2003 Nissan Altima Service Repair Manual.pdf

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QUICK REFERENCE INDEX
A GENERAL INFORMATION GI General Information
B ENGINE EM Engine Mechanical
LU Engine Lubrication System
CO Engine Cooling System
EC Engine Control System
FL Fuel System
EX Exhaust System
ACC Accelerator Control System
C TRANSMISSION/
TRANSAXLE
CL Clutch
MT Manual Transaxle
AT Automatic Transaxle
D DRIVELINE/AXLE FAX Front Axle
RAX Rear Axle
E SUSPENSION FSU Front Suspension
RSU Rear Suspension
WT Road Wheels & Tires
F BRAKES BR Brake System
PB Parking Brake System
BRC Brake Control System
G STEERING PS Power Steering System
H RESTRAINTS SB Seat Belts
SRS Supplemental Restraint System (SRS)
I BODY BL Body, Lock & Security System
GW Glasses, Window System & Mirrors
RF Roof
EI Exterior & Interior
IP Instrument Panel
SE Seat
J AIR CONDITIONER ATC Automatic Air Conditioner
MTC Manual Air Conditioner
K ELECTRICAL SC Starting & Charging System
LT Lighting System
DI Driver Information System
WW Wiper, Washer & Horn
BCS Body Control System
LAN LAN System
AV Audio Visual & Telephone System
ACS Auto Cruise Control System
PG Power Supply, Ground & Circuit Elements
L MAINTENANCE MA Maintenance
M INDEX IDX Alphabetical Index
Edition: September 2002
Revision: May 2004
Publication No. SM3E-1L31U2
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© 2004 NISSAN NORTH AMERICA, INC.
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, photo-copying, recording or otherwise, without the prior written permission
of Nissan North America, Inc., Gardena, California.
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FOREWORD
This manual contains maintenance and repair procedures for the
2003 NISSAN ALTIMA.
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 specifi-
cations 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: ALTIMA (EQUIPPED WITH 2.5L,
QR ENGINE)
2003
QUICK REFERENCE CHART: ALTIMA (EQUIPPED WITH 2.5L, QR ENGINE)
PFP:00000
Engine Tune-Up Data ELS000ME
Drive Belt Deflection and Tension
Spark Plugs (Double Platinum Tipped)
Front Wheel Alignment (Unladen*1) ELS000MF
Cylinder arrangement In-line 4
Displacement cm3 (cu in) 2,488 (151.82)
Bore and stroke mm (in) 89.0 x 100 (3.50 - 3.94)
Valve arrangement DOHC
Firing order 1-3-4-2
Number of piston rings
Compression 2
Oil 1
Compression ratio 9.5:1
Compression pressure
kPa (kg/cm2, psi) / 250 rpm
Standard 1,250 (12.8, 182)
Minimum 1,060 (10.8, 154)
Differential limit between cylinders 98 (1.0, 14)
Idle speed A/T (in neutral)
rpm
700 ± 50
Ignition timing (BTDC at idle speed) 15° ± 5°
CO% at idle 0.3 – 9.5% and engine runs smoothly
Radiator cap relief pressure
kPa (kg/cm2, psi)
Standard 79 – 98 (0.8 – 1.0, 11 – 14)
Limit 59 (0.6, 9)
Cooling system leakage testing pressure
kPa (kg/cm2
, psi)
157 (1.6, 23)
Tension of drive belts Auto adjustment by auto-tensioner
Type
Standard PLFR5A-11
Hot PLFR4A-11
Cold PLFR6A-11
Plug gap Nominal: 1.1 mm (0.043 in)
Tire size 205/65R16 215/55R17
Camber
Degree minute (Decimal degree)
Minimum −1°00′ (−1.00°)
Nominal −0°15′ (−0.25°)
Maximum 0°30′ (0.50°)
Left and right difference 45′ (0.75°) or less
SFA234AC

2003
QR ENGINE)
*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
*2: On power steering models, wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with
engine idle.
Rear Wheel Alignment (Unladen*) ELS000MG
*: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
Caster
Minimum 2°05′ (2.08°)
Nominal 2°50′ (2.83°)
Maximum 3°35′ (3.58°)
Kingpin inclination
Minimum 13°50′ (13.83°)
Nominal 14°35′ (14.58°)
Maximum 15°20′ (15.33°)
Total toe-in
Distance (A − B)
mm (in)
Minimum −0.5 (−0.02)
Nominal 0.5 (0.02)
Maximum 1.5 (0.06)
Angle (left plus right)
Minimum −4′ (−0.07°)
Nominal 2′ (0.03°)
Maximum 8′ (0.13°)
Wheel turning angle
Full turn*2
Inside
Minimum 34°30′ (34.5°) 32°00′ (32.0°)
Nominal 38°00′ (38.0°) 35°30′ (35.5°)
Maximum 39°00′ (39.0°) 36°30′ (36.5°)
Outside
Nominal 30°30′ (30.5°) 29°00′ (29.0°)
Camber
Minimum −0°04′ (−0.07°)
Nominal −0°34′ (−0.57°)
Maximum 0°64′ (-1.07°)
Total toe-in
Distance (A − B)
mm (in)
Minimum 2.4 (0.09)
Nominal 3.9 (0.15)
Maximum 5.4 (0.21)
Minimum 6′ (0.1°)
Nominal 10′ (0.167°)
Maximum 14′ (0.233°)
SFA234AC

QR ENGINE)
2003
Brake ELS000MH
Unit: mm (in)
Disc Brake - Repair Limits
Unit: mm (in)
Brake Pedal
Unit: mm (in)
Front brake
Brake model CLZ25VD disc brake
Cylinder bore diameter 57.2 (2.252)
Pad Length × width × thickness 125.6 × 46 × 11 (4.94 × 1.81 × 0.43)
Rotor outer diameter × thickness 296 × 26 (11.65 × 1.02)
Rear brake
Brake model AD9V disc brake
Pad Length × width × thickness 89.1 × 39.5 × 10 (3.508 × 1.555 × 0.31)
Master cylinder Cylinder bore diameter 23.81 (15/16)
Control valve Screw in type 30 × 0.4 (1.18 × 0.02)
Brake booster
Booster model M215T
Diaphragm diameter
Primary 230 (9.06)
Secondary 205 (8.07)
Recommended brake fluid
Genuine NISSAN Super Heavy Duty Brake Fluid
or equivalent, DOT 3 (US FMVSS No. 116)
Brake model CLZ25VD (Front) AD9V (Rear)
Pad wear limit Minimum thickness 2.0 (0.079) 1.5 (0.059)
Rotor repair limit
Maximum runout 0.07 (0.0028) 0.07 (0.0028)
Minimum thickness 22.0 (0.866) 8.0 (0.31)
Free height “H”*
M/T 164.1 - 174.1 (6.46 - 6.85)
A/T 173.1 - 183.1 (6.81 - 7.21)
Clearance “C” between pedal stopper and threaded end of stop lamp switch or ASCD switch 0.74 - 1.96 (0.0291 - 0.0772)
WFIA0022E

2003
QR ENGINE)
*: Measured from surface of dash reinforcement panel to surface of pedal pad
Refill Capacities ELS000MI
Engine Coolant Capacity (Approximate)
Unit: (US qt, Imp qt)
Engine Oil Capacity (Approximate)
Miscellaneous Capacity (Approximate)
Drain and refill (without reservoir) 6.9 (7 1/4, 6 1/8)
Reservoir tank (at MAX level) 0.7 (3/4, 5/8)
Drain and refill
With oil filter change 4.2 (4 1/2, 3 3/4)
Without oil filter change 4.0 (4 1/4, 3 1/2)
Dry engine (engine overhaul) 4.6 (4 7/8, 4)
System description Metric measurement US measurement Imp measure
Fuel tank 75.5 20 gal 16 5/8 gal
Power steering system 1.0 2 1/8 pt 1 3/4 pt
Transaxle
M/T (RS5F51A) 2.3 2 3/8 qt 2 qt
A/T (RE4F04B) 9.2 9 3/4 qt 8 1/8 qt
Air conditioning system
Refrigerant 0.475 - 0.525 kg 1.045 - 1.155 lb 1.045 - 1.155 lb
Compressor oil 150 m 5.01 fl oz 5.03 fl oz

VQ ENGINE)
2003
QUICK REFERENCE CHART: ALTIMA (EQUIPPED WITH 3.5L, VQ ENGINE)
PFP:00027
Engine Tune-Up Data ELS000MJ
*1: Under the following conditions:
● Air conditioner switch: OFF
● Electric load: OFF (Lights, heater fan & rear window defogger)
● Steering wheel: Kept in straight-ahead position
Cylinder arrangement V-6
Displacement cm3 (cu in) 3,498 (213.45)
Bore and stroke mm (in) 95.5 x 81.4 (3.76 - 3.205)
Valve arrangement DOHC
Firing order 1-2-3-4-5-6
Number of piston rings
Compression 2
Oil 1
Number of main bearings 4
Compression ratio 10.0:1
Compression pressure
kPa (kg/cm2, psi) / 250 rpm
Standard 1,275 (13.0, 185)
Minimum 981 (10.0, 142)
Differential limit between cylinders 98 (1.0, 14)
Idle speed rpm
No-load*1 (in “P” or N” position)
700 ± 50
Ignition timing (BTDC at idle speed) 15° ± 5°
CO% at idle 0.7 – 9.9% and engine runs smoothly
Radiator cap relief pressure
kPa (kg/cm2
, psi)
Standard 79 – 98 (0.8 – 1.0, 11 – 14)
Limit 59 (0.6, 9)
Cooling system leakage testing pressure
kPa (kg/cm2
, psi)
157 (1.6, 23)

2003
VQ ENGINE)
Drive Belt Deflection and Tension
Spark Plugs (Double Platinum Tipped)
Front Wheel Alignment (Unladen*1) ELS000MK
Deflection adjustment Unit: mm (in) Tension adjustment Unit: N (kg, lb)
Used belt
New belt
Used belt
New belt
Limit After adjustment Limit After adjustment
Alternator,
Air conditioner
compressor
7.0 (0.28)
4.2 - 4.6
(0.17 - 0.18)
3.7 - 4.1
(0.15 - 0.16)
294 (30, 66)
730 - 818
(74.5 - 83.5, 164
- 184)
838 - 926
(85.5 - 94.5, 188
- 208)
Power steering
oil pump
11.0 (0.43)
7.3 - 8.0
(0.29 - 0.32)
6.5 - 7.2
(0.26 - 0.28)
196 (20, 44)
495 - 583
(50.5 - 59.5,
111.3 - 131.1)
603 - 691
(61.5 - 70.5,
135.6 - 155.4)
Type
Standard PLFR5A-11
Hot PLFR4A-11
Cold PLFR6A-11
Plug gap Nominal: 1.1 mm (0.043 in)
Tire size 205/65R16 215/55R17
Camber
Minimum −1°00′ (−1.00°)
Nominal −0°15′ (−0.25°)
Maximum 0°30′ (0.50°)
Caster
Minimum 2°05′ (2.08°)
Nominal 2°50′ (2.83°)
Maximum 3°35′ (3.58°)
Kingpin inclination
Minimum 13°50′ (13.83°)
Nominal 14°35′ (14.58°)
Maximum 15°20′ (15.33°)
Total toe-in
Distance (A − B)
mm (in)
Minimum −0.5 (−0.02)
Nominal 0.5 (0.02)
Maximum 1.5 (0.06)
Minimum −4′ (−0.07°)
Nominal 2′ (0.03°)
Maximum 8′ (0.13°)
SFA234AC

VQ ENGINE)
2003
*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
*2: On power steering models, wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with
engine idle.
Rear Wheel Alignment (Unladen*) ELS000ML
*: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
Brake ELS000MM
Unit: mm (in)
Wheel turning angle
Full turn*2
Inside
Minimum 34°30′ (34.5°) 32°00′ (32.0°)
Nominal 38°00′ (38.0°) 35°30′ (35.5°)
Maximum 39°00′ (39.0°) 36°30′ (36.5°)
Outside
Nominal 30°30′ (30.5°) 29°00′ (29.0°)
Camber
Minimum −0°10′ (−0.17°)
Nominal −0°40′ (−0.67°)
Maximum -0°70′ (-1.17°)
Total toe-in
Distance (A − B)
mm (in)
Minimum 2.5 (0.10)
Nominal 4.0 (0.16)
Maximum 5.5 (0.22)
Minimum 6′ (0.1°)
Nominal 10′ (0.167°)
Maximum 14′ (0.233°)
SFA234AC
Front brake
Brake model CLZ25VD disc brake
Pad Length × width × thickness 125.6 × 46 × 11 (4.94 × 1.81 × 0.43)
Rear brake
Brake model AD9V disc brake
Pad Length × width × thickness 89.1 × 39.5 × 10 (3.508 × 1.555 × 0.31)
Master cylinder Cylinder bore diameter 23.81 (15/16)
Control valve Screw in type 30 × 0.4 (1.18 × 0.02)
Brake booster
Booster model M215T
Diaphragm diameter
Primary 230 (9.06)
Secondary 205 (8.07)
Recommended brake fluid
Genuine NISSAN Super Heavy Duty Brake Fluid or
equivalent, DOT 3 (US FMVSS No. 116)

2003
VQ ENGINE)
Disc Brake - Repair Limits
Unit: mm (in)
Brake Pedal
Unit: mm (in)
*: Measured from surface of dash reinforcement panel to surface of pedal pad
Refill Capacities ELS000MN
Engine Coolant Capacity (Approximate)
Engine Oil Capacity (Approximate)
Miscellaneous Capacity (Approximate)
Brake model CLZ25VD (Front) AD9V (Rear)
Pad wear limit Minimum thickness 2.0 (0.079) 1.5 (0.059)
Rotor repair limit
Maximum runout 0.07 (0.0028) 0.07 (0.0028)
Minimum thickness 22.0 (0.866) 8.0 (0.31)
Free height “H”* M/T 164.1 - 174.1 (6.46 - 6.85)
A/T 173.1 - 183.1 (6.81 - 7.21)
Clearance “C” between pedal stopper and threaded end of stop lamp switch or ASCD switch 0.74 - 1.96 (0.0291 - 0.0772)
WFIA0022E
Drain and refill (without reservoir) 7.5 (7 7/8, 6 5/8)
Reservoir tank (at MAX level) 0.7 (3/4, 5/8)
Drain and refill
With oil filter change 4.0 (4 1/4, 3 1/2)
Without oil filter change 3.7 (3 7/8, 3 1/4)
Dry engine (engine overhaul) 5.0 (5 1/4, 4 3/8)
System description Metric measurement US measurement Imp measurement
Fuel tank 75.5 20 gal 16 5/8 gal
Power steering system 1.0 2 1/8 pt 1 3/4 pt

VQ ENGINE)
2003
Transaxle
M/T (RS5F51A) 2.3 2 3/8 qt 2 qt
A/T (RE4F04B) 9.2 9 3/4 qt 8 1/8 qt
Air conditioning system
Refrigerant 0.475 - 0.525 kg 1.045 - 1.155 lb 1.045 - 1.155 lb
Compressor oil 150 m 5.01 fl oz 5.03 fl oz

GI-1
GENERAL INFORMATION
A GENERAL INFORMATION
CONTENTS
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SECTION
Revision: May 2004 2003 Altima
PRECAUTIONS .....................................................
..... 3
Description ..........................................................
..... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .............................................................
..... 3
General Precautions ...........................................
..... 3
Precautions for Three Way Catalyst ....................
..... 5
Precautions For Fuel ...........................................
..... 5
GASOLINE ENGINE (PREMIUM GASOLINE) ..... 5
GASOLINE ENGINE (REGULAR GASOLINE)..... 5
Precautions for Multiport Fuel Injection System or
Engine Control System .......................................
..... 5
Precautions for Hoses .........................................
..... 6
HOSE REMOVAL AND INSTALLATION ..........
..... 6
HOSE CLAMPING ...........................................
..... 6
Precautions for Engine Oils .................................
..... 6
HEALTH PROTECTION PRECAUTIONS ........
..... 6
ENVIRONMENTAL PROTECTION PRECAU-
TIONS ..............................................................
..... 7
Precautions for Air Conditioning ..........................
..... 7
HOW TO USE THIS MANUAL ..............................
..... 8
Description ..........................................................
..... 8
Terms ..................................................................
..... 8
Units ....................................................................
..... 8
Contents ..............................................................
..... 8
Components ........................................................
..... 8
SYMBOLS ........................................................
..... 9
How to Follow Trouble Diagnoses .......................
..... 9
DESCRIPTION .................................................
..... 9
HOW TO FOLLOW TEST GROUPS IN TROU-
BLE DIAGNOSES ............................................
... 10
REFERENCE INFORMATION .........................
....11
KEY TO SYMBOLS SIGNIFYING MEASURE-
MENTS OR PROCEDURES ............................
....11
How to Read Wiring Diagrams ............................
... 12
CONNECTOR SYMBOLS ................................
... 12
SAMPLE/WIRING DIAGRAM - EXAMPL - ......
... 14
DESCRIPTION .................................................
... 15
Abbreviations ......................................................
... 20
SERVICEINFORMATIONFORELECTRICALINCI-
DENT ......................................................................
... 22
How to Check Terminal ........................................
... 22
CONNECTOR AND TERMINAL PIN KIT .........
... 22
HOW TO PROBE CONNECTORS ...................
... 22
Howto Perform Efficient Diagnosis foran Electrical
Incident ................................................................
... 25
WORK FLOW ...................................................
... 25
INCIDENT SIMULATION TESTS .....................
... 25
CIRCUIT INSPECTION ....................................
... 28
Control Units and Electrical Parts ........................
... 33
PRECAUTIONS ...............................................
... 33
SMJ INSTALLATION ........................................
... 34
CONSULT-II CHECKING SYSTEM .......................
... 35
Description ...........................................................
... 35
Function and System Application ........................
... 35
Nickel Metal Hydride Battery Replacement .........
... 36
Checking Equipment ...........................................
... 36
CONSULT-II Start Procedure ...............................
... 36
CONSULT-II Data Link Connector (DLC) Circuit .
... 37
INSPECTION PROCEDURE ...........................
... 37
LIFTING POINT ......................................................
... 38
Special Service Tools ..........................................
... 38
Garage Jack and Safety Stand ............................
... 38
2-pole Lift .............................................................
... 40
Board-on Lift ........................................................
... 40
TOW TRUCK TOWING ..........................................
... 41
Tow Truck Towing ................................................
... 41
Vehicle Recovery (Freeing a stuck vehicle) .........
... 41
TIGHTENING TORQUE OF STANDARD BOLTS .
... 42
Tightening Torque Table ......................................
... 42
RECOMMENDED CHEMICAL PRODUCTS AND
SEALANTS ............................................................
... 43
Recommended Chemical Products and Sealants... 43
IDENTIFICATION INFORMATION .........................
... 44
Model Variation ....................................................
... 44
IDENTIFICATION NUMBER ............................
... 45
IDENTIFICATION PLATE ................................
... 46
ENGINE SERIAL NUMBER .............................
... 46
AUTOMATIC TRANSAXLE NUMBER .............
... 46
MANUAL TRANSAXLE NUMBER ....................
... 47

GI-2
Dimensions ..........................................................
... 47
Wheels & Tires ....................................................
... 47
TERMINOLOGY .....................................................
...48
SAE J1930 Terminology List ................................
...48

PRECAUTIONS
GI-3
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PRECAUTIONS PFP:00001
Description EAS000W2
Observe the following precautions to ensure safe and proper servicing. These precautions are not
described in each individual section.
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” EAS000W3
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
● Improper maintenance, including incorrect removal and installation 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.
● 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.
General Precautions EAS000W4
● 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, refriger-
ant gas, etc. When working in a pit or other enclosed area, be
sure to properly ventilate the area before working with hazard-
ous materials.
Do not smoke while working on the vehicle.
● 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 tran-
saxle/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.
SGI285
SGI231

GI-4
PRECAUTIONS
● 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.
● 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.
● Use hand tools, power tools (disassembly only) and recom-
mended special tools where specified for safe and efficient ser-
vice repairs.
● When repairing the fuel, oil, water, vacuum or exhaust systems,
check all affected lines for leaks.
● Before servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate cov-
ers.
Take caution that keys, buckles or buttons do not scratch paint.
SEF289H
SGI233
PBIC0190E
SGI234

PRECAUTIONS
GI-5
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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.
Precautions for Three Way Catalyst EAS000W5
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.
Precautions For Fuel EAS000W6
GASOLINE ENGINE (PREMIUM GASOLINE)
Use premium unleaded gasoline with an octane rating of at least 95 RON (research octane number). If pre-
mium unleaded gasoline is not available, regular unleaded gasoline with an octane rating of at least 91 RON
(research octane number) can be used. However, for maximum vehicle performance, the use of premium
unleaded gasoline is recommended.
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Using a fuel
other than that specified could adversely affect the emission control devices and systems, and could
also affect the warranty coverage validity.
GASOLINE ENGINE (REGULAR GASOLINE)
● Three way catalyst equipped models ... use unleaded gasoline with an octane rating of at least 91 RON
(research octane number).
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst.
● Except for the above models ... use unleaded or leaded gasoline with an octane rating of at least 88 RON
(research octane number).
Use unleaded gasoline if instructed on the fuel filler lid.
Precautions for Multiport Fuel Injection System or Engine Control System EAS000W7
● 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.
SGI787

GI-6
PRECAUTIONS
Precautions for Hoses EAS000W8
HOSE REMOVAL AND INSTALLATION
● To prevent damage to rubber hose, do not pry off rubber hose
with tapered tool or screwdriver.
● To reinstall the rubber hose securely, make sure that hose inser-
tion length and orientation is correct. (If tube is equipped with
hose stopper, insert rubber hose into tube until it butts up
against hose stopper.)
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.
● After installing plate clamps, apply force to them in the direction
of the arrow, tightening rubber hose equally all around.
Precautions for Engine Oils EAS000W9
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.
SMA019D
SMA020D
SMA021D
SMA022D

PRECAUTIONS
GI-7
C
D
E
F
G
H
I
J
K
L
M
B
GI
● Wear protective clothing, including impervious gloves where practicable.
● Do not put oily rags in pockets.
● Avoid contaminating clothes, particularly underpants, with oil.
● Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regu-
larly.
● 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). Prepa-
rations 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.
● 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
Dispose of used oil and used oil filters through authorized waste disposal contractors to licensed waste dis-
posal 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.
Precautions for Air Conditioning EAS000WA
Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to
ATC/MTC section “HFC-134a (R-134a) Service Procedure”, “REFRIGERANT LINES” for specific instructions.

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