INFINITI FX35 2004 Service Manual

FFD-36
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
CAUTION:
Clean inside of companion flange before measuring runout.

If runout is exceed limit, remove the companion from the drive pinion. Turn the companion flange posi-
tion 90° each, and measure the runout again.

If runout still exceed limit, replace companion flange.

If runout still exceed limit after replacing companion flange, check pinion bearing and drive pinion
assembly, and pinion bearing damage.
5. Turn companion flange in both directions 20 times to more,
check total preload with tool.

If the preload value is out of standard, adjust pinion bearing
preload and side bearing preload.
If preload value too large:
–Decrease the drive pinion bearing adjusting washer thick-
ness.
–Decrease the drive pinion adjusting washer thickness.
–Increase the side bearing adjusting shim thickness.
If preload value too small:
If preload value to small:
–Increase the drive pinion bearing adjusting washer thickness.
–Increase the drive pinion adjusting washer thickness.
–Decrease the side bearing adjusting shim thickness.
Carrier Cover InstallationADS000NT
1. Apply sealant to mating surface of carrier cover and carrier case
as shown.
CAUTION:
Clean any residual gasket material off from mating surface
before applying sealant.
2. Install the carrier cover to carrier case, tighten the bolts to spec-
ified torque. Refer to FFD-14, "
COMPONENTS (VQ35DE)" or
FFD-16, "
COMPONENTS (VK45DE)" .
3. Apply sealant to drain plug and filler plug threads.
Install and tighten the plugs to specified torque.
NOTE:
After installing front final drive on vehicle, fill it with specified
amount of gear oil. Refer to FFD-14, "
COMPONENTS
(VQ35DE)" or FFD-16, "COMPONENTS (VK45DE)" . Tool number : ST3127S000 (see J25765-A)
Total preload with oil seal installed
: 1.56 - 2.65 N·m
(0.16 - 0.27 kg-m, 14 - 23 in-lb)
SDIA1649E
SDIA1683E
SDIA1648E

SERVICE DATA AND SPECIFICATIONS (SDS)
FFD-37
C
E
F
G
H
I
J
K
L
MA
B
FFD
Revision: 2004 November 2004 FX35/FX45
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsADS000NE
Drive Gear RunoutADS000NF
Unit: mm (in)
Side Gear Adjustment ADS000NG
Unit: mm (in)
Available Side Gear Thrust WashersADS000OG
Unit: mm (in)
SIDE BEARING PRELOAD ADJUSTING SHIMS
Side Retainer Side:
Differential Case to Side Bearing:
Applied modelVQ35DE engine VK45DE engine
5A/T 5A/T
Final drive model F160A (2-pinion)
Gear ratio3.692
Number of teeth (Drive gear/drive pinion) 48/13
Oil capacity (Approx.) (US qt, lmp qt)0.65 (0.7,0.6)
Type F160 A
Drive gear runout limit 0.05 mm (0.002 in)
Type F16 0A
Clearance limit between side gear and differential case 0.20 mm (0.0079 in) or less
Type F16 0A
Thrust washerThickness Part number Thickness Part number
0.68 (0.0268) 38424 W1010 0.86 (0.0339) 38424 W1016
0.71 (0.0280) 38424 W1011 0.89 (0.0350) 38424 W1017
0.74 (0.0291) 38424 W1012 0.92 (0.0362) 38424 W1018
0.77 (0.0303) 38424 W1013 0.95 (0.0374) 38424 W1019
0.80 (0.0315) 38424 W1014 0.98 (0.0386) 38424 W1020
0.83 (0.0327) 38424 W1015 1.01 (0.0398) 38424 W1021
Type F16 0A
Adjusting shimsThickness Part number Thickness Part number
0.20 (0.0079) 38453 AR000 0.40 (0.0157) 38453 AR003
0.25 (0.0098) 38453 AR001 0.50 (0.0197) 38453 AR004
0.30 (0.0118) 38453 AR002
Type F16 0A
Adjusting shimsThickness Part number Thickness Part number
0.10 (0.0040) 38453 AR010 0.25 (0.0098) 38453 AR015
0.12 (0.0047) 38453 AR011 0.30 (0.0118) 38453 AR016
0.15 (0.0059) 38453 AR012 0.40 (0.0157) 38453 AR017
0.17 (0.0067) 38453 AR013 0.50 (0.0197) 38453 AR018
0.20 (0.0079) 38453 AR014 - -

FFD-38
SERVICE DATA AND SPECIFICATIONS (SDS)
Revision: 2004 November 2004 FX35/FX45
Drive Pinion Height AdjustmentADS000NH
AVAILABLE PINION HEIGHT ADJUSTING WASHERS
Unit: mm (in)
Drive Pinion Preload AdjustmentADS000NI
AVAILABLE PINION HEIGHT ADJUSTING WASHERS
Unit: mm (in)
Total Preload AdjustmentADS000NK
Type F160A
Adjusting washersThickness Part number Thickness Part number
3.09 (0.1217) 38154 U1500 3.39 (0.1335) 38154 U1510
3.12 (0.1228) 38154 U1501 3.42 (0.1346) 38154 U1511
3.15 (0.1240) 38154 U1502 3.45 (0.1358) 38154U1512
3.18 (0.1252) 38154 U1503 3.48 (0.1370) 38154 U1513
3.21 (0.1264) 38154 U1504 3.51 (0.1382) 38154 U1514
3.24 (0.1276) 38154 U1505 3.54 (0.1394) 38154 U1515
3.27 (0.1283) 38154 U1506 3.57 (0.1406) 38154 U1516
3.30 (0.1299) 38154 U1507 3.60 (0.1429) 38154 U1517
3.33 (0.1323) 38154 U1508 3.63 (0.1429) 38154 U1518
3.36 (0.1323) 38154 U1509 3.66 (0.1441) 38154 U1519
Type F160A
Drive pinion preload without front oil seal 0.78 − 1.57 N·m (0.08 − 0.16 kg−m, 7 − 13 in-lb)
Type F160A
Adjusting washersThickness Part number Thickness Part number
3.81 (0.1500) 38125 61001 4.01 (0.1579) 38135 61001
3.83 (0.1508) 38126 61001 4.03 (0.1587) 38136 61001
3.85 (0.1516) 38127 61001 4.05 (0.1594) 38137 61001
3.87 (0.1524) 38128 61001 4.07 (0.1602) 38138 61001
3.89 (0.1531) 39129 61001 4.09 (0.1610) 38139 61001
3.91 (0.1539) 38130 61001 5.19 (0.2043) 38151 AR000
3.93 (0.1547) 38131 61001 5.49 (0.2161) 38151 AR001
3.95 (0.1555) 38132 61001 5.79 (0.2280) 38151 AR002
3.97 (0.1563) 38133 61001 6.09 (0.2398) 38151 AR003
3.99 (0.1571) 38134 61001 6.39 (0.2516) 38151 AR004
Type F160A
Total preload with oil seal 1.56 − 2.65 N·m (0.16 − 0.27 kg−m, 14 − 23 in-lb)
Drive gear to drive pinion backlash 0.10 − 0.15 mm (0.0039 − 0.0059 in)

FL-1
FUEL SYSTEM
B ENGINE
CONTENTS
C
D
E
F
G
H
I
J
K
L
M
SECTION FL
A
FL
Revision: 2004 November 2004 FX35/FX45
FUEL SYSTEM
PREPARATION ........................................................... 2
Commercial Service Tool ......................................... 2
FUEL SYSTEM ........................................................... 3
Checking Fuel Lines ................................................. 3
General Precautions ................................................ 3
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND
FUEL PUMP ASSEMBLY ........................................... 4
Removal and Installation .......................................... 4
REMOVAL ............................................................. 4
INSTALLATION ..................................................... 6INSPECTION AFTER INSTALLATION .................. 7
Disassembly and Assembly ...................................... 8
DISASSEMBLY ..................................................... 8
ASSEMBLY ........................................................... 9
FUEL TANK .............................................................. 10
Removal and Installation ........................................ 10
REMOVAL ........................................................... 10
INSTALLATION ................................................... 11
INSPECTION AFTER INSTALLATION ................ 11
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 12
Standard and Limit .................................................. 12

FL-2
PREPARATION
Revision: 2004 November 2004 FX35/FX45
PREPARATIONPFP:00002
Commercial Service ToolABS005YW
Tool nameDescription
Power toolLoosening bolts and nuts
PBIC0190E

FUEL SYSTEM
FL-3
C
D
E
F
G
H
I
J
K
L
MA
FL
Revision: 2004 November 2004 FX35/FX45
FUEL SYSTEMPFP:17503
Checking Fuel LinesABS005YX
Inspect fuel lines, fuel filler cap and fuel tank for improper attach-
ment, leaks, cracks, damage, loose connections, chafing or deterio-
ration.
If necessary, repair or replace damaged parts.
General PrecautionsABS005YY
WARNING:
When replacing fuel line parts, be sure to observe the following.

Put a “CAUTION: INFLAMMABLE” sign in the workshop.

Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.

Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.
CAUTION:

Before removing fuel line parts, carry out the following procedures:
–Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area.
–Release fuel pressure from the fuel lines. Refer to EC-51, "FUEL PRESSURE RELEASE" (VQ35DE)
or EC-700, "
FUEL PRESSURE RELEASE" (VK45DE).
–Disconnect negative battery terminal.

Always replace O-ring and clamps with new ones.

Do not kink or twist tubes when they are being installed.

Do not tighten hose clamps excessively to avoid damaging hoses.

After connecting fuel tube quick connectors, make sure
quick connectors are secure.
Ensure that connector and resin tube do not contact any
adjacent parts.

After installing tubes, make sure there is no fuel leakage at
connections in the following steps.
–Apply fuel pressure to fuel lines with turning ignition switch
“ON” (with engine stopped). Then check for fuel leaks at
connections.
–Start engine and rev it up and check for fuel leaks at con-
nections.

Use only a genuine NISSAN fuel filler cap as a replacement.
If an incorrect fuel filler cap is used, the “MIL” may come
on.

For servicing “Evaporative Emission System” parts, refer to
EC-643, "
EVAPORATIVE EMISSION SYSTEM" (VQ35DE) or
EC-1320, "
EVAPORATIVE EMISSION SYSTEM" (VK45DE).

For servicing“On Board Refueling Vapor Recovery (ORVR)”
parts, refer to EC-650, "
ON BOARD REFUELING VAPOR
RECOVERY (ORVR)" (VQ35DE) or EC-1327, "ON BOARD
REFUELING VAPOR RECOVERY (ORVR)" (VK45DE).
SMA803A
SBIA0504E

FL-4
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLYPFP:17042
Removal and InstallationABS005YZ
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on the fuel system. Refer to FL-3, "
General Pre-
cautions" .
1. Check fuel level on fuel gauge. If fuel gauge indicates more than
the level as shown in the figure (full or almost full), drain fuel
from fuel tank until gauge indicates level as shown in the figure
or below.
NOTE:
Because fuel will be spilled when removing main and sub fuel
level sensor units for the top of the fuel is above the main and
sub fuel level sensor units installation surface.

As a guide, fuel level becomes the position as shown in the
figure or below when approximately 20 (5-1/4 US gal, 4-3/8
Imp gal) of fuel are drained from fuel tank.

In a case that fuel pump does not operate, perform the follow-
ing procedure.
a. Insert hose of less than 25 mm (0.98 in) in diameter into fuel filler tube through fuel filler opening to draw
fuel from fuel filler tube.
b. Disconnect fuel filler hose from fuel filler tube. Refer to FL-10, "
FUEL TANK" .
c. Insert fuel tube into fuel tank through fuel filler hose to draw fuel from fuel tank.
2. Release the fuel pressure from the fuel lines. Refer to EC-51, "
FUEL PRESSURE RELEASE" (VQ35DE)
or EC-700, "
FUEL PRESSURE RELEASE" (VK45DE).
1. Retainer 2.Main fuel level sensor unit, fuel filter -
and fuel pump assembly3. O-ring
4. Sub fuel level sensor unit
PBIC1585E
PBIC1575E

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
FL-5
C
D
E
F
G
H
I
J
K
L
MA
FL
Revision: 2004 November 2004 FX35/FX45
3. Open fuel filler lid.
4. Open filler cap and release the pressure inside fuel tank.
5. Remove rear seat cushion. Refer to SE-107, "
REAR SEAT" .
6. Peel off floor carpet, then remove inspection hole cover for main
and sub fuel level sensor units by turning clips clockwise by 90
degrees.
7. Disconnect harness connector and fuel feed tube.
Disconnect quick connector as follows:

Hold the sides of connector, push in tabs and pull out tube.

If quick connector sticks to tube of main fuel level sensor unit,
push and pull quick connector several times until they start to
move.Then disconnect them by pulling.
PBIC1576E
PBIC1577E
SFE562A

FL-6
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
CAUTION:

Quick connector can be disconnected when the tabs
are completely depressed. Do not twist it more than
necessary.

Do not use any tools to disconnected quick connector.

Keep resin tube away from heat. Be especially careful
when welding near the resin tube.

Prevent acid liquid such as battery electrolyte, etc.
from getting on resin tube.

Do not bend or twist resin tube during installation and
disconnection.

Do not remove the remaining retainer on hard tube (or
the equivalent) except when resin tube or retainer is
replaced.

When resin tube or hard tube (or the equivalent) is
replaced, also replace retainer with new one.

To keep the connecting portion clean and to avoid
damage and foreign materials, cover them completely
with plastic bags or something similar.
8. Remove main fuel level sensor unit, fuel filter and fuel pump assembly, and sub fuel level sensor unit as
follows:
CAUTION:

Do not bend float arm during removal.

Avoid impacts such as falling when handling components.
a. Removal of main fuel level sensor unit, fuel filter and fuel pump assembly:
i. Remove retainer.
ii. Raise main fuel level sensor unit, fuel filter and fuel pump
assembly, and using snap ring pliers, remove fuel hose connec-
tor.
CAUTION:
Be careful not to damage fuel hose connector by expanding
them excessively.
b. Removal of sub fuel level sensor unit:
i. Remove retainer.
ii. Raise and release sub fuel level sensor unit to remove.
INSTALLATION
Note to the following, and install in the reverse order of removal.Retainer color: White
SBIA0504E
PBIC0163E
PBIC1578E

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
FL-7
C
D
E
F
G
H
I
J
K
L
MA
FL
Revision: 2004 November 2004 FX35/FX45
Main and Sub Fuel Level Sensor Unit

When installing fuel hose connector insert them fully until a click
sound of full stopper engagement is heard.

Face main and sub fuel level sensor units as shown in the fig-
ure, and install them with the knock pin on back aligned with pin
hole on fuel tank.

Install retainer so that its notch becomes parallel with the notch
on fuel tank.

Tighten retainer mounting bolts evenly.
Quick Connector
Connect quick connector as follows:
1. Check the connection for damage or any foreign materials.
2. Align the connector with the tube, then insert the connector straight into the tube until a click sound is
heard.
3. After connecting, make sure that the connection is secure by following method.

Pull the tube and the connector to make sure they are
securely connected.

Visually confirm that the two retainer tabs are connected to
the connector.
INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.
PBIC1579E
PBIC1065E
PBIC1652E
PBIC1653E