Service Procedure
Repair the Vehicle Body Harness for the Front Seat Belt Pre-Tensioners as follows:NOTE:
Use suitable covers to protect upholstery, carpet, paint, etc. when performing this procedure.
Preliminary Steps:
1. Write down all radio station presets.
2. Remove any accessory (phone charger, etc.) from the 12V Power Outlet(s).
WARNING:
Do NOT use a "Computer Memory Saver" (9-volt power source), that plugs into the 12V Power Outlet(s), to retain memory settings on the computer and radio.
No voltage should be present in the system when performing this procedure.
3. Disconnect both the positive and negative battery cables, negative cable first.
4. Wait at least 3 minutes before proceeding with the following steps.
5. Remove the center pillar lower garnish. Refer to "BODY SIDE TRIM" in the "EI" (Exterior & Interior) Section of the 2002 Altima Service Manual.
6. Pull the carpet back so you can reach the pre-tensioner harness branch.
7. Disconnect the pre-tensioner connector.
Using a terminal pick, disengage connector secondary lock.
8. Remove the "existing" pre-tensioner connector.
a. Pull the harness covering (vinyl tube) back slightly, so you can see the wires.
b. Cut off the existing connector at approximately 5 mm from the end of the connector.
9. Remove the harness covering.
a. Use cutters to carefully slit the vinyl tube.
b. Pull back and remove vinyl tube until you can see the wires fully exposed all the way back to the main Body harness (drivers side) or Body harness # 2 (passenger side).
10. Use essential Crimper Tool J-38751-2 to strip off 10-15 mm of insulation from each of the existing pre-tensioner branch wires.
CAUTION:
Use the correct size opening in the wire Crimper tool so you won't cut off any strands of wire. Less strands reduces the electrical load the wire can handle.
11. Prepare the pre-tensioner sub-harness (from kit) for a splice.
a. Cut pre-tensioner sub-harness to proper length.
- For driver side pre-tensioner sub-harness length is 60 mm measured from back of the connector.
- For passenger side pre-tensioner sub-harness length is 160 mm measured from back of the connector.
b. Strip about 10-15 mm of insulation from each wire of the pre-tensioner sub-harness.
12. Slide a solder connector over each pre-tensioner sub-harness wire (see Figure 9), then
^ Twist one end of the sub-harness wires onto one of the Body Harness wires (it doesn't matter which wire).
^ Twist the other sub-harness wire onto the other Body Harness wire.
NOTE:
Matching the wire colors between the sub-harness and Body Harness (polarity) is not critical.
^ Make sure the wires are securely twisted together (see Figure 10).
13. Position the solder connectors so that the solder ring (in the connector) is centered around the exposed twisted wire area (see Figure 11).
14. Use the special "Flame-Less" Heat Gun # J-46538 (essential tool) to heat the Solder Connector. This operation will:
a. Melt the solder (silver ring inside solder connector) into the wires you twisted together (see Figure 12).
b. Melt the sealant (red rings inside solder connector) onto the wires (see Figure 13). This seals the soldered joint. joint.
c. Shrink the plastic sleeve tightly around the wires (see Figure 14).
WARNING:
The Flame-Less Heat Gun and the Solder Connectors become HOT during the soldering process. Allow the Gun and connectors to cool down before handling them.
Important Soldering Tips:
^ Put the Solder Connector in the middle of the heat shield (of the Heat Gun).
^ Start heating the connector from the center and move back and forth (side to side) and around to send the heat evenly to the entire connector.
^ Make sure the solder completely flows into the exposed twisted wires and the adhesive properly seals the wire insulation to the connector sleeve. Watch it carefully and stop applying heat immediately after this happens.
CAUTION:
Be careful not to damage the connector or wires with the heat gun:
^ Do NOT apply heat for more than about 40 seconds.
^ Do NOT overheat the connector or wires. If you see darkening of connector sleeve or wire insulation they have been overheated.
15. Add harness protection.
a. Trim excess tube length as necessary.
b. Slide vinyl tube over new pretensioner branch.
c. Wrap new branch completely with tape.
16. If the car has DTC "SHORT" codes stored for both sides, you'll need to do the same operation (steps 5-15) on the other side of the Vehicle Body Harness. Once you're done, go on to:
^ Step 17 & 18 for Driver Side repair and /or Step 19 & 20 for Passenger Side repair.
17. Secure Driver Side Harness "Branch"
a. Tape the harness branch you just repaired onto the main Body Harness.
b. The part you soldered should be located under fastening tape as shown.
c. Be careful NOT to bend the soldered area.
18. Pre-Tension connection-Driver Side
a. Insert the new connector all the way into the pre-tensioner.
b. Depress secondary lock until you hear a "click" sound.
c. Tug slightly on the connector to make sure it is locked down. Don't pull too hard!
d. Reinstall the carpet and trim.
e. Go to Step 19 or Step 21 as needed.
19. Secure Passenger Side Harness "Branch".
a. Tape the harness branch you just repaired onto the main Body # 2 harness.
b. The part you soldered should be located under fastening tape as shown.
c. Be careful NOT to bend the soldered area.
20. Pre-Tension connection-Passenger Side.
a. Insert the new connector all the way into the pre-tensioner.
b. Depress the secondary lock until you hear a "click" sound.
c. Tug slightly on the connector to verify lock. Make sure it is locked. Don't pull too hard!
d. Reinstall the carpet and trim.
e. Go to Step 21.
Check Air Bag Module Warning Light (on Instrument Panel):
CAUTION:
Make sure the ignition key is in the OFF position and all doors are closed before reconnecting the battery cables (next step).
21. Re-connect both the positive and negative battery cables, negative cable last.
22. Using Consult-II, erase SELF DIAGNOSIS codes
^ SELF-DIAG [CURRENT], make sure no codes are displayed.
^ SELF-DIAG [PAST], erase all codes.
NOTE:
If you don't erase the memory of the malfunction in "SELF-DIAG [PAST]" the warning lamp will be ON.
Refer to "CONSULT-II FUNCTION, DIAGNOSIS MODE FOR CONSULT-II" in the "SRS" section of the 2002 Altima Service Manual for more detail, if needed.
^ TROUBLE DIAG RECORD, the memory cannot be erased.
Final Steps:
23. Turn the ignition key to the ON position and make sure the Air Bag Warning Light turns OFF after 7 seconds.
24. Re-program all radio station presets.
25. Re-set the clock.