ps-34 - 4 8 15 16 23 42
Contents
1. Washer 4 KV48100410 Joint Revision 2004 April M16x1 5 3 KV481 02500 04 A M16x1 5 lt 4 KV481 00400 2 3 KV481 3 KV481 02500 04 2 KV481 00400 1 02500 04 1 KV481 03500 SGIA0321J PS 3 Measuring oil pump relief pressure 2003 350Z PREPARATION Commercial Service Tools AGS0001W Tool name Description Power tool Removing oil pump and wheel nuts PBIC0190E Revision 2004 April PS 4 2003 350Z NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING PFP 00003 NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING NVH Troubleshooting Chart AGS0001X Use chart below to help you find the cause of the symptom If necessary repair or replace these parts Wei D uonoes Hg UI HAN S34vud X X x x uonoes ut HAN ldvHSdAldd X x X uonoes LM U HAN Ti3HM X lt uonoes M Ul HAN X X X X uonoes MSH NSA XV4 Ul HAN NOISNAdSNS pue dTXV X X X X X uonoes 048 U HAN TVILNVH3HHIG ul HAN 1 5 X X 41 5 sseuesoo x x 05 uuunjoo Buueeis sseuesoo 10 uorejersur x 01 5 10 Duugee x 11 x x Xx Xx S Sd 1 A 490 111 JO Sseuesoo 10 uonejejsu x x2. gt Se E 14 7186 n d 9 5 SN 1 5 1 8 11 13 0 40 0 49 7129 4 39 2 3 0 3 9 22 28 4 9 13 7 0 50 1 3 44 121 DX Always replace after every disassembly N m kg m in Ib D N m kg m ft Ib SGIA0339E Lower joint 2 Lower shaft 3 Hole cover 4 Clamp 5 Hole cover seal 6 Collar 7 Steering column assembly 8 Combination switch amp spiral cable 9 Escutcheon 10 Column lower cover 11 Right lid 12 Combination meter amp column upper cover 13 Steering wheel 14 Steering wheel lock nut 15 Left lid 16 Driver air bag module CAUTION e Care must be taken not to give axial impact to steering column assembly during removal and installation e Care must be taken not to move steering gear during removal of steering column assembly REMOVAL 1 Setvehicle to the straight ahead direction 2 Remove driver air bag module from steering wheel Refer to SRS 37 DRIVER AIR BAG MODULE 3 Disconnect steering switch connector remove steering wheel lock nut then remove steering wheel 4 Remove dash side finisher LH Refer to IP 11 Removal and Installation 5 Remove instrument driver panel lower Refer to IP 11 Removal and Installation 6 Remove column lower cover and combination meter which is connected with steering column upper cover from steering column assembly Refer to 01 4 COMBINATION METERS Revision 2004 April PS 10 2003 350Z STEERING COLUMN 7 Remove combination s
3. n 13 Steering Fluid 37 INSPECTION AFTER INSTALLATION 14 Disassembly and Assembly 15 DISASSEMBLY rette s ei 15 INSPECTION AFTER REMOVAL 16 ASSEMBLY ance epe ER 16 Revision 2004 April PS 1 2003 350Z PRECAUTIONS PRECAUTIONS PFP 00001 Precautions for Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TENSIONER AGS00084 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 and SB section of this Service Man ual WARNING e 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 per formed by an authorized NISSAN INFINITI dealer e Improper maintenance including incorrect removal and installation
4. 2004 April PS 27 2003 350Z POWER STEERING GEAR d Confirm the twisted point with clamp faces in the opposite direc tion to adjusting screw within 30 as shown in the figure e 1 58in SGIA0361E e After twisting wire 4 to 4 5 turns bend cut end of wire Cut end of wire should not touch boot Be sure wire end is at least 5 mm 0 20 in away from clearance for tube SGIA0166E 23 Install cylinder tubes to gear housing assembly Cylinder tubes Copper plates SGIA0360E 24 Tighten lightly tie rod in specified length L then tighten lock nut at specified torque Refer to PS 20 Disassembly and Assem bly Reconfirm if tie rod length is within limit of specified length E Inner socket length L 107 7 mm 4 240 in CAUTION Perform toe in adjustment after this procedure Length achieved after toe in adjustment is not necessarily value given here Outer socket Inner socket Lock nut SGIA0167E Revision 2004 April PS 28 2003 350Z POWER STEERING OIL PUMP POWER STEERING OIL PUMP PEP 49110 On Vehicle Service AGS00028 CHECKING RELIEF OIL PRESSURE CAUTION Before starting work confirm belt tension is proper 1 Connect oil pressure gauge SST and oil pressure gauge KV48103500 i adapter SST between oil pump discharge connector and high pressure hose and then bleed air from the hydraulic circuit bd High pressure piping Low pressure N piping Oil flow gt SGIA036
5. and keep for about three seconds Then check whether a fluid leakage has occurred 3 Repeat 2nd procedure several times at about three seconds intervals CAUTION Do not hold steering wheel in the locked position more than 10 seconds There is the possibility that oil pump may be damaged 4 Check generation of air bubbles and cloud in the fluid 5 If air bubbles and the cloud don t fade stop engine hold air bleeding until air bubbles and the cloud fade Perform the 2nd and the 3rd procedures again SGIA0232J SST836C Revision 2004 April PS 6 2003 350Z POWER STEERING FLUID 6 Stop engine check fluid level Revision 2004 April PS 7 2003 350Z STEERING WHEEL STEERING WHEEL PFP 48430 On Vehicle Inspection and Service AG500021 CHECKING CONDITION OF INSTALLATION e Checkinstallation condition of steering gear assembly front sus Z 4 SAC Mounting bolts y E pension axle and steering column AN e Check if movement exists when steering wheel is moved up and ANS BERL down to the left and right and to the axial direction A BAI End play of the axle direction for steering wheel Ce gek 0 mm 0 in e Check if the mounting bolts for steering gear assembly are loose E assonbiy or not Refer to PS 17 POWER STEERING GEAR AND LINK EE NS Ze n gt RAW Venice front SGIA0348E CHECKING STEERING WHEEL PLAY 1 Set tires to the straight ahead start engi
6. nut at the specified torque 14 7 18 6 1 5 1 8 11 13 Installation hole P N m kg m ft Ib SGIA0371E INSPECTION AFTER INSTALLATION After installing steering column to vehicle check tilt device and its operation range Ranges of operation are shown in the figure Check if steering operation can turn to the end of the left and right smoothly e 25 96mm 1 022in 13 01mm 0 512in SGIA0362E Revision 2004 April PS 14 2003 350Z STEERING COLUMN Disassembly and Assembly AGS00024 SEC 488 Wheel bearing grease NWB 2 E N m kg m ft lb SGIA0340E 1 Steering column shaft 2 Adjusting bolt 3 Adjusting stopper 4 Jacket tube 5 Steering column shaft lock nut 6 Spring 7 Column mounting bracket 8 Tilt lever stopper 9 Tiltlever 10 Lock nut DISASSEMBLY Remove steering column shaft lock nut then remove steering column shaft from front side of jacket tube Remove tilt device from jacket tube Remove lock nut and adjusting stopper according to the following procedure Turn tilt lever to the unlock side Remove spring from column mounting bracket DED 400 tic Jacket tube Adjusting bolt Tilt lever D Unlock ma Vehicle front sciaoz42e Revision 2004 April PS 15 2003 350Z STEERING COLUMN Lock adjusting bolt then remove lock nut d Remove adjusting bolt adjusting stopper column mounting bracket tilt lever stopper and tilt lever from jacket t
7. of the SRS can lead to per sonal injury caused by unintentional activation of the system For removal of Spiral Cable and Air Bag Module see the SRS section e Do not use electrical test equipment 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 for Battery Service AGS00049 Before disconnecting the battery lower both the driver and passenger windows This will prevent any interfer ence 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 Precautions for Steering System 5 0 e Before disassembly thoroughly clean the outside of the unit e Disassembly should be done in a clean work area It is important to prevent the internal parts from becom ing contaminated by dirt or other foreign matter For easier and proper assembly place disassembled parts in order on a parts rack e Use nylon cloth or paper towels to clean the parts common shop rags can leave lint that might interfere with their operation e Before inspection or reassembly carefully clean all parts with a general purpose non flammable solvent e Before assembly apply a coat of recommended Genuine NISSAN PSF or e
8. plate the thread of inner socket Screw inner socket into the rack and QA Always replace after every disassembly tighten at the specified torque Three Bond 1324 or equivalent SGIA0177E Caulk lock plate at two points on rack slit e Install spacer ring to lock plate as shown in the figure CAUTION When installing spacer ring avoid damaging it 10 Decide neutral position of rack gear Rack stroke L 64 5 mm 2 54 in Caulking groove SGIA0629J Revision 2004 April PS 25 2003 350Z POWER STEERING GEAR 11 Install the projection part Tip of rear cover cap to gear sub assembly as shown in the figure ese Projection on rear cover cap 12 Apply thread locking adhesive Three Bond TB1111B or equiva lent to the thread of adjusting screw to the adjusting screw height from gear housing assembly The adjusting screw height is the same as it was measured in the overhaul in advance 13 Rotate pinion ten times whole range of rack so that parts get to fit with each other Y Caulking 4 positions Gear housing BE 14 Measure pinion rotating torque within from 180 to 180 make preload gauge SST and torque adapter SST in rack neutral position then hold preload gauge SST at maximum torque 15 After loosening adjusting screw once tighten it again with torque of 4 9 5 9 N m 0 50 0 60 kom 44 52 in Ib After that loosen it within from 20 to 40 7 8731275000 KV4
9. x 8 Sd Buueeijs 1edouduJ X x x N eAug X 8 Sd 9040 1ee6 Duuaee X 8 Sd e d Buueejs 9 Sd Beye Buueejs X pue X anbio 19005 X Gerd 9010 BuiBuiws 1urof eq 1990s X 9 Sd ulejs s ul X 9 Sd Dm X c olg 2 E o e 4 S 5 3 2 518 5 2 gt gt o o 2 o S 8 5 e 8 u o 2 o 8 E ke a x Applicable 2003 350Z PS 5 Revision 2004 April POWER STEERING FLUID POWER STEERING FLUID PFP KLF20 Checking Fluid Level AGS0001Y e Stop engine before performing a fluid level check e Ensure that fluid level is between the MAX range and MIN level e Because fluid level differs within the HOT range and the COLD range check it carefully HOT Fluid temperatures from 50 to 80 C 122 to HOT MAX 176 F COLD MAX pe HOT MIN COLD Fluid temperatures from 0 to 30 C 32 to 86 F COLD MIN CAUTION e Do not overfill the MAX level e Do not reuse any used power steering fluid e Recommended fluid is Genuine NISSAN PSF or equivalent Checking Fluid Leakage AG500012 Check that hydraulic piping lines for improper attachment and for leaks cracks damage loose connections chafing or deterioration 1 Run engine until fluid tempe
10. 4E 2 Start engine Allow engine to run until tank temperature reaches 50 to 80 C 122 to 176 F CAUTION e Warm up engine with shut off valve fully opened If engine is started with shut off valve closed fluid pres sure in power steering pump increases to maximum This will raise fluid temperature excessively e Be careful not to contact hose with belt when engine is started OES CX VS 3 With engine at idle close shut off valve and read the relief oil lt CTS 00400 2 GS sauosese Relief oil pressure 9 600 10 200 kPa 98 104 kg cm 1 390 1 480 psi CAUTION Do not close shut off valve of pressure gauge for more than 10 seconds 4 After measurement open shut off valve slowly e If relief oil pressure is outside the specification disassemble and repair oil pump Refer to PS 30 Dis assembly and Assembly 5 After inspection disconnect oil pressure gauge SST and oil pressure gauge adapter SST from hydrau lic circuit connect oil pump discharge connector and high pressure hose Add fluid and bleed air from hydraulic circuit thoroughly Refer to PS 6 Air Bleeding Hydraulic System Removal and Installation anus REMOVAL 1 Remove engine cover 2 Remove air cleaner box 3 Drain water from radiator upper tank then remove radiator upper hose 4 Remove radiator fan shroud Refer to CO 11 Removal and Installation 5 Loosen idler pulley the
11. 8103400 SGIA0159E 16 Measure pinion rotating torque with torque adapter SST and preload gauge SST then confirm whether its reading is within Right turning m the specified value If the reading is not within the specified value readjust screw angle with adjusting screw Change gear 2 assembly to new one if the reading is still not within the speci 2 9 fied value or the rotating torque of adjusting screw is less than 5 5 d A 0 51kg m 44 in Ib 569 100 SP 100 569 Pinion rotation torque E Around neutral position within 100 WW ang WW Average A Turning angle SGIA0160E 0 8 2 0 N m 0 09 0 20 kg m 7 17 in Ib Other than above more than 100 Maximum variation B 2 3 N m 0 23 kg m 20 in Ib 17 Turn pinion fully to the end of the left with tie rods to rack Revision 2004 April PS 26 2003 350Z POWER STEERING GEAR 18 Set dial gauge to rack as shown in the figure Measure vertical movement of rack when pinion is turned counterclockwise with T3127S000 torque of 19 6 N m 2 0 kg m 14 ft lb Check reading is within the specified value If reading is outside of the specification Bring inner readjust screw angle with adjusting screw If reading is still out socket into side of specification or if the rotating torque of adjusting screw is contact with 2 less than 5 0 51 kg m 44 in Ib replace steering gear 979 cover ass
12. 9 98 8 0 10 59 72 Apply Genuine NISSAN PSF or equivalent 8 Nc m kg m ft Ib Three Bond TB1111B Multi purpose grease or equivalent 6 Always replace after every disassembly SGIA0743E Revision 2004 April PS 19 2003 350Z POWER STEERING GEAR 1 Outer socket 2 clamp 3 Boot 4 Inner socket 5 Lock plate 6 Spacer ring 7 Boot clamp 8 Rear cover cap 9 Gear sub assembly 10 O ring 11 Gear housing assembly 12 Cylinder tubes 13 Rack oil seal 14 Rack 15 Rack Teflon ring 16 O ring 17 Rack oil seal 18 End cover assembly CAUTION Secure steering gear assembly with a vise using copper plates or something similar to prevent it from being dam aged Do not grip cylinder with a vise Before performing disassembly clean steering gear assem bly with kerosene Be careful not to bring any kerosene into contact with the discharge and return port connectors Cylinder tubes Copper plates SGIA0360E Disassembly and Assembly AGS00048 DISASSEMBLY 1 2 3 Remove cylinder tubes from gear housing assembly Remove rear cover cap from gear sub assembly Measure adjusting screw height from gear housing assembly then loosen adjusting screw CAUTION e Do not turn adjusting screw more than twice Lire Adjusting screw e Replace steering gear assembly when adjusting screw is removed or more than twice Remove fixing bolt of gear sub assembly and remove gear sub assembly fro
13. A0358E Specified value Item Outer socket Inner socket Measuring point Cotter pin hole of stud shown as L 48 5 mm 1 91 in Swing torque 0 30 2 90 N m 0 03 0 29 kg m 3 25 in Ib 1 0 7 8 0 10 0 80 kg m 9 69 in Ib Measuring value 4 42 42 7 N 0 45 4 4 kg 1 0 9 7 Ib 10 78 N 1 1 7 9 kg 2 25 17 5 Ib Rotating Torque e Using a preload gauge SST check if reading is within the value specified below If the value is outside the standard n replace outer sockets J25765 A Rotating torque 0 30 2 90 N m 0 03 0 29 kg m 3 25 in Ib SST882B Revision 2004 April PS 22 2003 350Z POWER STEERING GEAR Axial End Play e Apply load of 490 N 50 kg 110 Ib to ball stud axially Use a dial 490 50 kg 111 Ib gauge to measure the amount of the movement that the stud makes Check if the reading is within the specified below If the 490 N value is outside the standard replace outer and inner sockets 50 kg 111 Ib Outer socket 0 5 mm 0 020 in or less Inner socket 0 2 mm 0 008 in or less socket Outer socket SGIA0057E ASSEMBLY 1 Apply Genuine NISSAN PSF or equivalent to O ring Put an O ring into rack Teflon ring NOTE Do not reuse O ring Heat rack Teflon ring to approximately 40 C 104 F with a dryer Assemble it to mounting groove of rack NOTE Do not reuse rack Teflon ring To fit rack Teflon ring on rack use rack Teflon ring install
14. G STEERING SECTION S POWER STEERING SYSTEM CONTENTS PRECAUTIONS u nettement Sis 2 POWER STEERING GEAR AND LINKAGE 17 Precautions for Supplemental Restraint System Removal and Installation SRS AIR BAG and SEAT BELT PRE TEN REMOVAL eic repere orba ena SIONER ete eti tns 2 INSTALLATION tene Precautions for Battery Service 2 POWER STEERING GEAR Precautions for Steering System 2 COMPONENT PREPARATION LU Uu tine 3 Disassembly and Assembly 20 Special Service Tools SST 3 DISASSEMBLY sitet ad tivities 20 Commercial Service Tools 4 INSPECTION AFTER DISASSEMBLY 22 NOISE VIBRATION AND HARSHNESS NVH ASSEMBLY E 23 TROUBLESHOOTING 5 POWER STEERING OIL PUMP 29 NVH Troubleshooting Chart 5 On Vehicle Service 29 POWER STEERING FLUID 6 CHECKING RELIEF OIL PRESSURE 29 Checking Fluid 6 Removal and Installation 29 Checking Fluid Leakage 6 REMOVA LD a
15. URNING ANGLE e Check front wheel turning angle after the toe in inspection Place front wheels on turning radius gauges and rear wheels on stands so that vehicle can be level Check the maximum inner and outer wheel turning angles for LH and RH road wheels FAA0016D Revision 2004 April PS 8 2003 350Z STEERING WHEEL e Start engine and run at idle turn steering wheel all the way right and left measure the turning angle Minimum 35 55 35 9 Inner wheel Angle A Nominal 38 55 38 9 Maximum 39 55 39 9 Outer wheel Angle B Nominal 30 40 30 7 SGIA0055E e fitis not within specification measure rack strokes Rack stroke L 64 5 mm 2 54 in e f rack stroke is out of specification disassemble steering gear assembly to check rack stroke e Any turning angles are not adjustable If any of steering angles are out of the specification check if the following parts are wear or damaged Steering gear Steering column Front suspension components If found that they are worn or damaged replace them with new ones respectively Removal and Installation Sen Refer to PS 10 STEERING COLUMN Revision 2004 April PS 9 2003 350Z STEERING COLUMN STEERING COLUMN PFP 48810 Removal and Installation oe 481 488 9 C3 d 7 14 7 18 6 2 1 5 1 8 11 13 77 SK OO 39 2 49 0 lo Sam Ng 4 0 4 9 29 36 Le
16. VICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS Steering Wheel End play of the axle direction for steering wheel PFP 00030 AGS0002C 0 mm 0 in Steering wheel play on the outer circumference Steering Angle 0 35 mm 0 1 38 in or less AGS0002D Tire size 17 and 18 inch tires Minimum 35 55 35 9 Inner wheel OBE o Degree minute Decimal degree Nominal 08799 0988 39 55 39 9 Outer wheel TS Degree minute Decimal degree Nominal 30 40 30 7 Steering Column Steering column length L AGS0002E 568 mm 22 36 in SGIA0306J Steering Outer Socket and Inner Socket Steering gear type AGS0002F PR26AD Outer socket ball joint outer socket Swinging torque 0 3 2 9 N m 0 03 0 29 kg m 3 25 in Ib Measurement on spring balance e Measuring point stud cotter pin hole 4 42 42 7 N 0 45 4 4 kg 1 0 9 7 Ib Rotating torque 0 3 2 9 0 03 0 29 kg m 3 25 in Ib Axial end play 0 5 mm 0 02 in or less Inner socket ball joint inner socket Swinging torque 1 0 7 8 0 11 0 79 kg m 9 69 in Ib Measurement on spring balance e Measuring point L mark see below L 48 5 mm 1 91 in 10 78 N 1 1 7 9 kg 2 43 17 44 Ib Axial end play 0 2 mm 0 08 in or less Revision 2004 April Spring balance Hanging point with
17. am ring to side plate as shown in the figure e Position large chamfered side of cam ring as shown in the fig ure SGIA0172E 6 Install rotor to shaft of shaft kit rotor direction is the same regardless of the front and back 7 Install vane to rotor vane direction is the same regardless of inside and outside 8 Install rotor snap ring to shaft of shaft kit NOTE e Do not reuse rotor snap ring CAUTION Be careful not to damage rotor and pulley shaft 9 Apply a coat of NISSAN PSF or equivalent to O ring A then A cc install O ring A to body assembly NOTE Do not reuse O ring A 10 Attach cover assembly to body assembly and tighten fixing bolts diagonally at the specified torque 11 Install flow control valve assembly relief valve assembly and flow control valve spring to body assembly 12 Apply a coat of NISSAN PSF or equivalent to O ring D and install to plug then tighten plug at the specified torque NOTE Do not reuse O ring D 13 Apply a coat of NISSAN PSF or equivalent to O ring E and install to suction connector assembly then install suction connector to body assembly Revision 2004 April PS 32 2003 350Z POWER STEERING OIL PUMP NOTE Do not reuse O ring E 14 Install bracket to body assembly and tighten mounting bolts at the specified torque Revision 2004 April PS 33 2003 350Z HYDRAULIC LINE Removal and Installation SEC 497 3 0 3 9 0 31 0 39 27 34 pressure sensor wi
18. ation tool SST from tooth side Compress rim of ring with the tool Position and secure seal SGIA0154E Apply Multi purpose grease or equivalent to rack oil seal Insert rack oil seal then insert rack to gear housing assembly NOTE Do not reuse rack oil seal CAUTION e When inserting rack do not damage retainer sliding part If it is damaged replace gear housing assembly e When unstring rack do not damage cylinder inner wall If it is damaged it may cause oil leaks Replace gear housing assembly Revision 2004 April PS 23 2003 350Z POWER STEERING GEAR e Attach rack oil seal Both inner lip and outer lip should face each other Rack oil seal Rack oil seal inner outer End cover assembly SGIA0205E a To avoid damaging inner rack oil seal wrap an OHP sheet approximately 70 mm 2 76 in x 100 mm 3 94 in around rack tooth Place oil seal on sheet Then pull oil seal along with OHP sheet until they pass the toothed section of rack then remove it 7 the OHP sheet with rack oil seal SGIA0155E b Insert rack oil seal inner to piston rack Teflon ring position and push retainer to adjust screw side with fingers lightly and then make rack move in gear housing assembly install rack oil seal inner to fit in with gear housing assembly Pack oil seal inner Piston rack Teflon ring position in the rack SGIA0548bE c Wheninstalling outer rack oil s
19. ble power steering oil pump only if the following items are found e Oil leakage from oil pump e Deformed or damaged pulley e Poor performance SGIA0170E DISASSEMBLY NOTE Fix oil pump in vise as the occasion demands CAUTION When retaining drive shaft in a vise always use copper or aluminium plates between vise and shaft 1 Unscrew two front bracket bolts and remove bracket from body assembly 2 Unscrew four cover assembly bolts and remove cover assembly from body assembly 3 Remove O ring A from body assembly Revision 2004 April PS 30 2003 350Z POWER STEERING OIL PUMP 4 Remove rotor snap ring with snap ring pliers and remove shaft kit from body assembly CAUTION When removing rotor snap ring be careful not to damage pulley shaft of shaft kit SGIA0059E 5 Using a screwdriver remove oil seal for body assembly 6 Remove cam ring rotor vane side plate O ring B and O ring C from body assembly 7 Remove plug then remove O ring D flow control valve spring relief valve assembly and flow control value assembly from body assembly CAUTION Be careful not to drop and deform relief valve assembly and flow control valve assembly 8 Remove fixing bolt of suction connector assembly then remove suction connector assembly and O ring E from body assembly INSPECTION AFTER DISASSEMBLY Body Assembly and Cover Assembly Inspection e Check body assembly and cover assembly for damage If any damage is foun
20. d replace with new part for cover assembly and replace with new power steering pump assembly for body assembly SST034A Cartridge Assembly Inspection e Check cam ring side plate rotor and vane for damage If any damage is found replace cartridge assem bly with new one Relief Valve Assembly Inspection e Check relief valve assembly for damage If any damage is found replace it with new one Flow Control Valve Assembly Inspection e Check flow control valve assembly for damage If any damage is found replace it with new one ASSEMBLY NOTE Fix oil pump in vise as occasion demands CAUTION When retaining drive shaft in a vise always use copper or aluminum plates between vise and shaft 1 Apply a coat of Multi purpose grease or equivalent to oil seal lip and to the circumference of oil seal Using proper tool such as hand press machine install it to body assembly NOTE Do not reuse oil seal 2 Install shaft kit to body assembly 3 Apply a coat of NISSAN PSF or equivalent to O ring B and O ring C then install O ring B and O ring C to body assembly NOTE Do not reuse O ring B and O ring C SST038A Revision 2004 April PS 31 2003 350Z POWER STEERING OIL PUMP 4 Set dowel pin at the illustration position The position is the same regardless of right or left direction and install side plate to body assembly Dowel pin 5 Install cam ring on side plate as follows e Turn chamfered edge side of c
21. eal cover the end of rack with an OHP sheet 70 mm 2 76 in x 100 mm 3 94 in It will avoid Rack oil seal o ter damaging rack oil seal Then place oil seal on sheet Pull rack oil OHP sheet seal along with OHP sheet until they pass rack end Then remove OHP sheet d Install end cover assembly to rack move it to gear housing assembly Rack end End cover assembly SGIA0157E 5 Using a 42 mm 1 65 in open head suitable tool tighten end cover assembly at the specified torque CAUTION Do not damage rack surface If it is damaged it may cause oil leaks Replace rack assembly SST081B Revision 2004 April PS 24 2003 350Z POWER STEERING GEAR 6 After tightening end cover assembly caulk cylinder at one point 2 3 mm as shown in the figure using a punch This will prevent end cover 0 08 0 12 in from getting loose Caulking point 7 Apply Genuine NISSAN PSF or equivalent to O ring Install O ring to gear housing assembly NOTE Do not reuse O ring End cover Gear assembly housing SGIA0158E 8 Install gear sub assembly to gear housing assembly C N m kg m ft lb SGIA0359E 9 Attach lock plate to rack NOTE Do not reuse lock plate Groove a Tack spacer ring to rack NOTE Inner socket Do not reuse spacer ring Dee ock plate e b Install lock plate to inner socket E Spacer tin c Apply thread lock adhesive Three Bond 1324 or equivalent to Sja et ing tore
22. embly Adjusting screw SGIA0773E Specified value Amount of vertical movement with rack Less than 0 265 mm 0 010 in Axial direction of rack 5 mm 0 197 in away from end of gear housing measuring point Radius direction of rack Shaft direction of adjusting screw 19 Install large diameter side of boot to gear housing assembly Boot clamp of large side 20 Install small diameter side of boot to the mounting groove of Boot Boot clamp of small side inner socket boot 21 Install boot clamp to the small diameter side of boot 22 Install boot clamp to the large diameter side of boot NOTE Do not reuse boot clamp Three Bond TB1111B or equivalent Refer to GI section Multi purpose grease SGIAOBSDE a Tighten large diameter side of RH LH boot with boot clamp stainless wire Wire length L 370 mm 14 567 in b After wrapping clamp around boot groove for two turns insert screwdriver in loop on both ends of wire Twist 4 to 4 5 turns while pulling with a force of approx 98 N 10 kg 22 1 Ib Pull wire with approx 98 N 10 kg 22 Ib 2 n o o 5 D o E o c Twist boot clamp as shown in the figure pay attention to rela tionship between winding and twisting directions Wire left direction to wind Wire right direction to wind Wind wire right direction Wind wire left direction SGIA0164E Revision
23. embly from steering member 13 Remove collar from lower shaft 14 Remove hole cover seal from lower shaft 15 Remove mounting bolts then remove hole cover from panel 16 Raise vehicle then loosen bolt for lower yoke of lower joint and remove joint together with lower shaft ZPbio NN 0 Mm kg m ft Ib Revision 2004 April PS 12 2003 350Z STEERING COLUMN INSPECTION AFTER REMOVAL e Check if there is something wrong with jacket tube of steering column assembly and collar etc And then if they are damaged replace with new one e f vehicle has a collision light shocked check column length L as shown in the figure Then if it is out of the specified value replace with new one Specified value Steering column length L 568 mm 22 36 in e Check the turning torque of steering column with preload gauge SST If it is out of the specified value repair it or replace with new one SGIA0306J Specified value Turning torque 0 0 2 0 0 021 kg m 0 1 in Ib INSTALLATION 1 Install collar to lower shaft SR V Collar KR SGIA0356E 2 Install yoke of column shaft to collar tack bolt and nut Revision 2004 April PS 13 2003 350Z STEERING COLUMN Put steering column assembly installation hole P on bolt for steering member side and install nut A then tighten it together with the other bolts at the specified torque Connect yoke and collar with bolt tighten
24. era ner ean oaa ana a aa 29 Air Bleeding Hydraulic System 6 INSTALLATION tt etre 30 STEERING WHEEL 8 Disassembly and Assembly 30 On Vehicle Inspection and Service 8 INSPECTION AFTER DISASSEMBLY 30 CHECKING CONDITION OF INSTALLATION 8 DISASSEMBLY 30 CHECKING STEERING WHEEL PLAY 8 INSPECTION AFTER DISASSEMBLY 31 CHECKING NEUTRAL POSITION ON STEER ASSEMBLY nde teo eee 31 ING WHEEL Zongen rrt ttt tnter 8 HYDRAULIC LINE 34 CHECKING STEERING WHEEL TURNING Removal and Installation 34 FORGE ette ed ae HC etes 8 SERVICE DATA AND SPECIFICATIONS SDS 36 CHECKING FRONT WHEEL TURNING ANGLE 8 Steering Wheel 36 Removal and Installation 9 Steering Angle m ntn 36 STEERING COLUMN 10 Steering Column a 36 Removal and Installation 10 Steering Outer Socket and Inner Socket 36 ate u e test Leite a sy 10 Steering Gear 37 INSPECTION AFTER REMOVAL 13 WT 37 INSTALLATION
25. ft Sepa rate steering gear assembly from lower shaft Lower shaft 9 Tack bolt on upper yoke of lower joint fix lower joint to lower 2 joint shaft 0 23 5 29 4 2 4 2 9 18 21 Rear cover cap Projection on rear cover cap Slit part SGIA0367E 10 Remove the fixing bolt and remove steering gear assembly rack AS Mounting bolts mounting bracket and insulator from vehicle AAT A e lt 2 BN S ka S AZ AG d Le KaU ix P TS Se Een ANS SGIA0348E INSTALLATION e Refer to PS 17 Removal and Installation for tightening torque Install in the reverse order of removal NOTE Refer to component parts location and to not reuse non reusable parts e After removing installing or replacing steering components check wheel alignment Refer to FSU 6 Wheel Alignment Inspection e When steering wheel is set in the straight ahead direction con firm slit of lower joint fits with the projection on rear cover cap furthermore marking position on steering gear assembly nearly fits with the projection on rear cover cap e After installation bleed air from piping Refer to PS 6 Air Bleeding Hydraulic System Projection on rear cover cap Vehicle front Rack center line SGIA0351E Revision 2004 April PS 18 2003 350Z POWER STEERING GEAR POWER STEERING GEAR PFP 49001 Component AGS0004A SEC 492 18 58 9 73 5 6 0 7 4 44 54 7
26. g gear assembly 3 Rack mounting bracket 4 Rack mounting insulator CAUTION Spiral cable may snap due to steering operation if steering column is separated from steering gear assembly Therefore fix steering wheel with a string to avoid turns REMOVAL 1 Set wheels in the straight ahead position 2 Remove undercover and tires from vehicle with the power tool 3 Remove front crossbar Refer to FSU 5 FRONT SUSPENSION ASSEMBLY 4 Confirm slit of lower joints fits with the projection on rear cover cap furthermore marking position on steering gear assembly nearly fits with the projection on rear cover Vehicle front 5 s cotter pin at steering outer socket then loosen mount SN 1235 284 ing nut 2 4 2 8 18 20 uw N rear cover cap Low pressure piping N m kg m ft Ib 6 Use ball joint remover SST to remove steering outer socket from steering knuckle Be careful not to damage ball joint boot CAUTION Tighten temporarily mounting nut to prevent damage to threads and to prevent ball joint remover SST from com ing off 7 Remove oil pipings high pressure side and low pressure side from steering gear assembly then drain fluid from pipings HT72520000 J25730 A SGIA0341E Revision 2004 April PS 17 2003 350Z POWER STEERING GEAR AND LINKAGE 8 Loosen bolt on upper yoke of lower joint and remove bolt on lower yoke of joint then slide lower joint into lower sha
27. m gear housing assembly CAUTION oe In order to protect oil seal from any damage pull sub gear Gear h using icu assembly out straightly Loosen lock nut of outer socket and remove outer socket Remove boot clamps of the small diameter side and the large diameter side then remove boots CAUTION On removing boots be careful not to damage inner socket and gear housing assembly If they are is damaged change them to avoid oil leaks Move spacer ring to rack side raise caulking part at two points Boor cl id of part A of lock plate and loosen inner socket then remove Lock plate Boot clamp of inner socket from rack small side Retainer Adjusting screw height SGIAOS68E Always replace Inner socket after every disassembly SGIA0363E Revision 2004 April PS 20 2003 350Z POWER STEERING GEAR 8 Drill out the clinching part of cylinder outer rim with a 3 mm 0 12 in drill in 1 5 mm 0 059 in depth STCO0013D 9 Remove end cover assembly with a 42 mm 1 65 in open head suitable tool CAUTION Be careful not to damage rack If it is damaged replace rack Otherwise oil leaks may result 10 Pull rack with rack oil seal out of gear housing assembly CAUTION Be careful not to damage cylinder If it is damaged replace gear housing assembly Otherwise oil leaks may result 11 Heat rack Teflon ring to approximately 40 C 104 F with a dryer then remove it and O
28. n remove belt FS Copper washer Eye bolt 7 50 69 5 1 7 0 37 50 6 Drain power steering fluid from reservoir tank Law pressure 7 Remove piping of high pressure and low pressure drain fluid EL Pipi Engine front from their pipings A 8 Remove bolt common to water pump and power steering pump 9 Remove bolt then remove power steering pump Gommon b ltin water pump amp PS pump 56 9 65 7 5 8 6 7 42 48 Pump mounting bracket SGIA0376E Revision 2004 April PS 29 2003 350Z POWER STEERING OIL PUMP INSTALLATION Refer to PS 34 HYDRAULIC LINE for tightening torque Install in the reverse order of removal e After installation adjust belt tension Refer to EM 13 DRIVE BELTS e After installation bleed air Refer to PS 6 Air Bleeding Hydraulic System Disassembly and Assembly AGS0002A SEC 490 493 Multi purpose grease or X equivalent Genuine NISSAN PSF or equivalent Always replace after every disassembly O kg m ft lb 2 6 2 9 19 21 SGIA0774E 1 Plug 2 O ring D 3 Flow control valve spring 4 Relief valve assembly 5 Flow control valve assembly 6 Shaft kit 7 Oilseal 8 Bracket 9 Body assembly 10 Suction connector assembly 11 O ring E 12 O ring C 13 O ring B 14 Cartridge assembly 15 O ring A 16 Cover assembly 17 Side plate 18 Vane 19 Rotor snap ring 20 Cam ring 21 Rotor 22 Dowel pin INSPECTION AFTER DISASSEMBLY Disassem
29. ne then turn steering wheel to the left and right lightly and mea sure steering wheel movement on the outer circumference when steering wheel is turned up to the point where tires start moving Steering wheel play on the circumference 0 35 mm 0 1 38 in CHECKING NEUTRAL POSITION ON STEERING WHEEL e Check neutral position on steering wheel after confirming that front wheel alignment is correct Refer to FSU 21 SERVICE DATA 1 Setthe vehicle to the straight ahead direction check if steering wheel is in the neutral position 2 lfitis notin the neutral position remove steering wheel and reinstall it correctly 3 If the neutral position cannot adjust in the two teeth of steering gear assembly loosen tie rod lock nuts of steering outer sockets then adjust tie rods by the same amount in the opposite direction CHECKING STEERING WHEEL TURNING FORCE 1 Park vehicle on a level and dry surface set parking brake 2 Remove driver air bag module from steering wheel Refer to SRS 37 DRIVER AIR BAG MODULE 3 Start engine at idle make steering fluid reach to normal operat ing temperature 50 to 80 C 122 to 176 F then check steering wheel turning torque with pre load gauge SST Turning torque 7 45 N m 0 76 kg m 66 in Ib 4 If steering wheel turning force is out of the specification check relief hydraulic pressure of oil pump Refer to PS 29 POWER STEERING OIL PUMP STA0005D CHECKING FRONT WHEEL T
30. quivalent to hydraulic parts Petroleum jelly may be applied to O rings and seals Do not use any grease e Replace all gaskets seals and O rings Avoid damaging O rings seals and gaskets during installation Perform functional tests whenever designated Revision 2004 April PS 2 2003 350Z PREPARATION Special Service Tools SST PREPARATION PFP 00002 AGS0001V 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 HT72520000 J25730 A Ball joint remover a 33 mm 1 30 in b 50 mm 1 97 in r 11 5 mm 0 453 in Removing outer socket ball joint ST3127S000 See J25765 A Preload gauge 1 GG9103000 J25765 A Torque wrench 2 HT62940000 C S Socket adapter 3 HT62900000 Socket adapter 1 4 M wrench Gi ith range of 1 4 to 308 Wan rang 2 9 Nem 8 80 te 3 8 to 1 2 SSC S NT541 Inspecting of sliding torque steering torque and rotating torque for ball joint KV48104400 dms EI Teflon ring correcting tool a 50 mm 1 97 in dia b 36 mm 1 42 in dia c 100 mm 3 94 in Fine finishing S NT550 Installing of rack Teflon ring KV48103404 CAM Torque adapter ZZA0824D Inspecting rotating torque 1 KV48103500 J26357 and J26357 10 Pressure gauge 2 KV48100400 1 Connector 3 KV48102500 04
31. rature reaches 50 to 80 C 122 to 176 F in reservoir tank Keep engine speed idle 2 Turn steering wheel right to left several times 3 Hold steering wheel at each lock position for five seconds to check fluid leakage CAUTION Do not hold steering wheel in a locked position for more than 10 seconds There is the possibility that oil pump may be damaged 4 If fluid leakage at connections is noticed then loosen flare nut and then retighten Do not over tighten con nector as this can damage O ring washer and connector 5 If fluid leakage at the connectors is noticed then loosen the flare nut and retighten it 6 Check steering gear boots for accumulation of fluid indicating a from steering gear Air Bleeding Hydraulic System AGS00020 Incomplete air bleeding causes the following When this happens bleed air again e Generation of air bubbles in reservoir tank e Generation of clicking noise in oil pump e Excessive buzzing in oil pump NOTE When vehicle is stationary or while steering wheel is being turned slowly some noise may be heard from oil pump or gear This noise is normal and does not affect any system 1 Stop engine and then turn steering wheel fully to right and left several times CAUTION Do not allow steering fluid reservoir tank to go below the low level line Check tank frequenter and add fluid as needed 2 Run engine at idle speed Turn steering wheel fully to the right and then fully to the left
32. ring from rack CAUTION Rack Teflon ring Be careful not to damage rack If it is damaged change to a new one to avoid oil leaks SGIA0151E 12 Use a taped 29 mm 1 14 in socket and an extension bar Remove rack oil seal from gear housing assembly CAUTION Be careful not to damage gear housing assembly and cylin Rack oil seal der inner wall If it is damaged gear housing assembly must be replaced Otherwise oil leaks will result des aes bar 29 mm 1 14 in socket SGIA0179E Revision 2004 April PS 21 2003 350Z POWER STEERING GEAR INSPECTION AFTER DISASSEMBLY Boot Check boot for cracks and deformation Replace it if necessary Rack Check rack for damage and wear Replace it if necessary Gear Sub Assembly e Check pinion gear for damage and wear Replace it if necessary e Check bearing while rotating it Replace bearing if bearing ball race was dent worn or damaged Gear Housing Assembly Check gear housing assembly for damage and scratches inner wall Replace it if necessary Outer Socket and Inner Socket Swing Torque e Hook a spring balance at the point shown in the figure Confirm if the reading is within the specification When ball stud and inner socket start moving the measured value must be within the specification If the reading is outside the specification replace socket Spring balance Hanging point with spring balance 2 67in hm Inner socket Outer socket SGI
33. spring M 67 9mm L 2 67in cfm A Outer socket Inner socket SGIA0358E PS 36 2003 350Z SERVICE DATA AND SPECIFICATIONS SDS Inner socket length L 107 7 mm 4 240 in Inner socket Lock nut Outer socket SGIA0167E Steering Gear AGS0002G Steering gear model PR26AD Rack neutral position dimension L rack stroke 64 5 mm 2 54 in SGIA0629J At the neutral point Area average value 147 211 N 14 99 21 52 kg 33 1 47 52 Ib Range within 11 5 mm 0 453in from the neutral St position Allowable variation 98 N 10 kg 22 Ib or less in power ON Rack sliding force Peak value 294 N 30 0 kg 66 Ib or less Allowable variation 147 N 16 kg 35 Ib or less Whole area in power OFF Oil Pump AGS0002H Oil pump relief hydraulic pressure 9 600 10 200 kPa 98 104 kg cm 1 390 1 480 psi Steering Fluid AGso002 Fluid capacity Approx 1 0 1 1 8 US qt 7 8 Imp qt Revision 2004 April PS 37 2003 350Z SERVICE DATA AND SPECIFICATIONS SDS Revision 2004 April PS 38 2003 350Z
34. th opponent harness con nector secur ely 0 31 0 39 27 34 Vehicle front 3 8mn 0 12 0 31in Tube Hose Connection between tube and hose Insert hose to spool of opponent tube or end of opponent tube securely Do not apply oil at this time Nissan PSF or equivalent N m kg m in Ib DI N m kg m ft Ib e ALways replace after every disassembly Revision 2004 April HYDRAULIC LINE PFP 49721 AGS0002B Low pressure piping pressure piping 7 14 8 24 5 1 5 2 4 11 18 0 31 0 39 27 34 Detail A 3 0 3 9 0 31 0 39 27 34 Install bracket to rack mounting bracket securely 5 Projection Install projection to opponent notch portion securely 3 3 4 2 24 30 2 56 9 65 7 5 8 6 7 71 44 1 52 4 5 5 3 33 38 D 2 56 9 65 7 5 8 6 7 42 48 Detail B Eye bolt Eye joint How to install eye joint Bring eye joint into contact with installation face of pump correctly tighten eye bolt by hand then tighten it at specified torgue 4 Copper washers pm Sealing Pump face Installation of eye joint SGIA0741E PS 34 2003 350Z HYDRAULIC LINE 1 Reservoir tank 2 Reservoir tank bracket 3 Hose amp tube assembly 4 Suction hose 5 Oil pressure sensor 6 Eye bolt 7 Oil cooler 8 Copper washer 9 Power steering oil pump 10 Steering gear assembly 11 Common bolt 12 Oil pump bracket 13 Clip Revision 2004 April PS 35 2003 350Z SER
35. ube SGIA0344E INSPECTION AFTER REMOVAL e Check if there is something wrong with the steering column shaft and bearing And then if they are dam aged replace with new one e Check if there is something wrong with the component of the tilt device And then if it is damaged replace with new one ASSEMBLY 1 Install tilt device to jacket tube Refer to PS 15 Disassembly and Assembly NOTE e Turn tilt lever to unlock side while at work to make it easier e That can avoid column shaft s sudden descent when tilt lever is operated on vehicle Tilt lever Vehicle front m SGIA0346E 2 When tilt lever is in the locked position operation range is about 40 tighten lock nut at the specified torque to make tilt lever locked Tightening torque 13 5 18 6 N m 1 4 1 8 kg m 10 13 ft Ib 3 Apply grease to the part shown in the figure of component Refer to PS 15 Disassembly and Assembly 4 Install steering column shaft to jacket tube tighten steering col umn shaft lock nut at the specified torque Tightening torque 25 34 N m 2 6 3 4 kg m 19 25 ft lb SGIA0347E Revision 2004 April PS 16 2003 350Z POWER STEERING GEAR AND LINKAGE POWER STEERING GEAR AND LINKAGE PFP 49001 Removal and Installation 492 029 5 39 2 3 0 3 9 22 28 Vehicle front Always replace after every disassembly DI N m kg m ft lb SGIA0337E 1 Cotter pin 2 Steerin
36. witch amp spiral cable from steering column assembly Refer to SRS 39 Removal and Installation 8 Disconnect the following connector from steering column assembly e Steering lock harness connector e Ignition switch harness connector e Key switch harness connector 9 Remove control unit with VDC TCS ABS Refer to BRC 150 VDC TCS ABS CONTROL UNIT 10 Disconnect brake switch harness connector 11 Remove steering column shaft from lower shaft in the following procedure a Remove lock nut from yoke d Hj Vi a Em Steering column assembly 0 39 2 49 0 4 0 29 36 _ b Turn steering wheel to the right to appear the head of the bolt c Remove the fixed part of collar for bolt to the outside of its head remove bolt d Remove the set lib of steering column assembly side from yoke push it equal to the thick part of yoke NOTE e Because oollar is set in lower shaft if the set lib is pushed gt Many action joint center will be lifted in the opposite direction 1 SS reaction and then the set lib will be in squeezed to the thick vac part of yoke SN Stopped part with gt collar for bolt d SGIA0354E Revision 2004 April PS 11 2003 350Z STEERING COLUMN e Yoke will be removed from collar when steering column assem bly is lifted about 45 oblique upward f Collar remains on lower shaft 12 Remove bolts and nut from steering member remove steering column ass
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