Nissan - LEAF - Service Manual - 2013 - 2013

Reference: Dat e: NTB13-034 April 2, 2013 VOLUNTARY SAFETY RECALL CAMPAIGN 2013 LEAF OCS SENSORS CAMPAIGN ID #: PC215 NHTSA #: 13V-069 APPLIED VEHICLES: 2013 Leaf (ZE0) Check Service COMM to confirm campaign eligibility. INTRODUCTION Nissan is conducting a Voluntary Safety Recall Campaign to inspect, and if needed, replace the Occupant Classification System (OCS) sensors on certain specific 2013 Leaf vehicles at no charge for parts or labor. IDENTIFICATION NUMBER Nissan has assigned identification number PC215 to this campaign. This number must appear on all communications and documentation of any nature dealing with this campaign. DEALER RESPONSIBILITY It is the dealer’s responsibility to check Service Comm for the campaign status on each vehicle falling within the range of this voluntary safety recall campaign which for any reason enters the service department. This includes vehicles purchased from private parties or presented by transient (tourist) owners and vehicles in a dealer’s inventory. Federal law requires that new vehicles in dealer inventory which are the subject of a safety recall must be corrected prior to sale. Failure to do so can result in civil penalties by the National Highway Traffic Safety Administration. While federal law applies only to new vehicles, Nissan strongly encourages dealers to correct any used vehicles in their inventory before they are retailed. Nissan Bulletins are intended for use by qualified technicians, not 'do-it-yourselfers'. Qualified technicians are properly trained individuals who have the equipment, tools, safety instruction, and know-how to do a job properly and safely. NOTE: If you believe that a described condition may apply to a particular vehicle, DO NOT assume that it does. See your Nissan dealer to determine if this applies to your vehicle. 1/29 Repair Overview Check Service Comm campaign ID # PC215 to confirm the vehicle you are working on requires this campaign Check OCS sensor lot codes Are the first four digits of the lot code on either of the sensors in this range? 2472 to 3102 No Yes No repair is required Replace OCS sensor(s) that have a lot code in the above range. Check Air Bag warning light operation Perform Zero Point Reset and Check for DTCs END END REQUIRED SPECIAL TOOL J-50079 • Video Borescope J-50079 is an essential tool. • Each dealer was previously shipped one J-50079. • Additional tools can be ordered from TECH-MATE at 1-800-662-2001. Figure ST1 2/29 NTB13-034 SERVICE PROCEDURE CAUTION: Handle interior trim carefully to avoid damage. Work with clean hands and clean tools to avoid dirt and stains. Use protective covers as needed. Check OCS Sensor Lot Codes 1. Slide the front passenger seat to the full forward position. 2. Use borescope (J-50079 or equivalent) to read the lot code on the side of the inboard seat-track. Figure A 3/29 NTB13-034 NOTE: The seat is removed in the photo below to illustrate the location of the lot code stickers. The seat does not need to be removed to see the stickers with the borescope. OCS sensor lot code example – your vehicles lot code numbers may be different. Example: First four digits of lot codes Seat removed for illustration only Figure B 3. Write the first four digits of the lot code for each sensor on the repair order. • In the example above, the first four digits are “3062” for both sensors. NG: Lot code is in this range: 2472 to 3102 • If the first four digits of the lot code are 2472 to 3102, replace the sensor. NOTE: Only replace a sensor if its lot code is in the above range. Some vehicles may require only one new sensor; some may require two new sensors. • Refer to Replace OCS Sensor(s) on the next page. OK: Lot code is not in the above range • If the first four digits of the lot code for both sensors are not in the above range, no repair is needed. a. Turn the ignition from OFF to ON and observe the air bag warning light: o Light should illuminate for 7 seconds and then go out: NOTE: If the Air Bag Warning light does not operate as described above, there may be an issue not covered by this campaign. Refer to ASIST and the Service Manual for additional diagnostic and repair information. b. Return the vehicle to the customer. 4/29 NTB13-034 Replace OCS Sensor(s) IMPORTANT: Follow all cautions, warnings, and notes in the Electronic Service Manual (ESM) when working on or near a Supplemental Restraint System (SRS), such as an air bag). CAUTION: Handle interior trim carefully to avoid damage. Work in a clean area with clean hands and clean tools to avoid dirt and stains. Use protective covers as needed. WARNING: This procedure involves working with the passenger seat frame. The metal seat frame has sharp edges. NOTE: Make sure to follow this procedure exactly as specified to ensure proper operation of the Occupant Classification System. 1. Write down the radio settings. Presets 1 2 3 4 5 6 AM FM 1 FM 2 SAT 1 SAT 2 SAT 3 Bass Treble Balance Fade Speed Sen. Vol. 2. If equipped; Write down the customer preferred setting for the Automatic Air Conditioning System. • If needed, refer to System Settings in the HAC section of the Service Manual. 3. Turn the ignition OFF. 4. Disconnect both battery cables from the 12 volt battery, negative cable first. CAUTION: Wait at least 3 minutes before disconnecting any air bag electrical connectors. 5/29 NTB13-034 5. Remove the recline lever finisher from the front passenger seat as follows: a. Position the seatback to the full upright/full forward position. NOTE: • With the seatback full forward, the recline lever will be in an UP position as shown. • The recline lever is easier to remove in this UP position. Recline lever finisher - UP Figure 1 b. At the same time: • Push down on the tip, and • Pull forward (toward the front of the vehicle). Figure 2 Seat cushion outer finisher (RH) 6. Use a plastic trim tool to remove the seat cushion outer finisher (RH). Figure 3 6/29 NTB13-034 WARNING: This procedure involves working with the passenger seat frame. The metal seat frame has sharp edges. 7. Disconnect the seat cushion trim J-hooks A (see Figures 4 and 5). • J-hooks are located on the sides, front, and front corners. Figure 4 NOTE: • The inboard side J-hook can be released using a hook tool. a. Slide the hook tool between the seat and the center console (see Figure 5A). b. Using the hook tool, push the J-hook down and away from the seat (see Figure 5B). Hook tool J-hook Figure 5A Hook tool Figure 5B 7/29 NTB13-034 8. Move the passenger seat to the full forward position. NOTE: Look under the front of the seat for steps 9, 10 and 11. Look under the front Figure 6 9. Disconnect the electrical harness connectors shown in Figure 7. • These connectors are accessed from under the front of the seat. Electrical harness connectors Figure 7 8/29 NTB13-034 10. Remove the 3 screws shown in Figure 8. • These screws are accessed from under the front to the seat. 11. Disconnect the electrical connector from the OCS control unit (see Figure 8). • The OCS control unit is accessed from under the front to the seat. Screw Screw Screw OCS control unit electrical connector Figure 8 12. Lift the seat cushion and remove the plastic liner. Plastic liner NOTE: Retain this liner for reassembly. Figure 9 9/29 NTB13-034 13. Lift the seat cushion to access the seat cushion pan. NOTE: The Seat cushion will need to be lifted for steps 14 through 19. 14. Release/disconnect the 4 harness mounting clips shown in Figure 10. 15. Remove the 2 Torx® head bolts shown in Figure 10. NOTE: These bolts will not be reused. Seat cushion pan Bolt Harness clips Bolt Figure 10 10/29 NTB13-034 16. Lift the seat cushion pan and disconnect the front OCS sensor electrical connector (see Figure 11). Seat cushion pan Front OCS sensor Figure 11 17. Lift the seat cushion pan and remove the 14 mm nut on the front of the inboard seat-track (see Figure 12). NOTE: This nut will not be reused. Seat cushion pan 14 mm nut Figure 12 11/29 NTB13-034 18. Disconnect the rear OCS sensor electrical connector (see Figure 13). 19. Remove the 14 mm nut and washer on the rear of the inboard seat-track (see Figure 13). NOTE: This nut will not be reused. Seat cushion Rear OCS sensor 14 mm nut and washer Figure 13 20. Remove all 4 of the 12 mm nuts from the outboard seat-track (see Figure 14). NOTE: These nuts will not be reused. 12 mm nuts 12 mm nuts Figure 14 12/29 NTB13-034 21. Lift the seat from the seat-tracks and set it to the rear as shown in Figure 15. Figure 15 22. Remove the old OCS sensor(s) from the inboard seat-track and install new OCS sensor(s). • Use new 12 mm OCS mounting nuts. • Torque nuts to 22 N•m (3.04 kg-m, 16 ft-lb). OCS sensor OCS sensor Figure 16 13/29 NTB13-034 23. Use a permanent marker to mark through the lot code stickers shown in Figure 17. • There is one sticker on the side of the seat cushion pan and one sticker on the side of the inboard seat-track. Lot code stickers Figure 17 14/29 NTB13-034 Reassmeble the Seat 24. Place the seat onto the seat-tracks. • Make sure the studs are located correctly in the seat frame. Figure 18 25. Install all 4 of the 12 mm nuts on the outboard seat-track finger tight only (see Figure 19). • Use new nuts. 12 mm nuts 12 mm nuts Figure 19 15/29 NTB13-034 26. Lift the seat cushion and reconnect the rear OCS sensor electrical connector (see Figure 20). NOTE: The seat cushion must be lifted for steps 27 though 30, and steps 32 and 33. 27. Install the 14 mm nut and washer on the rear of the inboard seat-track finger tight only (see Figure 20). • Use a new washer. • Use a new nut. Seat cushion Rear OCS sensor 14 mm nut and washer Figure 20 28. Lift the seat cushion pan and connect the front OCS sensor electrical connector (see Figure 21). Seat cushion pan Front OCS sensor Figure 21 16/29 NTB13-034 29. Lift the seat cushion pan and install the 14 mm nut on the front of the inboard seat-track (see Figure 22). • Use a new nut. • Torque nut to 45 N•m (4.56 kg-m, 33 ft-lb). Seat cushion pan 14 mm nut Figure 22 30. Torque the 14 mm nut on the rear of the inboard seat track (see Figure 23). • Torque nut to 45 N•m (4.56 kg-m, 33 ft-lb). Seat cushion 14 mm nut Figure 23 17/29 NTB13-034 31. Torque the 12 mm nuts on the outboard seat-track (see Figure 24). • Torque nuts to 22 N•m (3.04 kg-m, 16 ft-lb). 12 mm nuts 12 mm nuts Figure 24 18/29 NTB13-034 32. Install new Torx® head bolts shown in Figure 25. • Make sure locating pins are in place. • Use new bolts. • Torque bolts to 22 N•m (3.04 kg-m, 16 ft-lb). 33. Connect the 4 harness mounting clips shown in Figure 25. • Reach under the front of the seat and push the clips up from underneath. Locating pin Bolt Seat cushion pan Harness clips Bolt Locating pin Figure 25 19/29 NTB13-034 34. Move the passenger seat to the full forward position. NOTE: Look under the front of the seat for steps 35, 36, and 37. Look under the front Figure 26 35. Reinstall the 3 screws shown in Figure 27. • These screws are accessed from under the front to the seat. 36. Reconnect the electrical connector to the OCS control unit (see Figure 27). • The OCS control unit is accessed from under the front to the seat. Screw Screw Screw OCS control unit electrical connector Figure 27 20/29 NTB13-034 37. Reconnect the electrical harness connectors shown in Figure 28. • These connectors are accessed from under the front of the seat. Electrical harness connectors Figure 28 38. Lift the seat cushion and reinstall the plastic liner. Plastic liner Figure 29 39. Reconnect the seat cushion trim J-hooks A (see Figure 30). • J-hooks are located on sides, front, and front corners. Figure 30 21/29 NTB13-034 Seat cushion outer finisher (RH) 40. Reinstall the seat cushion outer finisher (RH). Figure 31 41. Reinstall the recline lever finisher. • Push the finisher onto the lever until it locks in place. Recline lever finisher Figure 32 42. Operate the seat slide and make sure both tracks (left and right side) lock in place at each adjustment point. 22/29 NTB13-034 43. Reconnect both cables for the 12 volt battery – positive cable first. 44. Reset the clock in the combination meter. 45. Reset the radio settings. 46. If equipped; check/reset the clock in the navigation system. 47. If equipped; reset the customer preferred settings for the Automatic Air Conditioning System. • If needed, refer to System Settings in the HAC section of the Service Manual. 48. Inform the customer: • If equipped; some memory settings in the navigation system may need to be reset. • If equipped; some charging and climate control timers may need to be reset. 49. Reinitialize and check the Anti-Pinch Function for all Auto-UP power windows: Reinitialize: a. Turn the ignition ON. b. Operate the power window switch to fully open the window (glass all the way down). c. Hold the window switch UP until the glass stops at the fully closed position, and then continue holding the switch UP for 2 seconds or more. d. Check that AUTO-UP function operates normally. Check Anti-Pinch Function a. Fully open the door window (glass all the way down). b. Hold a piece of wood near the fully closed position. c. Close the door window glass using the AUTO-UP switch. Allow the window glass to hit the wood. d. Check the following conditions: • Check that the glass lowers for approximately 150 mm (5.9 in), without pinching the wood, and stops. • Check that the glass does not rise when operating the power window main switch, while the widow is lowering after hitting the wood. CAUTION: Do not check anti-pinch function with hands or other body parts because they may be pinched. 50. Perform Zero Point Reset and Check for DTCs; next page. 23/29 NTB13-034 Zero Point Reset / Check for DTCs 1. Attach the CONSULT-III plus (C-III plus) VI to the vehicle. 2. Prepare the vehicle for Zero Point Reset. • Place the vehicle in a level area. • Minimize vibrations near the vehicle. • Remove any objects on the passenger seat. • No occupants in the vehicle – including the servicing technician. • Close all of the vehicle doors. • Do not touch the vehicle during zero point reset. 3. Place the CONSULT PC outside the vehicle and away from the vehicle. 4. Open/start C-III plus. 5. Wait for the plus VI to be recognized. • The serial number will display when the VI is recognized. 6. Select Diagnosis (One System). Step 5: VI is recognized Step 6 Figure Z1 24/29 NTB13-034 7. Select OCCUPANT DETECTION. Step 7 Figure Z2 8. Wait for System Call to complete. 9. Select Zero point reset function. 10. Select Start. Step 9 Step 10 Figure Z3 25/29 NTB13-034 11. Select Next. Step 11 Figure Z4 12. Select Start. Step 12 Figure Z5 NOTE: Zero Point Reset must performed even if: • “Current status” indicates “Completed”, or • “Zero point reset current status” indicates “Already performed” 26/29 NTB13-034 13. Wait for Zero Point Function to complete. Figure Z6 14. Make sure that “Current status” is Completed. Step 14 Figure Z7 27/29 NTB13-034 15. Select Home on C-III plus. 16. Check for Air Bag DTCs. Navigate C-III plus to: Diagnosis (One System) Ö AIR BAG Ö Self Diagnostic Results • No Air Bag DTCs stored – go to the next step. • DTC B00A0 stored (current or past) – erase stored code, then go to the next step. • Other DTCs stored: Refer to ASIST and the Service Manual for additional diagnostic and repair information. Issues other than replacement of the OCS sensors are not coved by this campaign. 17. Close C-III plus, turn the ignition OFF, and disconnect from the vehicle. 18. Turn the ignition ON and observe the air bag warning light: • Light should illuminate for 7 seconds and then go out. NOTE: If the Air Bag Warning light does not operate as described above, there may be an issue not covered by this campaign. Refer to ASIST and the Service Manual for additional diagnostic and repair information. 28/29 NTB13-034 PARTS INFORMATION DESCRIPTION Sen-Occupant (OCS Sensor) M10 Nut (14 mm wrench size) M8 Nut (12 mm wrench size) PART # QUANTITY 98853-3JA0A If needed, 1 or 2 23391-3NF0A If sensor is replaced; 2 23188-3NF0A If sensor is replaced; 8 Washer 01311-3NF0A If sensor is replaced; 1 Torx® Bolt 01141-3NF0A If sensor is replaced; 2 CLAIMS INFORMATION Submit a Campaign (CM) line claim using the following claims coding: CAMPAIGN ID # PC215 DESCRIPTION Inspect OCS Sensors OP CODE PC2150 FRT 0.2 hrs. DESCRIPTION Inspect and replace One (1) OCS Sensor OP CODE FRT PC2151 1.1 hrs. DESCRIPTION Inspect and replace Two (2) OCS Sensors OP CODE FRT PC2152 1.1 hrs. OR CAMPAIGN ID # PC215 OR CAMPAIGN ID # PC215 29/29 NTB13-034