UPPER LINK [2WD]


UPPER LINK

A

Exploded View

INFOID:0000000004670214

B

C

D

FSU

F

G

H

I

J

K

L

M

N

O

P

JPEIA0174GB

1.

Piston rod lock nut

2.

Mounting seal

3.

4.

Bound bumper

5.

Rubber seat

6.

Coil spring

7.

Transverse link

8.


9.



FSU-17


2009 G37 Coupe

UPPER LINK [2WD]




13. Stabilizer bar

14. Cotter pin


16. Upper link

17. Stopper rubber

18. Shock absorber



INFOID:0000000004670215

REMOVAL 1. 2. 3. 4.

Remove tires with power tool. Remove shock absorber. Refer to FSU-9, "Exploded View". Remove mounting bolts and nuts with power tool, and then remove upper link from steering knuckle. Remove mounting bolts and nuts, and then remove upper link and stopper rubber.

INSTALLATION Note the following, and install in the reverse order of removal. • Perform final tightening of bolts and nuts at the vehicle installation position (rubber bushing), under unladen conditions with tires on level ground.

Inspection

INFOID:0000000004670216

INSPECTION AFTER REMOVAL Appearance Check the following items, and replace the part if necessary. • Upper link and bushing for deformation, cracks or damage. • Ball joint boot for cracks or other damage, and also for grease leakage. Ball Joint Inspection Manually move ball stud to confirm it moves smoothly with no binding. Swing Torque Inspection NOTE: Before measurement, move ball stud at least ten times by hand to check for smooth movement. • Hook a spring balance (A) at cutout on ball stud. Confirm spring balance measurement value is within specifications when ball stud begins moving.

Standard Swing torque


- If it is outside the specified range, replace upper link assembly.

JPEIA0005ZZ





INSPECTION AFTER INSTALLATION • Check wheel sensor harness for proper connection. Refer to BR-21, "FRONT : Exploded View". • Check wheel alignment. Refer to FSU-8, "Inspection". • Adjust neutral position of steering angle sensor. Refer to BRC-8, "ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Special Repair Requirement".


FSU-18

2009 G37 Coupe

FRONT STABILIZER [2WD]


FRONT STABILIZER

A

Exploded View

INFOID:0000000004670217

B

C

D

FSU

F

G

H

I

J

K

L

M

N

O

P

JPEIA0174GB

1.

Piston rod lock nut

2.

Mounting seal

3.

4.

Bound bumper

5.

Rubber seat

6.

Coil spring

7.

Transverse link

8.


9.



FSU-19


2009 G37 Coupe

FRONT STABILIZER [2WD]




13. Stabilizer bar

14. Cotter pin


16. Upper link

17. Stopper rubber

18. Shock absorber



INFOID:0000000004670218

REMOVAL 1. 2. 3.

4. 5.

Remove tires with power tool. Remove under cover with power tool. Remove stabilizer connecting rod. CAUTION: Apply a matching mark to identify the installation position. Remove the stabilizer clamp and stabilizer bushing. Remove stabilizer bar.

INSTALLATION Note the following, and install in the reverse order of removal. • Check the mounting mark when installing. • Tighten the mounting nut to the specified torque while holding a hexagonal part of stabilizer connecting rod side.

Inspection

INFOID:0000000004670219

INSPECTION AFTER REMOVAL Check stabilizer bar, stabilizer connecting rod, stabilizer bushing and stabilizer clamp for deformation, cracks or damage. Replace it if a malfunction is detected.


FSU-20

2009 G37 Coupe

FRONT SUSPENSION MEMBER [2WD]

< UNIT REMOVAL AND INSTALLATION >


A

FRONT SUSPENSION MEMBER Exploded View

INFOID:0000000004670220

B

C

D

FSU

F

G

H

I

J

K

L

M

N

O

P

JPEIA0174GB


FSU-21

2009 G37 Coupe

FRONT SUSPENSION MEMBER [2WD]

< UNIT REMOVAL AND INSTALLATION > 1.

Piston rod lock nut

2.

Mounting seal

3.


4.

Bound bumper

5.

Rubber seat

6.

Coil spring

7.

Transverse link

8.


9.





13. Stabilizer bar

14. Cotter pin


16. Upper link

17. Stopper rubber

18. Shock absorber



INFOID:0000000004670221

REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Remove tire with power tool. Remove under cover with power tool. Remove suspension member stay with power tool. Separate steering gear assembly and lower joint. Refer to ST-24, "WITHOUT 4WAS : Exploded View" (without 4WAS), ST-25, "WITH 4WAS : Exploded View" (with 4WAS). Remove steering outer socket from steering knuckle. Refer to ST-30, "2WD : Exploded View". Remove wheel sensor from steering knuckle. Refer to BRC-100, "Exploded View". Remove stabilizer connecting rod from transverse link. Refer to FSU-19, "Exploded View". Remove front stabilizer. Refer to FSU-19, "Exploded View". Install engine slinger, and then hoist engine. Refer to EM-69, "2WD : Removal and Installation". Remove transverse link from front suspension member. Refer to FSU-14, "Exploded View". Remove steering hydraulic piping bracket and steering gear from front suspension member. Refer to ST59, "2WD : Exploded View". Set suitable jack front suspension member. Remove mounting nuts between engine mounting insulator and from suspension member. Refer to EM69, "2WD : Exploded View". Remove mounting bolts and nuts of front suspension member with power tool. Gradually lower jack to remove front suspension assembly from vehicle.

INSTALLATION Note the following, and install in the reverse order of removal. • Perform final tightening of installation position between front suspension member and transverse links (rubber bushing) under unladen condition with tires on level ground.

Inspection

INFOID:0000000004670222

INSPECTION AFTER REMOVAL Check the front suspension member for significant deformation, cracks, or damages. Replace if necessary.

INSPECTION AFTER INSTALLATION • Check wheel sensor harness for proper connection. Refer to BR-21, "FRONT : Exploded View". • Check wheel alignment. Refer to FSU-8, "Inspection". • Adjust the neutral position of the steering angle sensor. Refer to BRC-8, "ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Special Repair Requirement".


FSU-22

2009 G37 Coupe




A

SERVICE DATA AND SPECIFICATIONS (SDS) Wheel Alignment

INFOID:0000000004257338

Item

Standard

Camber Degree minute (Decimal degree)

Minimum

–1° 10′ (–1.17°)

Nominal

–0° 25′ (–0.42°)

Maximum

Caster Degree minute (Decimal degree)

Minimum

4° 05′ (4.08°)

Nominal

4° 50′ (4.83°)

Toe-in Toe angle (left wheel or right wheel) Degree minute (Decimal degree)

FSU

5° 35′ (5.58°)

Left and right difference

Total toe-in Distance

D

0° 33′ (0.55°) or less

Maximum

Kingpin inclination Degree minute (Decimal degree)

C

0° 20′ (0.33°)


B

0° 39′ (0.65°) or less

Minimum

6° 40′ (6.67°)

Nominal

7° 25′ (7.42°)

Maximum

8° 10′ (8.16°)

Minimum

0 mm (0 in)

Nominal

In 1 mm (0.04 in)

Maximum

In 2 mm (0.08 in)

G

H

Minimum

0° 00′ (0.00°)

Nominal

In 0° 02′ 30″ (0.04°)

Maximum

F

I

In 0° 05′ (0.08°)

Measure value under unladen* conditions.

J

*: Fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in designated positions.

Ball Joint

INFOID:0000000004257339

K Item Swing torque

Measurement on spring balance Rotating torque

Standard Transverse link

0.5 – 3.6 N·m (0.06 – 0.36 kg-m, 5 – 31 in-lb)

Upper link

L

0 – 2.0 N·m (0 – 0.2 kg-m, 0 – 17 in-lb)

Transverse link

7.8 – 56.3 N (0.8 – 5.7 kg, 1.8 – 12.7 lb)

Upper link

0 – 61.5 N (0 – 6.3 kg, 0 – 13.8 lb)

Transverse link

M

0.5 – 3.9 N·m (0.06 – 0.39 kg-m, 5 – 34 in-lb)

Axial end play

0 mm (0 in)

Wheelarch Height

N INFOID:0000000004257340

O Item

Standard

Applied model Wheel size Front (Hf)


Except for sports models 18 inch 712 mm (28.03 in)

For sports models

P

19 inch 715 mm (28.15 in)

FSU-23

716 mm (28.19 in)

2009 G37 Coupe


< SERVICE DATA AND SPECIFICATIONS (SDS) Item

Standard

Applied model

Except for sports models

Wheel size Rear (Hr)

For sports models

18 inch 702 mm (27.64 in)

19 inch 705 mm (27.76 in)

706 mm (27.80 in)

SFA818A

Measure value under unladen* conditions *: Fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in designated positions.


FSU-24

2009 G37 Coupe

Symptom

Revision: 2009 October Parts interference

FSU-25 Spring fatigue

Noise × × × × ×

Shake × × × ×

Vibration × × × ×

Shimmy × × × ×

Judder × × ×


×

×

×

× ×

× × × × × × × × ×

× × × × × × × ×

× × ×

× × × × ×

× × × × ×

×

×

×

×

× ×

STEERING

NVH in ST section.

NVH in BR section.

NVH in FAX section.


BRAKE

DRIVE SHAFT

NVH in WT section.

NVH in WT section.

NVH in FAX and FSU sections.

NVH in RFD section.

NVH in DLN section.

FSU-42

FSU-30

NVH Troubleshooting Chart

ROAD WHEEL

TIRE


Stabilizer bar fatigue

Incorrect wheel alignment

DIFFERENTIAL

× PROPELLER SHAFT

×


—

—

—

FSU-34


Reference page

Suspension looseness

Bushing or mounting deterioration

FRONT SUSPENSION Shock absorber deformation, damage or deflection

Possible cause and SUSPECTED PARTS Improper installation, looseness

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING [AWD]

SYMPTOM DIAGNOSIS

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING A

INFOID:0000000004670173

×: Applicable

2009 G37 Coupe

B

Use chart below to find the cause of the symptom. If necessary, repair or replace these parts. C

D

FSU

F

G

H

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L

×

M

N

O

P

PRECAUTIONS [AWD]

< PRECAUTION >


INFOID:0000000004679097






2. 3. 4.



FSU-26

2009 G37 Coupe

PRECAUTIONS [AWD] < PRECAUTION > 5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock when the push-button ignition switch is turned to LOCK position.) 6. Perform self-diagnosis check of all control units using CONSULT-III.

A


B

INFOID:0000000004679100


C

D

FSU PIIB3706J

F

Precautions for Suspension

INFOID:0000000004670177

• When installing rubber bushings, the final tightening must be carried out under unladen conditions with tires on ground. Spilled oil might shorten the life of rubber bushings. Be sure to wipe off any spilled oil. - Unladen conditions mean that fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in designated positions. • After servicing suspension parts, be sure to check wheel alignment. • Self-lock nuts are not reusable. Always use new ones when installing. Since new self-lock nuts are pre-oiled, tighten as they are.

G

H

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FSU-27

2009 G37 Coupe

PREPARATION [AWD]

< PREPARATION >


INFOID:0000000004670178


Description Disassembling and assembling shock absorber

ST35652000 ( – ) Shock absorber attachment

ZZA0807D

Measuring rotating torque of ball joint

ST3127S000 (J-25765-A) Preload gauge

ZZA0806D


INFOID:0000000004670179

Tool name

Description

Power tool


PBIC0190E

Spring compressor

Removing and installing coil spring

S-NT717


FSU-28

2009 G37 Coupe

FRONT SUSPENSION ASSEMBLY [AWD]



A

FRONT SUSPENSION ASSEMBLY Inspection

INFOID:0000000004670180

B

Make sure the mounting conditions (looseness, backlash) of each component and component conditions (wear, damage) are normal.

C

MOUNTING INSPECTION

BALL JOINT AXIAL END PLAY 1.

2. 3.

Set front wheels in a straight-ahead position. CAUTION: Never depress brake pedal. Place an iron bar or equivalent between transverse link or upper link and steering knuckle. Measure axial end play by prying it up and down. Standard Axial end play

D

FSU

F


CAUTION: Be careful not to damage ball joint boot. never damage the installation position by applying excessive force.

SHOCK ABSORBER

G

H

Check for oil leakage, damage and replace if malfunction is detected.

I

J

K

L

M

N

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P


FSU-29

2009 G37 Coupe

WHEEL ALIGNMENT [AWD]


WHEEL ALIGNMENT Inspection

INFOID:0000000004670181

DESCRIPTION CAUTION: • Camber, caster, kingpin inclination angles cannot be adjusted. • If camber, caster, or kingpin inclination angle is outside the standard, check front suspension parts for wear and damage. Replace suspect parts if a malfunction is detected. • Kingpin inclination angle is reference value, no inspection is required. • Measure wheel alignment under unladen conditions. NOTE: “Unladen conditions” means that fuel, engine coolant, and lubricant are full. Spare tire, jack, hand tools and mats are in designated positions.

GENENRAL INFORMATION AND RECOMMENDATIONS • A four-wheel thrust alignment should be performed. - This type of alignment is recommended for any NISSAN/INFINITI vehicle. - The four-wheel “thrust” process helps ensure that the vehicle is properly aligned and the steering wheel is centered. - The alignment rack itself should be capable of accepting any NISSAN/INFINITI vehicle. - The rack should be checked to ensure that it is level. • Make sure the machine is properly calibrated. - Your alignment equipment should be regularly calibrated in order to give correct information. - Check with the manufacturer of your specific equipment for their recommended Service/Calibration Schedule.

ALIGNMENT PROCESS IMPORTANT: Use only the alignment specifications listed in this Service Manual. • When displaying the alignment settings, many alignment machines use “indicators”: (Green/red, plus or minus, Go/No Go). Never use these indicators. - The alignment specifications programmed into your machine that operate these indicators may not be correct. - This may result in an ERROR. • Some newer alignment machines are equipped with an optional “Rolling Compensation” method to “compensate” the sensors (alignment targets or head units). Never use this “Rolling Compensation” method. - Use the “Jacking Compensation Method”. After installing the alignment targets or head units, raise the vehicle and rotate the wheels 1/2 turn both ways. - See Instructions in the alignment machine you're using for more information on this.

PRELIMINARY CHECK Check the following: • Tires for improper air pressure and wear. • Road wheels for runout. Refer to WT-95, "Inspection". • Wheel bearing axial end play. Refer to FAX-17, "Inspection". • Transverse link or upper link ball joint axial end play. Refer to FSU-37, "Inspection", FSU-40, "Inspection". • Shock absorber operation. • Each mounting part of axle and suspension for looseness and deformation. • Each of suspension member, shock absorber, upper link and transverse link for cracks, deformation and other damage. • Vehicle height (posture).


FSU-30

2009 G37 Coupe

FRONT COIL SPRING AND SHOCK ABSORBER [AWD]



A

FRONT COIL SPRING AND SHOCK ABSORBER Exploded View

INFOID:0000000004670182

B

C

D

FSU

F

G

H

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JPEIA0139GB


FSU-31

2009 G37 Coupe

FRONT COIL SPRING AND SHOCK ABSORBER [AWD]

< REMOVAL AND INSTALLATION > 1.

Piston rod lock nut

2.

Mounting seal

3.


4.

Bound bumper

5.

Rubber seat

6.

Coil spring

7.

Shock absorber

8.

Stopper rubber

9.

Upper link


11. Cotter pin

12. Insulator

13. Transverse link

14. Stabilizer bar




18. Front cross bar

19. Front suspension member Refer to GI-4, "Components" for symbols in the figure.


INFOID:0000000004670183

REMOVAL 1. 2. 3. 4. 5. 6.

Remove tires with power tool. Remove stabilizer connecting rod mounting nuts (upper side) with power tool, and then remove stabilizer connecting rod from transverse link. Remove shock absorber mounting bolts and nuts (lower side) with power tool, and then remove shock absorber from transverse link. Remove drive shaft. Refer to FAX-22, "Exploded View". Separate upper link from steering knuckle. Remove the mounting nuts of shock absorber mounting bracket, then remove shock absorber assembly.

INSTALLATION Note the following, and install in the reverse order of removal. CAUTION: Never tap on the ball joint cap of the stabilizer connecting rod with a hammer or a similar item when inserting the stabilizer connecting rod into the transverse link. • Perform final tightening of bolts and nuts at the shock absorber lower side (rubber bushing), under unladen conditions with tires on level ground.


INFOID:0000000004670184

DISASSEMBLY CAUTION: Never damage shock absorber piston rod when removing components from shock absorber. 1. Install shock absorber attachment (A) [SST: ST35652000 ( – )] to shock absorber and secure it in a vise. CAUTION: When installing the shock absorbershock absorber attachment to shock absorber, wrap a shop cloth around shock absorber to protect it from damage.

JPEIA0006ZZ


FSU-32

2009 G37 Coupe

FRONT COIL SPRING AND SHOCK ABSORBER < REMOVAL AND INSTALLATION > 2. Using a spring compressor (A) (commercial service tool), compress coil spring between rubber seat and shock absorber until coil spring with a spring compressor is free. CAUTION: Be sure a spring compressor is securely attached coil spring. Compress coil spring 3. Make sure coil spring with a spring compressor between rubber seat and shock absorber is free and then remove piston rod lock nut while securing the piston rod tip so that piston rod does not turn. 4. Remove mounting seal, shock absorber mounting bracket, rubber seat, bound bumper from shock absorber. 5. Remove coil spring with a spring compressor, and then gradually release a spring compressor. CAUTION: Loosen while making sure coil spring attachment position does not move. 6. Remove the shock absorber attachment from shock absorber.

[AWD] A

B

C JPEIA0168ZZ

D

FSU

ASSEMBLY 1.

2.

Install shock absorber attachment (A) [SST: ST35652000 ( − )] to shock absorber and secure it in a vise. CAUTION: When installing the shock absorber attachment to shock absorber, wrap a shop cloth around shock absorber to protect it from damage. Compress coil spring using a spring compressor (commercial service tool), and install it onto shock absorber. CAUTION: • Install with the large-diameter side (A) facing up and the small-diameter side (B) facing down. • Be sure a spring compress or is securely attached to coil spring. Compress coil spring.

F

G

H

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K

PEIA0108E

3.

4.

Install the shock absorber mounting bracket and rubber seat. CAUTION: Align the paint mark (A) to the stud bolt (1) position when assembling. Apply soapy water to bound bumper. CAUTION: Never use machine oil.

L

M

N

O JPEIA0009ZZ

P


FSU-33

2009 G37 Coupe

FRONT COIL SPRING AND SHOCK ABSORBER [AWD] < REMOVAL AND INSTALLATION > 5. Insert bound bumper into shock absorber mounting bracket, and then install it to shock absorber together with rubber seat.

JPEIA0017ZZ

1.


A.

Right side

B.

Left side

C.

Coil spring lower end position

: Vehicle front

• Install the shock absorber mounting bracket as shown in the figure. Angle (a) 6. 7.

8. 9.

: 35.4°

• Check that the lower end of the coil spring is positioned at the spring lower seat of the shock absorber. Secure piston rod tip so that piston rod does not turn, then tighten piston rod lock nut with specified torque. Gradually release a spring compressor, and remove coil spring. CAUTION: Loosen while making sure coil spring attachment position does not move. Remove the shock absorber attachment from shock absorber. Install the mounting seal to shock absorber mounting bracket.

Inspection

INFOID:0000000004670185

INSPECTION AFTER DISASSEMBLY Shock Absorber Check the following items, and replace the part if necessary. • Shock absorber for deformation, cracks or damage. • Piston rod for damage, uneven wear or distortion. • Oil leakage. Shock Absorber Mounting Bracket and Rubber Parts Inspection Check shock absorber mounting bracket for cracks and rubber parts for wear. Replace it if necessary. Coil Spring Check coil spring for cracks, wear or damage, and replace it if necessary.


FSU-34

2009 G37 Coupe

FRONT COIL SPRING AND SHOCK ABSORBER [AWD] < REMOVAL AND INSTALLATION > INSPECTION AFTER INSTALLATION 1. Check wheel sensor harness for proper connection. Refer to BRC-100, "Exploded View". 2. Check wheel alignment. Refer to FSU-30, "Inspection". 3. Adjust neutral position of steering angle sensor. Refer to BRC-8, "ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Special Repair Requirement".

A

B

C

D

FSU

F

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FSU-35

2009 G37 Coupe

TRANSVERSE LINK [AWD]


TRANSVERSE LINK Exploded View

INFOID:0000000004670186

JPEIA0139GB

1.

Piston rod lock nut

2.

Mounting seal

3.

4.

Bound bumper

5.

Rubber seat

6.

Coil spring

7.

Shock absorber

8.

Stopper rubber

9.

Upper link


FSU-36


2009 G37 Coupe

TRANSVERSE LINK [AWD]

< REMOVAL AND INSTALLATION > 10. Steering knuckle

11. Cotter pin

12. Insulator

13. Transverse link

14. Stabilizer bar




18. Front cross bar

A

19. Front suspension member

B



INFOID:0000000004670187

C

REMOVAL 1. 2. 3. 4. 5. 6. 7. 8.

Remove tires with power tool. Remove under cover with power tool. Remove shock absorber. Refer to FSU-31, "Exploded View". Remove front crossbar. Remove steering outer socket from steering knuckle. Refer to ST-37, "AWD : Exploded View". Remove transverse link from steering knuckle. Set suitable jack under transverse link. Remove mounting bolts and nuts, and then remove transverse link.

D

FSU

F

INSTALLATION Note the following, and install in the reverse order of removal. • Never tap on the ball joint cap of the stabilizer connecting rod with a hammer or a similar item when inserting the stabilizer connecting rod into the transverse link. • Perform final tightening of bolts and nuts at the front suspension member installation and shock absorber lower side (rubber bushing), under unladen conditions with tires on level ground.

Inspection

G

H

INFOID:0000000004670188

I

INSPECTION AFTER REMOVAL Appearance Check the following items, and replace the part if necessary. • Transverse link and bushing for deformation, cracks or damage. • Ball joint boot for cracks or other damage, and also for grease leakage.

J

K

Ball Joint Inspection Manually move ball stud to confirm it moves smoothly with no binding. Swing Torque Inspection NOTE: Before measurement, move ball stud at least ten times by hand to check for smooth movement. • Hook a spring balance (A) at cotter pin mounting hole. Confirm spring balance measurement value is within specifications when ball stud begins moving.

Standard Swing toque

L

M

N

:Refer to FSU-45, "Ball Joint".


O

JPEIA0005ZZ

Rotating Torque Inspection


FSU-37

2009 G37 Coupe

P

TRANSVERSE LINK < REMOVAL AND INSTALLATION > • Attach mounting nut to ball stud. Make sure that rotating torque is within specifications with a preload gauge (A) [SST: 3127S000 (J25765-A)]. Standard Rotating toque

[AWD]


- If it is outside the specified range, replace transverse link assembly. PDIA1258E



:Refer to FSU-45, "Ball Joint".


INSPECTION AFTER INSTALLATION 1. 2. 3.

Check wheel sensor harness for proper connection. Refer to BRC-100, "Exploded View". Check wheel alignment. Refer to FSU-30, "Inspection". Adjust neutral position of steering angle sensor. Refer to BRC-8, "ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Special Repair Requirement".


FSU-38

2009 G37 Coupe

UPPER LINK [AWD]


UPPER LINK

A

Exploded View

INFOID:0000000004670189

B

C

D

FSU

F

G

H

I

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K

L

M

N

O

P

JPEIA0139GB

1.

Piston rod lock nut

2.

Mounting seal

3.

4.

Bound bumper

5.

Rubber seat

6.

Coil spring

7.

Shock absorber

8.

Stopper rubber

9.

Upper link


FSU-39


2009 G37 Coupe

UPPER LINK [AWD]


11. Cotter pin

12. Insulator

13. Transverse link

14. Stabilizer bar




18. Front cross bar



INFOID:0000000004670190

REMOVAL 1. 2. 3. 4.

Remove tires from with power tool. Remove shock absorber. Refer to FSU-31, "Exploded View". Remove mounting bolts and nuts with power tool, and then remove upper link from steering knuckle. Remove mounting bolts and nuts, and then remove upper link and stopper rubber.

INSTALLATION Note the following, and install in the reverse order of removal. • Perform final tightening of bolts and nuts at the vehicle installation position (rubber bushing), under unladen conditions with tires on level ground.

Inspection

INFOID:0000000004670191

INSPECTION AFTER REMOVAL Appearance Check the following items, and replace the part if necessary. • Upper link and bushing for deformation, cracks or damage. • Ball joint boot for cracks or other damage, and also for grease leakage. Ball Joint Inspection Manually move ball stud to confirm it moves smoothly with no binding. Swing Torque Inspection NOTE: Before measurement, move ball stud at least ten times by hand to check for smooth movement. • Hook a spring balance (A) at cutout on ball stud. Confirm spring balance measurement value is within specifications when ball stud begins moving.

Standard Swing torque



JPEIA0005ZZ





INSPECTION AFTER INSTALLATION 1. 2. 3.

Check wheel sensor harness for proper connection. Refer to BRC-100, "Exploded View". Check wheel alignment. Refer to FSU-30, "Inspection". Adjust neutral position of steering angle sensor. Refer to BRC-8, "ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Special Repair Requirement".


FSU-40

2009 G37 Coupe

FRONT STABILIZER [AWD]


FRONT STABILIZER

A

Exploded View

INFOID:0000000004670192

B

C

D

FSU

F

G

H

I

J

K

L

M

N

O

P

JPEIA0139GB

1.

Piston rod lock nut

2.

Mounting seal

3.

4.

Bound bumper

5.

Rubber seat

6.

Coil spring

7.

Shock absorber

8.

Stopper rubber

9.

Upper link


FSU-41


2009 G37 Coupe

FRONT STABILIZER [AWD]


11. Cotter pin

12. Insulator

13. Transverse link

14. Stabilizer bar




18. Front cross bar



INFOID:0000000004670193

REMOVAL 1. 2. 3.

4. 5.

Remove tires with power tool. Remove under cover with power tool. Remove stabilizer connecting rod. CAUTION: Apply a matching mark to identify the installation position. Remove the stabilizer clamp and stabilizer bushing. Remove stabilizer bar.

INSTALLATION Note the following, and install in the reverse order of removal. • Check the mounting mark when installing. • Tighten the mounting nut to the specified torque while holding a hexagonal part of stabilizer connecting rod side.

Inspection

INFOID:0000000004670194

INSPECTION AFTER REMOVAL Check stabilizer bar, stabilizer connecting rod, stabilizer bushing and stabilizer clamp for deformation, cracks or damage. Replace it if necessary.


FSU-42

2009 G37 Coupe

FRONT SUSPENSION MEMBER [AWD]

< UNIT REMOVAL AND INSTALLATION >


A

FRONT SUSPENSION MEMBER Exploded View

INFOID:0000000004670195

B

C

D

FSU

F

G

H

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M

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P

JPEIA0139GB


FSU-43

2009 G37 Coupe

FRONT SUSPENSION MEMBER [AWD]

< UNIT REMOVAL AND INSTALLATION > 1.

Piston rod lock nut

2.

Mounting seal

3.


4.

Bound bumper

5.

Rubber seat

6.

Coil spring

7.

Shock absorber

8.

Stopper rubber

9.

Upper link


11. Cotter pin

12. Insulator

13. Transverse link

14. Stabilizer bar




18. Front cross bar



INFOID:0000000004670196

REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Remove tire with power tool. Remove under cover with power tool. Remove front cross bar. Separate steering gear assembly and lower joint. Refer to ST-24, "WITHOUT 4WAS : Exploded View". Remove steering outer socket from steering knuckle. Refer to ST-37, "AWD : Exploded View". Remove wheel sensor from steering knuckle. Refer to BRC-100, "Exploded View". Remove shock absorber. Refer to FSU-31, "Exploded View". Remove front stabilizer. Refer to FSU-41, "Exploded View". Install engine slinger, and then hoist engine. Refer to EM-74, "AWD : Removal and Installation". Remove transverse link from front suspension member with power tool. Refer to FSU-36, "Exploded View". Remove steering hydraulic piping bracket and steering gear from front suspension member. Refer to ST61, "AWD : Exploded View". Set suitable jack front suspension member. Remove mounting nuts between engine mounting insulator and from suspension member. Refer to EM73, "AWD : Exploded View". Remove mounting bolts and nuts of front suspension member with power tool. Gradually lower jack to remove front suspension assembly from vehicle.

INSTALLATION Note the following, and install in the reverse order of removal. • Perform final tightening of installation position between front suspension member and transverse links (rubber bushing) under unladen condition with tires on level ground.

Inspection

INFOID:0000000004670197

INSPECTION AFTER REMOVAL Check the front suspension member for significant deformation, cracks, or damages. Replace if necessary.

INSPECTION AFER INSTALLATION 1. 2. 3.

Check wheel sensor harness for proper connection. Refer to BRC-100, "Exploded View". Check wheel alignment. Refer to FSU-30, "Inspection". Adjust the neutral position of the steering angle sensor. Refer to BRC-8, "ADJUSTMENT OF STEERING ANGLE SENSOR NEUTRAL POSITION : Special Repair Requirement".


FSU-44

2009 G37 Coupe




A

SERVICE DATA AND SPECIFICATIONS (SDS) Wheel Alignment

INFOID:0000000004499007

Item


Standard Minimum

–1° 10′ (–1.17°)

Nominal

–0° 25′ (–0.42°)

Maximum


Minimum

3° 30′ (3.50°)

Nominal

4° 15′ (4.25°)

Toe-in Toe angle (left wheel or right wheel) Degree minute (Decimal degree)

FSU

5° 00′ (5.00°)


Total toe-in Distance

D

0° 33′ (0.55°) or less

Maximum

Kingpin inclination Degree minute (Decimal degree)

C

0° 20′ (0.33°)


B

0° 39′ (0.65°) or less

Minimum

6° 40′ (6.67°)

Nominal

7° 25′ (7.42°)

Maximum

8° 10′ (8.16°)

Minimum

0 mm (0 in)

Nominal

In 1 mm (0.04 in)

Maximum

In 2 mm (0.08 in)

G

H

Minimum

0° 00′ (0.00°)

Nominal

In 0° 02′ 30″ (0.04°)

Maximum

F

I

In 0° 05′ (0.08°)

Measure value under unladen* conditions.

J

*Fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in designated positions.

Ball Joint

INFOID:0000000004499008

K Item

Standard Transverse link

Swing torque

Measurement on spring balance Rotating torque

0.5 – 3.6 N·m (0.06 – 0.36 kg-m, 5 – 31 in-lb)

Upper link

0 – 2.0 N·m (0 – 0.2 kg-m, 0 – 17 in-lb)

Transverse link

7.8 – 56.3 N (0.8 – 5.7 kg, 1.8 – 12.5 lb)

Upper link

0 – 61.5 N (0 – 6.3 kg, 0 – 13.8 lb)

Transverse link

L

M

0.5 – 3.9 N·m (0.06 – 0.39 kg-m, 5 – 34 in-lb)

Axial end play

0 mm (0 in)

Wheelarch Height

N INFOID:0000000004499009

O Item

Standard

Front (Hf)

726 mm (28.58 in)

P


FSU-45

2009 G37 Coupe


< SERVICE DATA AND SPECIFICATIONS (SDS) Item

Standard

Rear (Hr)

718 mm (28.27 in)

SFA818A

Measure value under unladen* conditions. *: Fuel, engine coolant and lubricant are full. Spare tire, jack, hand tools and mats are in designated positions.


FSU-46

2009 G37 Coupe

QUICK REFERENCE INDEX Edition: September 2008 A GENERAL INFORMATION Revison: October 2009 Publication No. SM9E-1C36U1 B ENGINE

C HYBRID

D TRANSMISSION & DRIVELINE

E SUSPENSION

F BRAKES

G STEERING H RESTRAINTS

I


J BODY INTERIOR

K BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY

L DRIVER CONTROLS

All rights reserved. No part of this Service Manual may be reproduced or stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, recording or otherwise, without the prior written permission of NISSAN MOTOR CO., LTD.

M ELECTRICAL & POWER CONTROL

N DRIVER INFORMATION & MULTIMEDIA

O CRUISE CONTROL P MAINTENANCE

GI EM LU CO EC FL EX STR ACC HBB

General Information Engine Mechanical Engine Lubrication System Engine Cooling System Engine Control System Fuel System Exhaust System Starting System Accelerator Control System Hybrid Battery System

HBR CL TM DLN FAX RAX FSU RSU SCS WT BR PB BRC ST STC SB SBC SR SRC VTL HA HAC INT IP SE ADP DLK SEC GW PWC RF EXT BRM MIR EXL INL WW DEF HRN PWO BCS LAN PCS CHG PG MWI WCS SN AV CCS MA

Hybrid Brake System Clutch Transaxle & Transmission Driveline Front Axle Rear Axle Front Suspension Rear Suspension Suspension Control System Road Wheels & Tires Brake System Parking Brake System Brake Control System Steering System Steering Control System Seat Belt Seat Belt Control System SRS Airbag SRS Airbag Control System Ventilation System Heater & Air Conditioning System Heater & Air Conditioning Control System Interior Instrument Panel Seat Automatic Drive Positioner Door & Lock Security Control System Glass & Window System Power Window Control System Roof Exterior Body Repair Mirrors Exterior Lighting System Interior Lighting System Wiper & Washer Defogger Horn Power Outlet Body Control System LAN System Power Control System Charging System Power Supply, Ground & Circuit Elements Meter, Warning Lamp & Indicator Warning Chime System Sonar System Audio, Visual & Navigation System Cruise Control System Maintenance

A B C D E F G H I J K L M N O P

FOREWORD This manual contains maintenance and repair procedure for the 2009 INFINITI G37 Coupe. In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task. All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.

IMPORTANT SAFETY NOTICE The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle. The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately. Service varies with the procedures used, the skills of the technician and the tools and parts available. Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by NISSAN must first be completely satisfied that neither personal safety nor the vehicle’s safety will be jeopardized by the service method selected.

QUICK REFERENCE CHART G37 COUPE QUICK REFERENCE CHART G37 COUPE ENGINE TUNE-UP DATA (VQ37VHR) Engine model

PFP:00000 ELS0003W

VQ37VHR

Firing order

1-2-3-4-5-6 rpm

Idle speed A/T (In “P or N” position) M/T (In Neutral position)

650 ± 50

Ignition timing (BTDC at idle speed)

10° ± 5°

CO% at idle

0.7 - 9.9 % and engine runs smoothly Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.

Tensions of drive belt kPa (kg/cm2, psi)

Radiater cap relief pressure Standard

122.3 - 151.7 (1.2 - 1.5, 18 - 22)

Limit Cooling system leakage testing pressure

107 (1.1, 16) 2

kPa (kg/cm , psi)

157 (1.6, 23)

kPa (kg/cm2, psi)/200 rpm

Compression pressure Standard

1,667 - 2,354 (17 - 24, 242 - 341)

Minimum

1,226 (12.5, 178)

Differential limit between cylinders

98 (1.0, 14)

Make Spark plug (Iridium-tipped type)

2009

DENSO

Standard type Gap (Nominal)

FXE24HR11 mm (in)

1.1 (0.043)

QUICK REFERENCE CHART G37 COUPE

2009

FRONT WHEEL ALIGNMENT

ELS0003X

Applied model

2WD


Minimum

–1° 10′ (–1.17°)

Nominal

–0° 25′ (–0.42°)

Maximum Left and right difference


Distance Total toe-in Angle (Left wheel or right wheel) Degree minute (Decimal degree)

0° 20′ (0.33°) 0° 33′ (0.55°) or less

Minimum

4° 05′ (4.08°)

3° 30′ (3.50°)

Nominal

4° 50′ (4.83°)

4° 15′ (4.25°)

Maximum

5° 35′ (5.58°)

5° 00′ (5.00°)

Left and right difference Kingpin inclination Degree minute (Decimal degree)

AWD

0° 39′ (0.65°) or less

Minimum

6° 40′ (6.67°)

Nominal

7° 25′ (7.42°)

Maximum

8° 10′ (8.16°)

Minimum

0 mm (0 in)

Nominal

In 1 mm (0.04 in)

Maximum

In 2 mm (0.08 in)

Minimum

0° 00′ (0.00°)

Nominal

In 0° 02′ 30″ (0.04°)

Maximum

In 0° 05′ (0.08°)


REAR WHEEL ALIGNMENT Camber Degree minute (Decimal degree)

Distance Total toe-in Angle (Left wheel or right wheel) Degree minute (Decimal degree)

ELS0003Y

Minimum

–1° 45′ (–1.75°)

Nominal

–1° 15′ (–1.25°)

Maximum

–0° 45′ (–0.75°)

Minimum

0 mm (0 in)

Nominal

In 2.8 mm (0.110 in)

Maximum

In 5.6 mm (0.220 in)

Minimum

0° 00′ (0.00°)

Nominal

In 0° 07′ (0.12°)

Maximum

In 0° 14′ (0.23°)


BRAKE PEDAL Unit: mm (in) Brake pedal height (H1) Depressed brake pedal height (H2) [Depressing 490 N (50 kg, 110 lb) while turning the engine ON]

171.5 - 181.5 (6.75 - 7.15) 124.0 (4.88) or more


2009

FRONT DISK BRAKE 1 Piston Type Unit: mm (in) Item Brake pad

Disc rotor

Limit

Wear thickness

2.0 (0.079)

Wear thickness

30.0 (1.181)

Thickness variation (measured at 8 positions)

0.015 (0.0006)

Runout (with it attached to the vehicle)

0.035 (0.0014)

2 Piston Type Unit: mm (in) Item Brake pad

Disc rotor

Limit

Wear thickness

2.0 (0.079)

Wear thickness

26.0 (1.024)


0.015 (0.0006)


0.035 (0.0014)


Wear thickness Wear thickness

Disc rotor

Limit 2.0 (0.079) 30.0 (1.181)


0.015 (0.0006)


0.035 (0.0014)

REAR DISK BRAKE 1 Piston (Front 1 Piston) Type Unit: mm (in) Item Brake pad

Disc rotor

Limit

Wear thickness

2.0 (0.079)

Wear thickness

15.0 (0.591)


0.015 (0.0006)


0.055 (0.0022)

1 Piston (Front 2 Piston) Type Unit: mm (in) Item Brake pad

Wear thickness Wear thickness

Disc rotor

Limit 2.0 (0.079) 14.0 (0.551)


0.015 (0.0006)


0.055 (0.0022)


Disc rotor

Limit

Wear thickness

2.0 (0.079)

Wear thickness

18.0 (0.709)


0.015 (0.0006)


0.055 (0.0022)


2009

REFILL CAPACITIES

ELS00040

UNIT

Liter

US measure

Fuel tank

75.6

20 gal

A/T models

8.5

9 qt

M/T models

8.6

9-1/8 qt

With oil filter change

4.9

5-1/8 qt

Without oil filter change

4.6

4-7/8 qt

Dry engine (Overhaul)

5.7

6 qt

A/T

9.2

9-3/4 qt

VIN: UP to JNKCV64E09M605016

2.93

6-1/4 pt

VIN: From JNKCV64E09M605017

2.83

6 pt

1.0

2-1/8 pt

Front

0.65

1-3/8 pt

Rear

1.4

3 pt

1.0

1-1/8 qt

0.15

5.07 fl oz

0.55 kg

1.21 lb

Engine Coolant (With reservoir tank) at MAX level

Drain and refill Engine oil

M/T Transmission

Transfer Final drive Power steering system Air conditioning system

Compressor oil Refrigerant

GENERAL INFORMATION

SECTION

GI

GENERAL INFORMATION

GI

B

C

D

E

CONTENTS HOW TO USE THIS MANUAL ...................... 3 HOW TO USE THIS MANUAL ............................ 3 Description ................................................................ 3 Terms ........................................................................ 3 Units .......................................................................... 3 Contents .................................................................... 3 Relation between Illustrations and Descriptions ...... 4 Components .............................................................. 4

Dimensions ..............................................................25 Wheels & Tires ........................................................25

PRECAUTION .............................................. 26 Description ...............................................................26 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" .................................................................26 Precautions For Xenon Headlamp Service .............26 Precaution Necessary for Steering Wheel Rotation after Battery Disconnect ...................................27 Precaution for Battery Service .................................27 Precaution for Procedure without Cowl Top Cover....27 General Precautions ................................................28 Three Way Catalyst .................................................29 Multiport Fuel Injection System or Engine Control System .....................................................................29 Hoses ......................................................................29 Engine Oils ..............................................................30 Air Conditioning .......................................................31 Fuel ..........................................................................31

Description ................................................................ 6 How to Follow Test Groups in Trouble Diagnosis...... 6 Key to Symbols Signifying Measurements or Procedures ..................................................................... 7

HOW TO READ WIRING DIAGRAMS ................ 9 Connector Symbols ................................................... 9 Sample/Wiring Diagram -Example- ......................... 10 Description .............................................................. 11

ABBREVIATIONS ..............................................13 Abbreviation List ...................................................... 13

SAE J1930 Terminology List ................................... 18

VEHICLE INFORMATION ............................ 22

J

K

L

M

N

TOW TRUCK TOWING ..................................... 34 Tow Truck Towing ...................................................34 Vehicle Recovery (Freeing a Stuck Vehicle) ...........35

O

BASIC INSPECTION ................................... 37 SERVICE INFORMATION FOR ELECTRICAL INCIDENT .......................................................... 37

IDENTIFICATION INFORMATION .....................22 Model Variation ....................................................... 22 Information About Identification or Model Code ...... 23


I

Commercial Service Tools .......................................32 Garage Jack and Safety Stand and 2-Pole Lift .......32 Board-On Lift ...........................................................33

Recommended Chemical Products and Sealants.... 17

TERMINOLOGY .................................................18

H

LIFTING POINT ................................................. 32

Description .............................................................. 14 Tightening Torque Table (New Standard Included) ........................................................................... 14

RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ................................................17

G

PRECAUTIONS ................................................. 26

HOW TO FOLLOW TROUBLE DIAGNOSES ..... 6

TIGHTENING TORQUE OF STANDARD BOLTS ................................................................14

F

GI-1

Work Flow ................................................................37 Control Units and Electrical Parts ............................37 How to Check Terminal ...........................................38 Intermittent Incident .................................................41 Circuit Inspection .....................................................44

2009 G37 Coupe

P

CONSULT-III/GST CHECKING SYSTEM ......... 49

INSPECTION AND ADJUSTMENT ................... 56

Description .............................................................. 49 CONSULT-III Function and System Application*1... 49 CONSULT-III/GST Data Link Connector (DLC) Circuit ..................................................................... 50 Wiring Diagram - CONSULT-III/GST CHECKING SYSTEM - ............................................................... 51

ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL .................................. 56 ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL : Required Procedure After Battery Disconnection ................... 56


GI-2

2009 G37 Coupe

HOW TO USE THIS MANUAL < HOW TO USE THIS MANUAL >

HOW TO USE THIS MANUAL

GI

HOW TO USE THIS MANUAL Description

INFOID:0000000004257244

This volume explains “Removal, Disassembly, Installation, Inspection and Adjustment” and “Trouble Diagnoses”.

Terms

B

C

INFOID:0000000004257245

• The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury and/or damage to some part of the vehicle. WARNING indicates the possibility of personal injury if instructions are not followed. CAUTION indicates the possibility of component damage if instructions are not followed. BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful information. Standard value: Tolerance at inspection and adjustment. Limit value: The maximum or minimum limit value that should not be exceeded at inspection and adjustment.

Units

D

E

F

INFOID:0000000004257246

• The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit), and alternatively expressed in the metric system and in the yard/pound system. Also with regard to tightening torque of bolts and nuts, there are descriptions both about range and about the standard tightening torque.

G

H

“Example” Range I

Outer Socket Lock Nut

: 59 - 78 N·m (6.0 - 8.0 kg-m, 43 - 58 ft-lb) J

Standard Drive Shaft Installation Bolt

: 44.3 N·m (4.5 kg-m, 33 ft-lb) K

Contents

INFOID:0000000004257247

• A QUICK REFERENCE INDEX, a black tab (e.g. ) is provided on the first page. You can quickly find the first page of each section by matching it to the section's black tab. • THE CONTENTS are listed on the first page of each section. • THE TITLE is indicated on the upper portion of each page and shows the part or system. • THE PAGE NUMBER of each section consists of two or three letters which designate the particular section and a number (e.g. “BR-5”). • THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools, knacks of work and hidden or tricky steps which are not shown in the previous large illustrations. Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle or transmission, etc. are presented in a step-by-step format where necessary.

L

M

N

O

P


GI-3

2009 G37 Coupe

HOW TO USE THIS MANUAL < HOW TO USE THIS MANUAL >

Relation between Illustrations and Descriptions

INFOID:0000000004257248

The following sample explains the relationship between the part description in an illustration, the part name in the text and the service procedures.

SAIA0519E

Components

INFOID:0000000004257249

• THE LARGE ILLUSTRATIONS are exploded views (see the following) and contain tightening torques, lubrication points, section number of the PARTS CATALOG (e.g. SEC. 440) and other information necessary to perform repairs. The illustrations should be used in reference to service matters only. When ordering parts, refer to the appropriate PARTS CATALOG. Components shown in an illustration may be identified by a circled number. When this style of illustration is used, the text description of the components will follow the illustration.


GI-4

2009 G37 Coupe

HOW TO USE THIS MANUAL < HOW TO USE THIS MANUAL > GI

B

C

D

E

SFIA2959E

1.

Union bolt

2.

Copper washer

3.

Brake hose

4.

Cap

5.

Bleed valve

6.

Sliding pin bolt

7.

Piston seal

8.

Piston

9.

Piston boot

10. Cylinder body

11.

Sliding pin

12.

Torque member mounting bolt

13. Washer

14.

Sliding pin boot

15.

Bushing

16. Torque member

17.

Inner shim cover

18.

Inner shim

19. Inner pad

20.

Pad retainer

21.

Pad wear sensor

22. Outer pad

23.

Outer shim

24.

Outer shim cover

1: PBC (Poly Butyl Cuprysil) grease or silicone-based grease

2: Rubber grease

F

G

H

I

: Brake fluid

Refer to GI section for additional symbol definitions.

J

SYMBOLS K

L

M

N

SAIA0749E

O

P


GI-5

2009 G37 Coupe

HOW TO FOLLOW TROUBLE DIAGNOSES < HOW TO USE THIS MANUAL >

HOW TO FOLLOW TROUBLE DIAGNOSES Description

INFOID:0000000004257250

NOTICE: Trouble diagnoses indicate work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing. • Before performing trouble diagnoses, read the “Work Flow” in each section. • After repairs, re-check that the problem has been completely eliminated. • Refer to Component Parts and Harness Connector Location for the Systems described in each section for identification/location of components and harness connectors. • When checking circuit continuity, ignition switch should be OFF. • Refer to the Circuit Diagram for quick pinpoint check. If you need to check circuit continuity between harness connectors in more detail, such as when a sub-harness is used, refer to Wiring Diagram in each individual section and Harness Layout in PG section for identification of harness connectors. • Before checking voltage at connectors, check battery voltage. • After accomplishing the Diagnosis Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as they were.

How to Follow Test Groups in Trouble Diagnosis

INFOID:0000000004257251

JPAIA0021GB

1. 2. 3. 4.

Test group number and test group title • Test group number and test group title are shown in the upper portion of each test group. Work and diagnosis procedure • Start to diagnose a problem using procedures indicated in enclosed test groups. Questions and results • Questions and required results are indicated in test group. Action • Next action for each test group is indicated based on result of each question.


GI-6

2009 G37 Coupe


Key to Symbols Signifying Measurements or Procedures

INFOID:0000000004257252

GI

B

C

D

E

F

G

H JPAIA0397GB

I

J

K

L

M

N

O

P


GI-7

2009 G37 Coupe


JPAIA0398GB


GI-8

2009 G37 Coupe

HOW TO READ WIRING DIAGRAMS < HOW TO USE THIS MANUAL >

HOW TO READ WIRING DIAGRAMS Connector Symbols

GI INFOID:0000000004257253

Most of connector symbols in wiring diagrams are shown from the terminal side. • Connector symbols shown from the terminal side are enclosed by a single line and followed by the direction mark. • Connector symbols shown from the harness side are enclosed by a double line and followed by the direction mark. • Certain systems and components, especially those related to OBD, may use a new style slide-locking type harness connector. For description and how to disconnect, refer to PG section, “Description”, “HARNESS CONNECTOR”.

B

C

D

E

F

G

H SAIA0257E

I

• Male and female terminals Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams.

J

K

L

M

N

O

SGI363


GI-9

2009 G37 Coupe

P


Sample/Wiring Diagram -Example-

INFOID:0000000004257254

• For detail, refer to following GI-11, "Description".

JCAWA0005GB


GI-10

2009 G37 Coupe


Description

INFOID:0000000004257255

GI Number

Item

Description

B

1

Power supply

• This means the power supply of fusible link or fuse.

2

Fusible link

• “X” means the fusible link.

3

Number of fusible link/ fuse

• This means the number of fusible link or fuse location.

4

Fuse

• “/” means the fuse.

5

Current rating of fusible link/fuse

• This means the current rating of the fusible link or fuse.

6

Optional splice

• The open circle shows that the splice is optional depending on vehicle application.

7

Connector number

• The letter shows which harness the connector is located in. • Example “M”: main harness. For detail and to locate the connector, refer to PG-77, "How To Read Harness Layout", PG-79, "Main Harness".

8

Splice

• The shaded circle “

9

Page crossing

• This circuit continues to an adjacent page.

10

Option abbreviation

• This means the vehicle specifications which layouts the circuit between “

11

Relay

• This shows an internal representation of the relay.

12

Option description

• This shows a description of the option abbreviation used on the page.

13

Switch

• This shows that continuity exists between terminals 1 and 2 when the switch is in the A position. Continuity exists between terminals 1 and 3 when the switch is in the B position.

14

Circuit (Wiring)

• This means the wiring.

15

System branch

• This shows that the circuit is branched to other systems.

16

Shielded line

• The line enclosed by broken line circle shows shield wire.

17

Component name

• This shows the name of a component.

18

Ground (GND)

• This shows the ground connection.

19

Connector

• This means the connector information. • This unit-side is described by the connector symbols.

20

Connectors

• This means that a transmission line bypasses two connectors or more.

C

D

” means the splice.

E

F ”.

G

H

I

J

K

• This shows a code for the color of the wire.

21

Wire color

BR = Brown OR or O = Orange P = Pink PU or V (Violet) = Purple GY or GR = Gray SB = Sky Blue CH = Dark Brown DG = Dark Green

B = Black W = White R = Red G = Green L = Blue Y = Yellow LG = Light Green

L

M

• When the wire color is striped, the base color is given first, followed by the stripe color as shown below: Example: L/W = Blue with White Stripe 22

Terminal number

N

O

• This means the terminal number of a connector.

SWITCH POSITIONS Switches are shown in wiring diagrams as if the vehicle is in the “normal” condition. A vehicle is in the “normal” condition when:


GI-11

P

2009 G37 Coupe

HOW TO READ WIRING DIAGRAMS < HOW TO USE THIS MANUAL > • ignition switch is “OFF”, • doors, hood and trunk lid/back door are closed, • pedals are not depressed, and • parking brake is released.

SGI860

MULTIPLE SWITCH The continuity of multiple switch is described in two ways as shown below. • The switch chart is used in schematic diagrams. • The switch diagram is used in wiring diagrams.

JSAIA0017GB


GI-12

2009 G37 Coupe

ABBREVIATIONS < HOW TO USE THIS MANUAL >

ABBREVIATIONS

GI

Abbreviation List

INFOID:0000000005195961

The following ABBREVIATIONS are used:

B

ABBREVIATION

DESCRIPTION

A/C

Air Conditioner

A/T

Automatic Transaxle/Transmission

ATF

Automatic Transmission Fluid

D1

Drive range first gear

D2

Drive range second gear

D3

Drive range third gear

D4

Drive range fourth gear

FR, RR

Front, Rear

LH, RH

Left-Hand, Right-Hand

C

D

E

F

M/T

Manual Transaxle/Transmission

OD

Overdrive

P/S

Power Steering

SAE

Society of Automotive Engineers, Inc.

SDS

Service Data and Specifications

SST

Special Service Tools

2WD

G

H

2-Wheel Drive

22

2nd range second gear

21

2nd range first gear

12

1st range second gear

11

1st range first gear

I

J

K

L

M

N

O

P


GI-13

2009 G37 Coupe

TIGHTENING TORQUE OF STANDARD BOLTS < HOW TO USE THIS MANUAL >

TIGHTENING TORQUE OF STANDARD BOLTS Description

INFOID:0000000004655569

This vehicle has both new standard based on ISO* and previous standard bolts/nuts. There are some differences between these two types of bolts/ nuts; shape of the head, grade of strength, hexagonal width across flats and the standard tightening torque. • For guidance in discriminating, refer to GI-14, "Tightening Torque Table (New Standard Included)". • The new standard machine screws and tapping screws have a head of ISO standard torx recess. • If the tightening torque is not described in the description or figure, refer to GI-14, "Tightening Torque Table (New Standard Included)". *ISO: International Organization for Standardization

Tightening Torque Table (New Standard Included)

INFOID:0000000004655570

CAUTION: • The special parts are excluded. • The bolts/nuts in these tables have a strength (discrimination) number/symbol assigned to the head or the like. As to the relation between the strength grade in these tables and the strength (discrimination) number/symbol, refer to “DISCRIMINATION OF BOLTS AND NUTS”.

PREVIOUS STANDARD Grade (Strength grade)

4T

7T

9T

Tightening torque (Without lubricant)

Bolt diameter mm

Hexagonal width across flats mm

Pitch mm

M6

6.0

10

M8

8.0

12

Bolt size

Hexagon head bolt

Hexagon flange bolt

N·m

kg-m

ft-lb

in-lb

N·m

kg-m

ft-lb

in-lb

1.0

5.5

0.56

4

49

7

0.71

5

62

1.25

13.5

1.4

10

—

17

1.7

13

—

1.0

13.5

1.4

10

—

17

1.7

13

—

1.5

28

2.9

21

—

35

3.6

26

—

1.25

28

2.9

21

—

35

3.6

26

—

1.75

45

4.6

33

—

55

5.6

41

—

1.25

45

4.6

33

—

65

6.6

48

—

M10

10.0

14

M12

12.0

17

M14

14.0

19

1.5

80

8.2

59

—

100

10

74

—

M6

6.0

10

1.0

9

0.92

7

80

11

1.1

8

97

M8

8.0

12

1.25

22

2.2

16

—

28

2.9

21

—

1.0

22

2.2

16

—

28

2.9

21

—

M10

10.0

14

1.5

45

4.6

33

—

55

5.6

41

—

1.25

45

4.6

33

—

55

5.6

41

—

M12

12.0

17

1.75

80

8.2

59

—

100

10

74

—

1.25

80

8.2

59

—

100

10

74

—

M14

14.0

19

1.5

130

13

96

—

170

17

125

—

M6

6.0

10

1.0

11

1.1

8

—

13.5

1.4

10

—

M8

8.0

12

1.25

28

2.9

21

—

35

3.6

26

—

1.0

28

2.9

21

—

35

3.6

26

—

M10

10.0

14

1.5

55

5.6

41

—

80

8.2

59

—

1.25

55

5.6

41

—

80

8.2

59

—

M12

12.0

17

1.75

100

10

74

—

130

13

96

—

1.25

100

10

74

—

130

13

96

—

M14

14.0

19

1.5

170

17

125

—

210

21

155

—

CAUTION: Revision: 2009 October

GI-14

2009 G37 Coupe

TIGHTENING TORQUE OF STANDARD BOLTS < HOW TO USE THIS MANUAL > The parts with aluminum or the cast iron washer surface/thread surface are excluded. GI

NEW STANDARD BASED ON ISO Grade (Strength grade)

4.8 (Without lubricant)

4.8 (With lubricant)



Tightening torque

Bolt diameter mm

Hexagonal width across flats mm

Pitch mm

M6

6.0

10

M8

8.0

13

Bolt size

M10

10.0

16

Hexagon head bolt

B

Hexagon flange bolt

N·m

kg-m

ft-lb

in-lb

N·m

kg-m

ft-lb

in-lb

1.0

5.5

0.56

4

49

7

0.71

5

62

1.25

13.5

1.4

10

—

17

1.7

13

—

1.0

13.5

1.4

10

—

17

1.7

13

—

1.5

28

2.9

21

—

35

3.6

26

—

1.25

28

2.9

21

—

35

3.6

26

—

1.75

45

4.6

33

—

55

5.6

41

—

1.25

45

4.6

33

—

65

6.6

48

—

M12

12.0

18

M14

14.0

21

1.5

80

8.2

59

—

100

10

74

—

M6

6.0

10

1.0

4

0.41

3

35

5.5

0.56

4

49

M8

8.0

13

1.25

11

1.1

8

—

13.5

1.4

10

—

1.0

11

1.1

8

—

13.5

1.4

10

—

1.5

22

2.2

16

—

28

2.9

21

—

1.25

22

2.2

16

—

28

2.9

21

—

1.75

35

3.6

26

—

45

4.6

33

—

1.25

35

3.6

26

—

45

4.6

33

—

M10

10.0

16

M12

12.0

18

M14

14.0

21

1.5

65

6.6

48

—

80

8.2

59

—

M6

6.0

10

1.0

8

0.82

6

71

10

1.0

7

89

M8

8.0

13

1.25

21

2.1

15

—

25

2.6

18

—

1.0

21

2.1

15

—

25

2.6

18

—

M10

10.0

16

M12

12.0

18

M14

14.0

M6

1.5

40

4.1

30

—

50

5.1

37

—

1.25

40

4.1

30

—

50

5.1

37

—

1.75

70

7.1

52

—

85

8.7

63

—

1.25

70

7.1

52

—

85

8.7

63

—

21

1.5

120

12

89

—

140

14

103

—

6.0

10

1.0

10

1.0

7

89

12

1.2

9

106

M8

8.0

13

1.25

27

2.8

20

—

32

3.3

24

—

1.0

27

2.8

20

—

32

3.3

24

—

M10

10.0

16

M12

12.0

18

M14

14.0

21

1.5

55

5.6

41

—

65

6.6

48

—

1.25

55

5.6

41

—

65

6.6

48

—

1.75

95

9.7

70

—

110

11

81

—

1.25

95

9.7

70

—

110

11

81

—

1.5

160

16

118

—

180

18

133

—

CAUTION: 1. Use tightening torque with lubricant for the new standard bolts/nuts in principle. Friction coefficient stabilizer is applied to the new standard bolts/nuts. 2. However, use tightening torque without lubricant for the following cases. Friction coefficient stabilizer is not applied to the following bolts/nuts. Grade 4.8, M6 size bolt, Conical spring washer installed Paint removing nut (Size M6 and M8) for fixing with weld bolt


GI-15

2009 G37 Coupe

C

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TIGHTENING TORQUE OF STANDARD BOLTS < HOW TO USE THIS MANUAL > DISCRIMINATION OF BOLTS AND NUTS

SAIA0453E


GI-16

2009 G37 Coupe

RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS < HOW TO USE THIS MANUAL >

RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS Recommended Chemical Products and Sealants

GI INFOID:0000000004257258

Refer to the following chart for help in selecting the appropriate chemical product or sealant.

1

2

3

Product Description

Purpose

Rear View Mirror Adhesive

Used to permanently remount rear view mirrors to windows.

Anaerobic Liquid Gasket

For metal-to-metal flange sealing. Can fill a 0.38 mm (0.015 inch) gap and provide instant sealing for most powertrain applications.

High Performance Thread Sealant

Provides instant sealing on any threaded straight or parallel threaded fitting. (Thread sealant only, no locking ability.) • Do not use on plastic.

Gasket Maker 4

Nissan North America Part No. (USA) 999MP-AM000P

6

99998-50505

Medium Strength Thread Locking Sealant (Blue)

Threadlocker

Threadlocker (service tool removable)

Permatex 81844

D 999MP-AM001P

99998-50503

Permatex 51813 and 51817

E

F 999MP-AM002P

999MP-AM002P

Permatex 56521

G

999MP-AM003P (Ultra Grey)

99998-50506 (Ultra Grey)

Silicone RTV

High Temperature, High Strength Thread Locking Sealant (Red)

Aftermarket Crossreference Part Nos.

C

Gasket Maker for Maxima/ Quest 5-speed automatic transmission (RE5F22A)

5

Nissan Canada Part No. (Canada)

B

–

999MP-AM004P

999MP-AM005P

Permatex Ultra Grey 82194; Three Bond 1207,1215, 1216, 1217F, 1217G and 1217H Nissan RTV Part No. 999MP-A7007

H

I

Three Bond 1281B or exact equivalent in its quality

J

K

999MP-AM004P

Permatex 27200; Three Bond 1360, 1360N, 1305 N&P, 1307N, 1335, 1335B, 1363B, 1377C, 1386B, D&E and 1388 Loctite 648

999MP-AM005P

Permatex 24200, 24206, 24240, 24283 and 09178; Three Bond 1322, 1322N, 1324 D&N, 1333D, 1361C, 1364D, 1370C and 1374

–

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GI-17

2009 G37 Coupe

TERMINOLOGY < HOW TO USE THIS MANUAL >

TERMINOLOGY SAE J1930 Terminology List

INFOID:0000000005195962

All emission related terms used in this publication in accordance with SAE J1930 are listed. Accordingly, new terms, new acronyms/abbreviations and old terms are listed in the following chart. NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Air cleaner

ACL

Air cleaner

Barometric pressure

BARO

***

Barometric pressure sensor-BCDD

BAROS-BCDD

BCDD

Camshaft position

CMP

***

Camshaft position sensor

CMPS

Crank angle sensor

Canister

***

Canister

Carburetor

CARB

Carburetor

Charge air cooler

CAC

Intercooler

Closed loop

CL

Closed loop

Closed throttle position switch

CTP switch

Idle switch

Clutch pedal position switch

CPP switch

Clutch switch

Continuous fuel injection system

CFI system

***

Continuous trap oxidizer system

CTOX system

***

Crankshaft position

CKP

***

Crankshaft position sensor

CKPS

***

Data link connector

DLC

***

Diagnostic test mode

DTM

Diagnostic mode

Diagnostic test mode selector

DTM selector

Diagnostic mode selector

Diagnostic test mode I

DTM I

Mode I

Diagnostic test mode II

DTM II

Mode II

Diagnostic trouble code

DTC

Malfunction code

Direct fuel injection system

DFI system

***

Distributor ignition system

DI system

Ignition timing control

Early fuel evaporation-mixture heater

EFE-mixture heater

Mixture heater

Early fuel evaporation system

EFE system

Mixture heater control

Electrically erasable programmable read only memory

EEPROM

***

Electronic ignition system

EI system

Ignition timing control

Engine control

EC

***

Engine control module

ECM

ECCS control unit

Engine coolant temperature

ECT

Engine temperature

Engine coolant temperature sensor

ECTS

Engine temperature sensor

Engine modification

EM

***

Engine speed

RPM

Engine speed

Erasable programmable read only memory

EPROM

***

Evaporative emission canister

EVAP canister

Canister

Evaporative emission system

EVAP system

Canister control solenoid valve

Exhaust gas recirculation valve

EGR valve

EGR valve


GI-18

2009 G37 Coupe

TERMINOLOGY < HOW TO USE THIS MANUAL > NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

GI

Exhaust gas recirculation control-BPT valve

EGRC-BPT valve

BPT valve

Exhaust gas recirculation control-solenoid valve

EGRC-solenoid valve

EGR control solenoid valve

EGRT sensor

Exhaust gas temperature sensor

C

Flash electrically erasable programmable read only memory

FEEPROM

***

D

Flash erasable programmable read only memory

FEPROM

***

Flexible fuel sensor

FFS

***

Flexible fuel system

FF system

***

Fuel pressure regulator

***

Pressure regulator

Fuel pressure regulator control solenoid valve

***

PRVR control solenoid valve

Fuel trim

FT

***

Heated Oxygen sensor

HO2S

Exhaust gas sensor

Idle air control system

IAC system

Idle speed control

Idle air control valve-air regulator

IACV-air regulator

Air regulator

Idle air control valve-auxiliary air control valve

IACV-AAC valve

Auxiliary air control (AAC) valve

Idle air control valve-FICD solenoid valve

IACV-FICD solenoid valve

FICD solenoid valve

Idle air control valve-idle up control solenoid valve

IACV-idle up control solenoid valve

Idle up control solenoid valve

Idle speed control-FI pot

ISC-FI pot

FI pot

Idle speed control system

ISC system

***

Ignition control

IC

***

Ignition control module

ICM

***

Indirect fuel injection system

IFI system

***

Intake air

IA

Air

Intake air temperature sensor

IAT sensor

Air temperature sensor

Knock

***

Detonation

Knock sensor

KS

Detonation sensor

Malfunction indicator lamp

MIL

Check engine light

Manifold absolute pressure

MAP

***

Manifold absolute pressure sensor

MAPS

***

Manifold differential pressure

MDP

***

Manifold differential pressure sensor

MDPS

***

Exhaust gas recirculation temperature sensor

B

EGR temperature sensor

E

F

G

H

I

J

K

L

M

N

O

Manifold surface temperature

MST

***

Manifold surface temperature sensor

MSTS

***

Manifold vacuum zone

MVZ

***

Manifold vacuum zone sensor

MVZS

***

Mass air flow sensor

MAFS

Air flow meter

Mixture control solenoid valve

MC solenoid valve

Air-fuel ratio control solenoid valve

Multiport fuel injection system

MFI system

Fuel injection control


GI-19

P

2009 G37 Coupe


NEW TERM

OLD TERM

Nonvolatile random access memory

NVRAM

***

On board diagnostic system

OBD system

Self-diagnosis

Open loop

OL

Open loop

Oxidation catalyst

OC

Catalyst

Oxidation catalytic converter system

OC system

***

Oxygen sensor

O2S

Exhaust gas sensor

Park position switch

***

Park switch

Park/neutral position switch

PNP switch

Park/neutral switch Neutral position switch

Periodic trap oxidizer system

PTOX system

***

Positive crankcase ventilation

PCV

Positive crankcase ventilation

Positive crankcase ventilation valve

PCV valve

PCV valve

Powertrain control module

PCM

***

Programmable read only memory

PROM

***

Pulsed secondary air injection control solenoid valve

PAIRC solenoid valve

AIV control solenoid valve

Pulsed secondary air injection system

PAIR system

Air induction valve (AIV) control

Pulsed secondary air injection valve

PAIR valve

Air induction valve

Random access memory

RAM

***

Read only memory

ROM

***

Scan tool

ST

***

Secondary air injection pump

AIR pump

***

Secondary air injection system

AIR system

***

Sequential multiport fuel injection system

SFI system

Sequential fuel injection

Service reminder indicator

SRI

***

Simultaneous multiport fuel injection system

***

Simultaneous fuel injection

Smoke puff limiter system

SPL system

***

Supercharger

SC

***

Supercharger bypass

SCB

***

System readiness test

SRT

***

Thermal vacuum valve

TVV

Thermal vacuum valve

Three way catalyst

TWC

Catalyst

Three way catalytic converter system

TWC system

***

Three way + oxidation catalyst

TWC + OC

Catalyst

Three way + oxidation catalytic converter system

TWC + OC system

***

Throttle body

TB

Throttle chamber SPI body

Throttle body fuel injection system

TBI system

Fuel injection control

Throttle position

TP

Throttle position

Throttle position sensor

TPS

Throttle sensor

Throttle position switch

TP switch

Throttle switch

Torque converter clutch solenoid valve

TCC solenoid valve

Lock-up cancel solenoid Lock-up solenoid

Transmission control module

TCM

A/T control unit


GI-20

2009 G37 Coupe


NEW TERM

OLD TERM

Turbocharger

TC

Turbocharger

Vehicle speed sensor

VSS

Vehicle speed sensor

Volume air flow sensor

VAFS

Air flow meter

Warm up oxidation catalyst

WU-OC

Catalyst

Warm up oxidation catalytic converter system

WU-OC system

***

Warm up three way catalyst

WU-TWC

Catalyst

Warm up three way catalytic converter sysWU-TWC system tem

***

Wide open throttle position switch

Full switch

WOTP switch

GI

B

C

D

E

***: Not applicable

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GI-21

2009 G37 Coupe

IDENTIFICATION INFORMATION < VEHICLE INFORMATION >

VEHICLE INFORMATION IDENTIFICATION INFORMATION Model Variation Destination

Body

INFOID:0000000004257260

Transmission

Engine

Axle

7AT 2WD 6MT

Grade

Model

Standard

GLSALQL-EUA

Journey

GLSALSL-EUA

Journey + Premium

GLSALTL-EUA

Sport

7AT USA

Sport + Premium

7AT

4WAS

6MT VQ37VHR

AWD 7AT

7AT 6MT 7AT


GLSNLSL-EUA

Journey + Premium

GLSNLTL-EUA

Sport

GLSNLVL-EUA

Sport + Premium

GLSNLWL-EUA

Journey + Premium

GLSALTL-ENA GLSALWL-ENA

4WAS

GI-22

GLSBLWL-EUA

Journey

Sport + Premium

AWD

GLSALWY-EUA

GLSBLWY-EUA

2WD 6MT Canada

GLSALVY-EUA GLSALWL-EUA

6MT

Coupe

GLSALVL-EUA

GLSALWY-ENA GLSBLWL-ENA GLSBLWY-ENA

Journey + Premium

GLSNLTL-ENA

Sport + Premium

GLSNLWL-ENA

2009 G37 Coupe

IDENTIFICATION INFORMATION < VEHICLE INFORMATION > Model variation code (Prefix and suffix designations) GI

B

C

D

E

F

G

H JPAIA0451GB

Information About Identification or Model Code

INFOID:0000000004257261

I

IDENTIFICATION NUMBER J

K

L

M

N

JPAIA0143GB

1.

Vehicle identification plate

2. Emission control information label

3.

Vehicle identification number (Chassis number)

4.

Vehicle identification number plate

5. Air conditioner specification label

6.

Tire and loading information label

7.

FMVSS certification label


GI-23

2009 G37 Coupe

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IDENTIFICATION INFORMATION < VEHICLE INFORMATION > VEHICLE IDENTIFICATION NUMBER ARRANGEMENT

JPAIA0452GB

IDENTIFICATION PLATE

JPAIA0004ZZ

1.

Type

2.

Vehicle identification number (Chassis number) 3.

Model variation code

4.

Body color code

5.

Trim color code

6.

Engine model

7.

Engine displacement

8.

Transmission model

9.

Axle model

ENGINE SERIAL NUMBER : Vehicle front

JPAIA0005ZZ

AUTOMATIC TRANSMISSION NUMBER


GI-24

2009 G37 Coupe

IDENTIFICATION INFORMATION < VEHICLE INFORMATION > : Vehicle front

GI

B

C JPAIA0334ZZ

D

MANUAL TRANSMISSION NUMBER

E

F

G PAIA0068E

Dimensions

INFOID:0000000004257262

H

Unit: mm (in)

Overall length

4,650 (183.1)

Overall width

1,823 (71.8)

Overall height

1,393 (54.8)*1, 1,395 (54.9)*2, 1,406 (55.4)*3

Front tread

1,545 (60.8)

Rear tread

1,560 (61.4)

Wheelbase

2,850 (112.2)

I

J

K

*1: 2WD 18-in tire models *2: 2WD 19-in tire models *3: AWD models

L

Wheels & Tires

INFOID:0000000004257263

M Conventional 18 × 8J Aluminum/43 (1.69) Road wheel/offset mm (in)

Front: 19 × 8-1/2J Aluminum/43 (1.69) Rear: 19 × 9J Aluminum/45 (1.77) P225/50R18 94V

Tire size

Front: 225/45R19 92W Rear: 245/40R19 94W

Spare 17 × 4T Aluminum/30 (1.18) 18 × 4T Aluminum/0 (0)

N

T145/80D17 107M T145/70R18 107M

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GI-25

2009 G37 Coupe


PRECAUTION PRECAUTIONS Description

INFOID:0000000004257264

Observe the following precautions to ensure safe and proper servicing. These precautions are not described in each individual section.

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"

INFOID:0000000004684853



Precautions For Xenon Headlamp Service

INFOID:0000000004257266

WARNING: Comply with the following warnings to prevent any serious accident. • Disconnect the battery cable (negative terminal) or the power supply fuse before installing, removing, or touching the xenon headlamp (bulb included). The xenon headlamp contains high-voltage generated parts. • Never work with wet hands. • Check the xenon headlamp ON-OFF status after assembling it to the vehicle. Never turn the xenon headlamp ON in other conditions. Connect the power supply to the vehicle-side connector. (Turning it ON outside the lamp case may cause fire or visual impairments.) • Never touch the bulb glass immediately after turning it OFF. It is extremely hot. CAUTION: Comply with the following cautions to prevent any error and malfunction. • Install the xenon bulb securely. (Insufficient bulb socket installation may melt the bulb, the connector, the housing, etc. by high-voltage leakage or corona discharge.) • Never perform HID circuit inspection with a tester. • Never touch the xenon bulb glass with hands. Never put oil and grease on it. • Dispose of the used xenon bulb after packing it in thick vinyl without breaking it. • Never wipe out dirt and contamination with organic solvent (thinner, gasoline, etc.).


GI-26

2009 G37 Coupe





2. 3. 4. 5.

6.

GI

B

C

D

E

Connect both battery cables. NOTE: Supply power using jumper cables if battery is discharged. Turn the push-button ignition switch to ACC position. (At this time, the steering lock will be released.) Disconnect both battery cables. The steering lock will remain released with both battery cables disconnected and the steering wheel can be turned. Perform the necessary repair operation. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock when the push-button ignition switch is turned to LOCK position.) Perform self-diagnosis check of all control units using CONSULT-III.


F

G

H

I

INFOID:0000000004257268



J

K INFOID:0000000004257269


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N

PIIB3706J

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GI-27

2009 G37 Coupe


General Precautions

INFOID:0000000004257270

• Do not operate the engine for an extended period of time without proper exhaust ventilation. Keep the work area well ventilated and free of any inflammable materials. Special care should be taken when handling any inflammable or poisonous materials, such as gasoline, refrigerant gas, etc. When working in a pit or other enclosed area, be sure to properly ventilate the area before working with hazardous materials. Do not smoke while working on the vehicle.

SGI285

• Before jacking up the vehicle, apply wheel chocks or other tire blocks to the wheels to prevent the vehicle from moving. After jacking up the vehicle, support the vehicle weight with safety stands at the points designated for proper lifting before working on the vehicle. These operations should be done on a level surface. • When removing a heavy component such as the engine or transaxle/transmission, be careful not to lose your balance and drop them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder. SGI231

• Before starting repairs which do not require battery power: Turn off ignition switch. Disconnect the negative battery terminal. • If the battery terminals are disconnected, recorded memory of radio and each control unit is erased.

SEF289H

• To prevent serious burns: Avoid contact with hot metal parts. Do not remove the radiator cap when the engine is hot. • Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner. • Do not attempt to top off the fuel tank after the fuel pump nozzle shuts off automatically. Continued refueling may cause fuel overflow, resulting in fuel spray and possibly a fire. • Clean all disassembled parts in the designated liquid or solvent prior to inspection or assembly. • Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones. • Replace inner and outer races of tapered roller bearings and needle bearings as a set. • Arrange the disassembled parts in accordance with their assembled locations and sequence. • Do not touch the terminals of electrical components which use microcomputers (such as ECM). Static electricity may damage internal electronic components. • After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection. • Use only the fluids and lubricants specified in this manual. • Use approved bonding agent, sealants or their equivalents when required. Revision: 2009 October

GI-28

SGI233

2009 G37 Coupe

PRECAUTIONS < PRECAUTION > • Use hand tools, power tools (disassembly only) and recommended special tools where specified for safe and efficient service repairs. • When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks.

GI

B

C JPAIA0335ZZ

D

• Before servicing the vehicle: Protect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons do not scratch paint.

E

F

G SGI234

WARNING: To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness connectors which are related to the engine control system and TCM (transmission control module) system. The connectors should be disconnected only when working according to the WORK FLOW of TROUBLE DIAGNOSES in EC and AT sections.

Three Way Catalyst

I

INFOID:0000000004257271

J

If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To prevent this, follow the instructions. • Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst. • When checking for ignition spark or measuring engine compression, make tests quickly and only when necessary. • Do not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to the catalyst. Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three way catalyst.

Multiport Fuel Injection System or Engine Control System

INFOID:0000000004257272

• Before connecting or disconnecting any harness connector for the multiport fuel injection system or ECM: Turn ignition switch to “OFF” position. Disconnect negative battery terminal. Otherwise, there may be damage to ECM. • Before disconnecting pressurized fuel line from fuel pump to injectors, be sure to release fuel pressure. • Be careful not to jar components such as ECM and mass air flow sensor.

Hoses

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INFOID:0000000004257273

HOSE REMOVAL AND INSTALLATION

GI-29

K

N

SGI787


H

2009 G37 Coupe

PRECAUTIONS < PRECAUTION > • To prevent damage to rubber hose, do not pry off rubber hose with tapered tool or screwdriver.

SMA019D

• To reinstall the rubber hose securely, make sure that hose insertion length and orientation is correct. (If tube is equipped with hose stopper, insert rubber hose into tube until it butts up against hose stopper.)

SMA020D

HOSE CLAMPING • If old rubber hose is re-used, install hose clamp in its original position (at the indentation where the old clamp was). If there is a trace of tube bulging left on the old rubber hose, align rubber hose at that position. • Discard old clamps; replace with new ones.

SMA021D

• After installing plate clamps, apply force to them in the direction of the arrow, tightening rubber hose equally all around.

SMA022D

Engine Oils

INFOID:0000000004257274

Prolonged and repeated contact with used engine oil may cause skin cancer. Try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible.

HEALTH PROTECTION PRECAUTIONS • • • •

Avoid prolonged and repeated contact with oils, particularly used engine oils. Wear protective clothing, including impervious gloves where practicable. Do not put oily rags in pockets. Avoid contaminating clothes, particularly underpants, with oil.


GI-30

2009 G37 Coupe

PRECAUTIONS < PRECAUTION > • Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. GI • First aid treatment should be obtained immediately for open cuts and wounds. • Use barrier creams, applying them before each work period, to help the removal of oil from the skin. • Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). PreparaB tions containing lanolin replace the natural skin oils which have been removed. • Do not use gasoline, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin. • If skin disorders develop, obtain medical advice without delay. • Where practical, degrease components prior to handling. C • Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided.

ENVIRONMENTAL PROTECTION PRECAUTIONS

D

Dispose of used oil and used oil filters through authorized waste disposal contractors to licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt, contact the local authority for advice on disposal facilities. It is illegal to pour used oil on to the ground, down sewers or drains, or into water sources. The regulations concerning pollution vary between regions.

E

Air Conditioning

F

INFOID:0000000004257275

Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to HA section “REFRIGERANT” for specific instructions.

Fuel

G

INFOID:0000000004257276

INFINITI recommends the use of unleaded premium gasoline with an octane rating of at least 91 AKI (AntiKnock Index) number (Research octane number 96). If unleaded premium gasoline is not available, unleaded regular gasoline with an octane rating of at least 87 AKI number (Research octane number 91), may be temporarily used, but only under the following precautions: • Have the fuel tank filled only partially with unleaded regular gasoline, and fill up with unleaded premium gasoline as soon as possible. • Avoid full throttle driving and abrupt acceleration. However, for maximum vehicle performance, the use of unleaded premium gasoline is recommended. CAUTION: Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Do not use E-85 fuel (85% fuel ethanol, 15% unleaded gasoline) unless the vehicle is specifically designed for E-85 fuel (i.e. Flexible Fuel Vehicle - FFV models). Using a fuel other than that specified could adversely affect the emission control devices and systems, and could also affect the warranty coverage validity.

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GI-31

2009 G37 Coupe

LIFTING POINT < PRECAUTION >

LIFTING POINT Commercial Service Tools

INFOID:0000000004257277

Tool name

Description

Board on attachment

S-NT001

Safety stand attachment

S-NT002

CAUTION: • Every time the vehicle is lifted up, maintain the complete vehicle curb condition. • Since the vehicle's center of gravity changes when removing main parts on the front side (engine, transmission, suspension etc.), support a jack up point on the rear side garage jack with a mission jack or equivalent. • Since the vehicle's center of gravity changes when removing main parts on the rear side (rear axle, suspension, etc.), support a jack up point on the front side garage jack with a mission jack or equivalent. • Be careful not to smash or do not do anything that would affect piping parts.

Garage Jack and Safety Stand and 2-Pole Lift

INFOID:0000000004257278

WARNING: • Park the vehicle on a level surface when using the jack. Make sure to avoid damaging pipes, tubes, etc. under the vehicle. • Never get under the vehicle while it is supported only by the jack. Always use safety stands when you have to get under the vehicle. • Place wheel chocks at both front and back of the wheels on the ground. • When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced. • When setting the lift arm, do not allow the arm to contact the brake tubes, brake cable, fuel lines and sill spoiler.


GI-32

2009 G37 Coupe

LIFTING POINT < PRECAUTION > GI

B

C

D

E

F

JMAIA0060ZZ

1.

Safety stand point and lift up point (front) 2.

4.

Garage jack point (rear)

Safety stand point and lift up point (rear)

3.

Garage jack point (front)

G

CAUTION: There is canister just behind Garage jack point rear. Jack up be carefully.

Board-On Lift

H INFOID:0000000004257279

CAUTION: Make sure vehicle is empty when lifting. • The board-on lift attachment (A) set at front end of vehicle should be set on the front of the sill under the front door opening. • Position attachments at front and rear ends of board-on lift.

I

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: Vehicle front

L JMAIA0004ZZ

M

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GI-33

2009 G37 Coupe

TOW TRUCK TOWING < PRECAUTION >

TOW TRUCK TOWING Tow Truck Towing

INFOID:0000000004257280

CAUTION: • All applicable state or Provincial laws and local laws regarding the towing operation must be obeyed. • It is necessary to use proper towing equipment to avoid possible damage to the vehicle during towing operation. Towing is in accordance with Towing Procedure Manual at dealer. • Always attach safety chains before towing. • When towing, make sure that the transmission, steering system and powertrain are in good order. If any unit is damaged, dollies must be used. • Never tow an automatic transmission model from the rear (that is backward) with four wheels on the ground. This may cause serious and expensive damage to the transmission.

2WD MODELS

PIIB6402E

INFINITI recommends that vehicle be towed with the driving (rear) wheels off the ground or that a dolly be used as illustrated. CAUTION: • Never tow automatic transmission models with the rear wheels on the ground or four wheels on the ground (forward or backward), as this may cause serious and expensive damage to the transmission. If it is necessary to tow the vehicle with the front wheels raised, always use towing dollies under the rear wheels. • When towing rear wheel drive models with the front wheels on the ground or on towing dollies: - Turn the ignition key to the OFF position, and secure the steering wheel in a straight ahead position with a rope or similar device.Never secure the steering wheel by turning the ignition key to the LOCK position. This may damage the steering lock mechanism. - Move the selector lever to the N (Neutral) position. • When the battery of vehicle equipped with the Intelligent Key system is discharged, your vehicle should be towed with the front wheels on towing dollies or place the vehicle on a flat bed truck. If the speed or distance must necessarily be greater, remove the propeller shaft before towing to prevent damage to the transmission.


GI-34

2009 G37 Coupe

TOW TRUCK TOWING < PRECAUTION > AWD MODELS GI

B

C

D

E

PIIB6403E

F

INFINITI recommends that a dolly be used as illustrated when towing AWD models. CAUTION: Never tow AWD models with any of the wheels on the ground as this may cause serious and expensive damage to the powertrain.

G

Vehicle Recovery (Freeing a Stuck Vehicle)

H

INFOID:0000000004257281

FRONT Securely install the vehicle recovery hook stored with jacking tools. Make sure that the hook is properly secured in the stored place after use. WARNING: • Stand clear of a stuck vehicle. • Do not spin your tires at high speed. This could cause them to explode and result in serious injury. Parts of your vehicle could also overheat and be damaged. CAUTION: • Tow chains or cables must be attached only to the vehicle recovery hooks or main structural members of the vehicle. JMAIA0049ZZ Otherwise, the vehicle body will be damaged. • Do not use the vehicle tie downs to free a vehicle stuck in sand, snow, mud, etc. Never tow the vehicle using the vehicle tie downs or recovery hooks. • Always pull the cable straight out from the front of the vehicle. Never pull on the hook at an angle. • Pulling devices should be routed so they do not touch any part of the suspension, steering, brake or cooling systems. • Pulling devices such as ropes or canvas straps are not recommended for use in vehicle towing or recovery.

REAR

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WARNING: • Rear hook is not available.

AUTOMATIC TRANSMISSION

P

To tow a vehicle equipped with an automatic transmission, an appropriate vehicle dolly MUST be placed under the towed vehicle's drive wheels. Always follow the dolly manufacture's recommendations when using their product. If the vehicle is stuck in sand, snow, mud, etc., use the following procedure: 1. Turn off the Vehicle Dynamic Control System. 2. Make sure the area in front and behind the vehicle is clear of obstructions. Revision: 2009 October

I

GI-35

2009 G37 Coupe

TOW TRUCK TOWING < PRECAUTION > 3. Turn the steering wheel right and left to clear an area around the front tires. 4. Slowly rock the vehicle forward and backward. Shift back and forth between R (reverse) and D (drive). Apply the accelerator as little as possible to maintain the rocking motion. Release the accelerator pedal before shifting between R and D. Do not spin the tires above 35 mph (55 km/h). 5. If the vehicle can not be freed after a few tries, contact a professional towing service to remove the vehicle.


GI-36

2009 G37 Coupe

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION >

BASIC INSPECTION

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT Work Flow

INFOID:0000000004257282

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WORK FLOW C

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SGI838

STEP

DESCRIPTION Get detailed information about the conditions and the environment when the incident occurred. The following are key pieces of information required to make a good analysis:

STEP 1

WHAT

Vehicle Model, Engine, Transmission/Transaxle and the System (i.e. Radio).

WHEN

Date, Time of Day, Weather Conditions, Frequency.

WHERE

Road Conditions, Altitude and Traffic Situation.

HOW

System Symptoms, Operating Conditions (Other Components Interaction). Service History and if any After Market Accessories have been installed.

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STEP 2

Operate the system, road test if necessary. Verify the parameter of the incident. If the problem cannot be duplicated, refer to “Incident Simulation Tests”.

STEP 3

Get the proper diagnosis materials together including: • Power Supply Routing • System Operation Descriptions • Applicable Service Manual Sections • Check for any Service Bulletins Identify where to begin diagnosis based upon your knowledge of the system operation and the customer comments.

STEP 4

Inspect the system for mechanical binding, loose connectors or wiring damage. Determine which circuits and components are involved and diagnose using the Power Supply Routing and Harness Layouts.

STEP 5

Repair or replace the incident circuit or component.

STEP 6

Operate the system in all modes. Verify the system works properly under all conditions. Make sure you have not inadvertently created a new incident during your diagnosis or repair steps.

Control Units and Electrical Parts

L

INFOID:0000000004257283

Never reverse polarity of battery terminals. Install only parts specified for a vehicle. Before replacing the control unit, check the input and output and functions of the component parts. Do not apply excessive force when disconnecting a connector.


GI-37

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PRECAUTIONS • • • •

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2009 G37 Coupe

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > • Do not apply excessive shock to the control unit by dropping or hitting it. • Be careful to prevent condensation in the control unit due to rapid temperature changes and do not let water or rain get on it. If water is found in the control unit, dry it fully and then install it in the vehicle. • Be careful not to let oil to get on the control unit connector. • Avoid cleaning the control unit with volatile oil. • Do not disassemble the control unit, and do not remove the upper and lower covers. SAIA0255E

• When using a DMM, be careful not to let test probes get close to each other to prevent the power transistor in the control unit from damaging battery voltage because of short circuiting. • When checking input and output signals of the control unit, use the specified check adapter.

SEF348N

How to Check Terminal

INFOID:0000000004257284

CONNECTOR AND TERMINAL PIN KIT • Use the connector and terminal pin kits listed below when replacing connectors or terminals. • The connector and terminal pin kits contain some of the most commonly used NISSAN/INFINITI connectors and terminals. For detailed connector and terminal pin replacement procedures, refer to the latest NISSAN/ INFINITI CONNECTOR AND TERMINAL PIN SERVICE MANUAL.


GI-38

2009 G37 Coupe

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > Tool number (Kent-Moore No.) Tool name (J38751-95NI) Connector and terminal pin kit (NISSAN) (J38751-95INF) Connector and terminal pin kit (INFINITI) (J42992-98KIT) OBD and terminal repair kit (J42992-2000UPD) OBD-II Connector Kit Update

GI Description

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WAIA0005E

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HOW TO PROBE CONNECTORS • Connector damage and an intermittent connection can result from improperly probing of the connector during circuit checks. • The probe of a digital multimeter (DMM) may not correctly fit the connector cavity. To correctly probe the connector, follow the procedures below using a “T” pin. For the best contact grasp the “T” pin using an alligator clip. Probing from Harness Side Standard type (not waterproof type) connector should be probed from harness side with “T” pin. • If the connector has a rear cover such as a ECM connector, remove the rear cover before probing the terminal. • Do not probe waterproof connector from harness side. Damage to the seal between wire and connector may result.

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Probing from Terminal Side FEMALE TERMINAL

• There is a small notch above each female terminal. Probe each terminal with the “T” pin through the notch. Do not insert any object other than the same type male terminal into female terminal.

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SEL265V


GI-39

2009 G37 Coupe

P

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > • Some connectors do not have a notch above each terminal. To probe each terminal, remove the connector retainer to make contact space for probing.

SEL266V

MALE TERMINAL

• Carefully probe the contact surface of each terminal using a “T” pin. CAUTION: Dot not bend terminal.

SEL267V

How to Check Enlarged Contact Spring of Terminal • An enlarged contact spring of a terminal may create intermittent signals in the circuit. • If the intermittent open circuit occurs, follow the procedure below to inspect for open wires and enlarged contact spring of female terminal. 1. Assemble a male terminal and approx. 10 cm (3.9 in) of wire. NOTE: Use a male terminal which matches the female terminal. 2. Disconnect the suspected faulty connector and hold it terminal side up.

SEL270V

3.

While holding the wire of the male terminal, try to insert the male terminal into the female terminal. CAUTION: Do not force the male terminal into the female terminal with your hands.

SEL271V


GI-40

2009 G37 Coupe

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > 4. While moving the connector, check whether the male terminal can be easily inserted or not.

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• If the male terminal can be easily inserted into the female terminal, replace the female terminal. E

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Waterproof Connector Inspection If water enters the connector, it can short interior circuits. This may lead to intermittent problems. Check the following items to maintain the original waterproof characteristics.

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RUBBER SEAL INSPECTION

I

• Most waterproof connectors are provided with a rubber seal between the male and female connectors. If the seal is missing, the waterproof performance may not meet specifications. • The rubber seal may come off when connectors are disconnected. Whenever connectors are reconnected, make sure the rubber seal is properly installed on either side of male or female connector.

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WIRE SEAL INSPECTION

• The wire seal must be installed on the wire insertion area of a waterproof connector. Be sure that the seal is installed properly. L SEL275V

Terminal Lock Inspection Check for unlocked terminals by pulling wire at the end of connector. An unlocked terminal may create intermittent signals in the circuit.

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SEL330V

Intermittent Incident

INFOID:0000000004257285

DESCRIPTION Sometimes the symptom is not present when the vehicle is brought in for service. If possible, re-create the conditions present at the time of the incident. Doing so may help avoid a No Trouble Found Diagnosis. The fol-


GI-41

2009 G37 Coupe

P

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > lowing section illustrates ways to simulate the conditions/environment under which the owner experiences an electrical incident. The section is broken into the six following topics:

• Vehicle vibration • Heat sensitive • Freezing • Water intrusion • Electrical load • Cold or hot start up Get a thorough description of the incident from the customer. It is important for simulating the conditions of the problem.

VEHICLE VIBRATION The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle with A/C on). In such a case, you will want to check for a vibration related condition. Refer to the following illustration. Connector & Harness Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gently shake each connector and harness while monitoring the system for the incident you are trying to duplicate. This test may indicate a loose or poor electrical connection. Hint Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector terminals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs intermittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the terminals on related connectors in the system. Sensor & Relay Gently apply a slight vibration to sensors and relays in the system you are inspecting. This test may indicate a loose or poorly mounted sensor or relay.

SGI839

Engine Compartment There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the things to check for are: • Connectors not fully seated. • Wiring harness not long enough and is being stressed due to engine vibrations or rocking. • Wires laying across brackets or moving components. • Loose, dirty or corroded ground wires. • Wires routed too close to hot components. To inspect components under the hood, start by verifying the integrity of ground connections. (Refer to Ground Inspection described later.) First check that the system is properly grounded. Then check for loose connection by gently shaking the wiring or components as previously explained. Using the wiring diagrams inspect the wiring for continuity. Behind the Instrument Panel An improperly routed or improperly clamped harness can become pinched during accessory installation. Vehicle vibration can aggravate a harness which is routed along a bracket or near a screw. Under Seating Areas


GI-42

2009 G37 Coupe

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > An unclamped or loose harness can cause wiring to be pinched by seat components (such as slide guides) during vehicle vibration. If the wiring runs under seating areas, inspect wire routing for possible damage or GI pinching.

HEAT SENSITIVE B

• The customer's concern may occur during hot weather or after car has sat for a short time. In such cases you will want to check for a heat sensitive condition. • To determine if an electrical component is heat sensitive, heat the component with a heat gun or equivalent. CAUTION: Do not heat components above 60°C (140°). • If incident occurs while heating the unit, either replace or properly insulate the component.

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SGI842

E

FREEZING • The customer may indicate the incident goes away after the car warms up (winter time). The cause could be related to water freezing somewhere in the wiring/electrical system. • There are two methods to check for this. The first is to arrange for the owner to leave his car overnight. Make sure it will get cold enough to demonstrate his complaint. Leave the car parked outside overnight. In the morning, do a quick and thorough diagnosis of those electrical components which could be affected. • The second method is to put the suspect component into a freezer long enough for any water to freeze. Reinstall the part into the car and check for the reoccurrence of the incident. If it occurs, repair or replace the component.

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SGI843

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WATER INTRUSION The incident may occur only during high humidity or in rainy/snowy weather. In such cases the incident could be caused by water intrusion on an electrical part. This can be simulated by soaking the car or running it through a car wash. CAUTION: Do not spray water directly on any electrical components.

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SGI844

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ELECTRICAL LOAD The incident may be electrical load sensitive. Perform diagnosis with all accessories (including A/C, rear window defogger, radio, fog lamps) turned on.

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COLD OR HOT START UP On some occasions an electrical incident may occur only when the car is started cold, or it may occur when the car is restarted hot shortly after being turned off. In these cases you may have to keep the car overnight to make a proper diagnosis. Revision: 2009 October

GI-43

2009 G37 Coupe

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION >

Circuit Inspection

INFOID:0000000004257286

DESCRIPTION • In general, testing electrical circuits is an easy task if it is approached in a logical and organized method. Before beginning it is important to have all available information on the system to be tested. Also, get a thorough understanding of system operation. Then you will be able to use the appropriate equipment and follow the correct test procedure. • You may have to simulate vehicle vibrations while testing electrical components. Gently shake the wiring harness or electrical component to do this. OPEN

A circuit is open when there is no continuity through a section of the circuit. There are two types of shorts.

SHORT

• SHORT CIRCUIT

When a circuit contacts another circuit and causes the normal resistance to change.

• SHORT TO GROUND

When a circuit contacts a ground source and grounds the circuit.

NOTE: Refer to GI-38, "How to Check Terminal" to probe or check terminal.

TESTING FOR “OPENS” IN THE CIRCUIT Before you begin to diagnose and test the system, you should rough sketch a schematic of the system. This will help you to logically walk through the diagnosis process. Drawing the sketch will also reinforce your working knowledge of the system.

SGI846-A

Continuity Check Method The continuity check is used to find an open in the circuit. The digital multimeter (DMM) set on the resistance function will indicate an open circuit as over limit (no beep tone or no ohms symbol). Make sure to always start with the DMM at the highest resistance level. To help in understanding the diagnosis of open circuits, please refer to the previous schematic. • Disconnect the battery negative cable. • Start at one end of the circuit and work your way to the other end. (At the fuse block in this example) • Connect one probe of the DMM to the fuse block terminal on the load side. • Connect the other probe to the fuse block (power) side of SW1. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point A) • Connect the probes between SW1 and the relay. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point B) • Connect the probes between the relay and the solenoid. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point C) Any circuit can be diagnosed using the approach in the previous example. Voltage Check Method To help in understanding the diagnosis of open circuits please refer to the previous schematic. In any powered circuit, an open can be found by methodically checking the system for the presence of voltage. This is done by switching the DMM to the voltage function. • Connect one probe of the DMM to a known good ground. • Begin probing at one end of the circuit and work your way to the other end. • With SW1 open, probe at SW1 to check for voltage. voltage; open is further down the circuit than SW1.


GI-44

2009 G37 Coupe

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > no voltage; open is between fuse block and SW1 (point A). • Close SW1 and probe at relay. voltage; open is further down the circuit than the relay. no voltage; open is between SW1 and relay (point B). • Close the relay and probe at the solenoid. voltage; open is further down the circuit than the solenoid. no voltage; open is between relay and solenoid (point C). Any powered circuit can be diagnosed using the approach in the previous example.

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TESTING FOR “SHORTS” IN THE CIRCUIT To simplify the discussion of shorts in the system, please refer to the following schematic.

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Resistance Check Method • Disconnect the battery negative cable and remove the blown fuse. • Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the fuse. • Connect one probe of the DMM to the load side of the fuse terminal. Connect the other probe to a known good ground. • With SW1 open, check for continuity. continuity; short is between fuse terminal and SW1 (point A). no continuity; short is further down the circuit than SW1. • Close SW1 and disconnect the relay. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. continuity; short is between SW1 and the relay (point B). no continuity; short is further down the circuit than the relay. • Close SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. continuity; short is between relay and solenoid (point C). no continuity; check solenoid, retrace steps. Voltage Check Method • Remove the blown fuse and disconnect all loads (i.e. SW1 open, relay disconnected and solenoid disconnected) powered through the fuse. • Turn the ignition key to the ON or START position. Verify battery voltage at the battery + side of the fuse terminal (one lead on the battery + terminal side of the fuse block and one lead on a known good ground). • With SW1 open and the DMM leads across both fuse terminals, check for voltage. voltage; short is between fuse block and SW1 (point A). no voltage; short is further down the circuit than SW1. • With SW1 closed, relay and solenoid disconnected and the DMM leads across both fuse terminals, check for voltage. voltage; short is between SW1 and the relay (point B). no voltage; short is further down the circuit than the relay. • With SW1 closed, relay contacts jumped with fused jumper wire check for voltage. voltage; short is down the circuit of the relay or between the relay and the disconnected solenoid (point C). no voltage; retrace steps and check power to fuse block.

GROUND INSPECTION • Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit works. • Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface. Revision: 2009 October

GI-45

2009 G37 Coupe

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > • When inspecting a ground connection follow these rules: - Remove the ground bolt or screw. - Inspect all mating surfaces for tarnish, dirt, rust, etc. - Clean as required to assure good contact. - Reinstall bolt or screw securely. - Inspect for “add-on” accessories which may be interfering with the ground circuit. - If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one eyelet make sure no ground wires have excess wire insulation. • For detailed ground distribution information, refer to “Ground Distribution” in PG section.

SGI853

VOLTAGE DROP TESTS • Voltage drop tests are often used to find components or circuits which have excessive resistance. A voltage drop in a circuit is caused by a resistance when the circuit is in operation. • Check the wire in the illustration. When measuring resistance with DMM, contact by a single strand of wire will give reading of 0 ohms. This would indicate a good circuit. When the circuit operates, this single strand of wire is not able to carry the current. The single strand will have a high resistance to the current. This will be picked up as a slight voltage drop. • Unwanted resistance can be caused by many situations as follows: - Undersized wiring (single strand example) - Corrosion on switch contacts - Loose wire connections or splices. • If repairs are needed always use wire that is of the same or larger gauge. Measuring Voltage Drop — Accumulated Method • Connect the DMM across the connector or part of the circuit you want to check. The positive lead of the DMM should be closer to power and the negative lead closer to ground. • Operate the circuit. • The DMM will indicate how many volts are being used to “push” current through that part of the circuit.


GI-46

2009 G37 Coupe

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb. GI

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SGI974

Measuring Voltage Drop — Step-by-Step • The step-by-step method is most useful for isolating excessive drops in low voltage systems (such as those in “Computer Controlled Systems”). • Circuits in the “Computer Controlled System” operate on very low amperage. • The (Computer Controlled) system operations can be adversely affected by any variation in resistance in the system. Such resistance variation may be caused by poor connection, improper installation, improper wire gauge or corrosion. • The step by step voltage drop test can identify a component or wire with too much resistance.

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CONTROL UNIT CIRCUIT TEST System Description • When the switch is ON, the control unit lights up the lamp.

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CASE 1 P

MGI034A


GI-47

2009 G37 Coupe

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > INPUT-OUTPUT VOLTAGE CHART

Terminal No. +

1

2

−


Body ground

Switch

Body ground

Lamp

Value (Approx.)

In case of high resistance such as single strand (V) *

Switch ON

Battery voltage

Lower than battery voltage Approx. 8 (Example)

Switch OFF

0V

Switch ON

Battery voltage

Switch OFF

0V

Condition

Input/ Output Input

Output

Approx. 0 Approx. 0 (Inoperative lamp) Approx. 0

• The voltage value is based on the body ground. • *: If high resistance exists in the switch side circuit (caused by a single strand), terminal 1 does not detect battery voltage. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not supply power to light up the lamp.

CASE 2

MGI035A

INPUT-OUTPUT VOLTAGE CHART

Terminal No. +

−


Condition

Input/ Output

1

Body ground

Lamp

Output

2

Body ground

Switch

Input

Value (Approx.)

Switch ON

0V

Switch OFF

Battery voltage

In case of high resistance such as single strand (V) * Battery voltage (Inoperative lamp) Battery voltage

Switch ON

0V

Higher than 0 Approx. 4 (Example)

Switch OFF

5V

Approx. 5

• The voltage value is based on the body ground. • *: If high resistance exists in the switch side circuit (caused by a single strand), terminal 2 does not detect approx. 0V. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not control ground to light up the lamp.


GI-48

2009 G37 Coupe

CONSULT-III/GST CHECKING SYSTEM < BASIC INSPECTION >

CONSULT-III/GST CHECKING SYSTEM

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Description

INFOID:0000000004257287

• When CONSULT-III/GST is connected with a data link connector (A) equipped on the vehicle side, it will communicate with the control unit equipped in the vehicle and then enable various kinds of diagnostic tests. 1

B

C

: Instrument driver lower panel

• Refer to “CONSULT-III Software Operation Manual” for more information.

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JPAIA0024ZZ

CONSULT-III Function and System Application*1

E

INFOID:0000000004257288

ENGINE

TRANSMISSION

AIR BAG

METER/M&A

BCM

AUTO DRIVE POS.

ABS

IPDM E/R

ICC

4WAS (FRONT)

4WAS (MAIN/RAS/HICAS)

ADAPTIVE LIGHT

MULTI AV

PRE CRASH SEAT BELT

AIR PRESSURE MONITOR

ALL MODE AWD/4WD

F

Work Support

This mode enables a technician to adjust some devices faster and more accurately.

x

-

-

-

x

x

x

-

x

-

-

x

-

-

x

-

Self-Diagnostic Results

Retrieve DTC from ECU and display diagnostic items.

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

Data Monitor

Monitor the input/output signal of the control unit in real time.

x

x

-

x

x

x

x

x

x

x

x

x

x

x

x

x

CAN Diagnosis

This mode displays a network diagnosis result about CAN by a diagram.

x

x

x

x

x

x

x

x

x

-

x

x

x

x

-

x

CAN Diagnosis Support Monitor

It monitors the status of CAN communication.

x

x

-

x

x

x

x

x

x

x

x

x

x

x

-

x

Active Test

Send the drive signal from CONSULT-III to the actuator. The operation check can be performed.

x

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-

-

x

x

x

x

x

x

x

x

-

-

x

x

DTC & SRT confirmation

The status of system monitoring tests and the self-diagnosis status/result can be confirmed.

x

ECU Identification

Display the ECU identification number (part number etc.) of the selected system.

x

Function Test

This mode can show results of self-diagnosis of ECU with either “OK” or “NG”. For engine, more practical tests regarding sensors/switches and/or actuators are available.

x

Configuration

Function to READ/WRITE vehicle configuration.

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-

x

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-

-

-

-

-

-

-

-

-

-

Special Function

Other results or histories, etc. that are recorded in ECU are displayed.

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x

x

-

-

-

-

-

-

-

-

-

-

-

-

-

Diagnostic test mode

Function

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-

-

-

-

-

-

-

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-

-

-

-

N x

-

x

x

x

x

x

x

x

x

x

x

x

-

x

O x

x

-

-

-

x

-

-

-

-

-

-

-

-

-

P

x: Applicable *1: If GST application is equipped, functions in accordance with SAE J1979 and ISO 15031-5 can be used.


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GI-49

2009 G37 Coupe


CONSULT-III/GST Data Link Connector (DLC) Circuit

INFOID:0000000004257289

INSPECTION PROCEDURE If the CONSULT-III/GST cannot diagnose the system properly, check the following items. Symptom

Check item

CONSULT-III/GST cannot access any system.

• CONSULT-III/GST DLC power supply circuit (Terminal 8 and 16) and ground circuit (Terminal 4 and 5)

CONSULT-III cannot access individual system. (Other systems can be accessed.)

• Power supply and ground circuit for the control unit of the system (For detailed circuit, refer to wiring diagram for each system.) • Open or short circuit between the system and CONSULT-III DLC (For detailed circuit, refer to wiring diagram for each system.) • Open or short circuit CAN communication line. Refer to LAN-18, "Trouble Diagnosis Flow Chart".

NOTE: The DDL1 and DDL2 circuits from DLC pins 12, 13, 14 and 15 may be connected to more than one system. A short in a DDL circuit connected to a control unit in one system may affect CONSULT-III access to other systems. If the GST cannot operate properly, check the circuit based on the information of SAE J1962 and ISO 150313.


GI-50

2009 G37 Coupe


Wiring Diagram - CONSULT-III/GST CHECKING SYSTEM -

INFOID:0000000004257290

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GI-51

2009 G37 Coupe

P


JCAWM0135GB


GI-52

2009 G37 Coupe

CONSULT-III/GST CHECKING SYSTEM < BASIC INSPECTION > GI

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GI-53

2009 G37 Coupe


JCAWM0137GB


GI-54

2009 G37 Coupe

CONSULT-III/GST CHECKING SYSTEM < BASIC INSPECTION > GI

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GI-55

2009 G37 Coupe

INSPECTION AND ADJUSTMENT < BASIC INSPECTION >

INSPECTION AND ADJUSTMENT ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL : Required Procedure After Battery Disconnection

INFOID:0000000004257291

SYSTEM

ITEM Temperature setting trimmer

HAC-7, "Temperature Setting Trimmer"

Foot position setting trimmer

HAC-9, "Foot Position Setting Trimmer"

Inlet port memory function Automatic temperature control

REFERENCE

HAC-10, "Inlet Port Memory Function"

Inlet port memory function (FRE)*

—

Inlet port memory function (REC)*

—

Gas sensor sensitivity adjustment function*

—

Auto intake switch Interlocking movement change*

—

Clean switch interlocking movement change*

—

Automatic drive positioner

Automatic drive positioner system

ADP-9, "ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL : Description"

Power window control

Power window control system

PWC-5, "ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL : Description"

Sunroof system*

Sunroof system

—

Sunshade system*

Sunshade system

—

Rear view monitor

Rear view monitor possible route line center position adjustment

Around view monitor*

Predicted course line center position adjustment

—

Automatic back door system*

Automatic back door system

—

Engine oil level read*

Engine oil level read

—

AV-374, "ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL : Description"

*: Not equipped.


GI-56

2009 G37 Coupe

infiniti G37-09-Coupe4

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