atc INFINITI FX35 2005 Service Manual

RF-2
PRECAUTIONS
Revision: 2005 July 2005 FX
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
AIS003AR
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:

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.
Precautions AIS003AS

Disconnect both battery cables in advance.

Do not tamper with or force air bag lid open, as this may adversely affect air bag performance.

Be careful not to scratch pad and other parts.

When removing or disassembling any part, be careful not to damage or deform it. Protect parts, which
may get in the way with cloth.

When removing parts with a screwdriver or other tool, protect parts by wrapping them with vinyl or tape.

Keep removed parts protected with cloth.

If a clip is deformed or damaged, replace it.

If an unreusable part is removed, replace it with a new one.

Tighten bolts and nuts firmly to the specified torque.

After re-assembly has been completed, make sure each part functions correctly.

Remove stains in the following way.
Water-soluble stains:
Dip a soft cloth in warm water, and then squeeze it tightly. After wiping the stain, wipe with a soft dry cloth.
Oil stain:
Dissolve a synthetic detergent in warm water (density of 2 to 3% or less), dip the cloth, then clean off the stain
with the cloth. Next, dip the cloth in fresh water and squeeze it tightly. Then clean off the detergent completely.
Then wipe the area with a soft dry cloth.

Do not use any organic solvent, such as thinner or benzine.

SUNROOF RF-25
C
D E
F
G H
J
K L
M A
B
RF
Revision: 2005 July 2005 FX
LID WEATHERSTRIP OVERLAP ADJUSTMENT AND SURFACE MISMATCH ADJUSTMENT
1. Tilt up glass lid.
2. After loosening glass lid TORX bolts (T25) (left and right), tilt down glass lid.
3. Adjust glass lid from outside of vehicle so it resembles “A–A” “B– B” “C–C” as shown in the figure to the right.
4. To prevent glass lid from moving after adjustment, first tighten the TORX bolts (T25) of front left, and then tighten the TORX
bolts (T25) of rear right.
5. Tighten remaining TORX bolts (T25), being careful to prevent glass lid from moving.
6. Tilt glass lid up and down several times to make sure it moves smoothly.
Removal and InstallationAIS003BS

After any adjustment, check sunroof operation and glass lid alignment.

Handle finisher plate and glass lid with care so as not to cause damage.

It is desirable for easy installation to mark each point before removal.
CAUTION:

Always work with a helper.

Fully close the glass lid assembly, before removal, then do not operate motor assembly after
removal.
PIIA3501E

RFD-2
PRECAUTIONS
Revision: 2005 July 2005 FX
PRECAUTIONSPFP:00001
Service Notice or PrecautionsADS001AF

Check for the correct installation status prior to removal or disassembly. If matching marks are required,
be certain they do not interfere with the function of the parts when applied.

Overhaul should be done in a clean work area, it is preferable to work in dustproof area.

Before disassembly, using steam or white gasoline, completely remove sand and mud from the exterior of
the unit, preventing them from entering into the unit during disassembly or assembly.

Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with a new ones if necessary.

Gaskets, seals and O-rings should be replaced any time when the unit is disassembled.

In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.

Clean and flush the parts sufficiently and blow-dry them.

Be careful not to damage sliding surfaces and mating surfaces.

When applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil,
and foreign materials from the application and mounting surfaces.

Always use shop paper for cleaning the inside of components.

Avoid using cotton gloves or shop rags to prevent entering of lint.

During assembly, observe the specified tightening torque, and apply new gear oil, petroleum jelly, or multi-
purpose grease as specified for each vehicle, if necessary.

RFD-10
FRONT OIL SEAL
Revision: 2005 July 2005 FX
FRONT OIL SEALPFP:38189
Removal and InstallationADS001AM
REMOVAL
1. Remove propeller shaft. Refer to PR-9, "Removal and Installation" .
2. Put matching mark on the end of the drive pinion. The matching mark should be in line with the matching mark A on companion
flange.
CAUTION:
For matching mark, use paint. Do not damage drive pinion.
NOTE:
The matching mark A on the final drive companion flange indi-
cates the maximum vertical runout position.
3. Remove drive pinion lock nut using the flange wrench.
4. Remove companion flange using a puller.
5. Remove front oil seal using the puller.
PDIA0478E
Tool number : KV40104000 ( — )
SDIA1589E
PDIA0406E
Tool number : KV381054S0 (J-34286)
SDIA0485E

FRONT OIL SEAL RFD-11
C E F
G H
I
J
K L
M A
B
RFD
Revision: 2005 July 2005 FX
INSTALLATION
1. Apply multi-purpose grease to front oil seal lips.
2. Using the drift, install front oil seal as shown in figure.
CAUTION:

Do not reuse oil seal.

When installing, do not incline oil seal.
3. Align the matching mark of drive pinion with the matching mark A of companion flange, then install the companion flange.
4. Apply gear oil on the screw part of drive pinion and the seating surface of drive pinion lock nut.
5. Install drive pinion lock nut with the flange wrench, tighten to the specified torque. Refer to RFD-16, "
COMPONENTS" .
CAUTION:
Do not reuse drive pinion lock nut.
6. Install propeller shaft. Refer to PR-9, "
Removal and Installation"
. Tool number : ST30720000 (J-25405)
PDIA0565E
PDIA0478E
Tool number : KV40104000 ( — )
SDIA1589E

REAR FINAL DRIVE ASSEMBLY RFD-21
C E F
G H
I
J
K L
M A
B
RFD
Revision: 2005 July 2005 FX
DISASSEMBLY
Differential Assembly
1. Drain gear oil, if necessary.
2. Remove side flange.
3. Remove rear cover mounting bolts.
4. Remove rear cover to insert the seal cutter between gear carrier and rear cover.
CAUTION:

Be careful not to damage the mating surface.

Do not insert flat-bladed screwdriver, this way damage
the mating surface.
5. Using two 45 mm (1.77 in) spacers, mount carrier on the attach- ment.
6. For proper reinstallation, paint matching marks on one side of the bearing cap.
CAUTION:

For matching mark, use paint. Do not damage bearing
caps and gear carrier.

Bearing caps are line-board during manufacture. The
matching marks are used to reinstall them in their origi-
nal positions.
7. Remove bearing caps. Tool number : KV10111100 (J-37228)
PDIA0491E
Tool number : KV38100800 (J-25604-01)
SDIA1008E
SDIA1795E
S-PD343

RFD-22
REAR FINAL DRIVE ASSEMBLY
Revision: 2005 July 2005 FX
8. Lift differential case assembly out with a suitable tool.

Keep side bearing outer races together with inner race. Do
not mix them up.
Also, keep side bearing adjusting washers together with bear-
ings.
9. Remove side bearing inner race. To prevent damage to bearing, engage puller jaws in groove.
CAUTION:

To prevent damage to the side bearing and drive gear,
place copper plates between these parts and vise.

It is not necessary to remove side bearing inner race
except it is replaced.
10. For proper reinstallation, paint matching mark on one differential case assembly.
CAUTION:
For matching mark, use paint. Do not damage differential
case and drive gear.
11. Remove drive gear mounting bolts.
12. Tap drive gear off differential case assembly with a soft hammer. CAUTION:
Tap evenly all around to keep drive gear from bending.
PDIA0547E
SPD527
Tool number A: ST33051001 (J-22888-20)
B: ST33061000 (J-8107-2)
SPD920
PDIA0496E

RFD-24
REAR FINAL DRIVE ASSEMBLY
Revision: 2005 July 2005 FX
3. Put matching mark on the end of drive pinion. The matching
mark should be in line with the matching mark A on companion
flange.
CAUTION:
For matching mark, use paint. Do not damage companion
flange and drive pinion.
NOTE:
The matching mark A on the final drive companion flange indi-
cates the maximum vertical runout position.
When replacing companion flange, matching mark is not neces-
sary.
4. Remove companion flange using the suitable puller.
5. Press drive pinion assembly out of gear carrier. CAUTION:
Do not drop drive pinion assembly.
6. Remove front oil seal.
7. Remove side oil seal.
8. Remove pinion front bearing inner race.
9. Remove collapsible spacer.
10. Remove pinion rear bearing inner race and drive pinion height adjusting washer with the replacer.
11. Tap pinion front/rear bearing outer races uniformly a brass rod or equivalent to removed.
CAUTION:
Be careful not to damage gear carrier.
PDIA0478E
SDIA1129E
SPD892
Tool number : ST30031000 (J-22912-01)
S-PD179
SDIA0817E

REAR FINAL DRIVE ASSEMBLY RFD-25
C E F
G H
I
J
K L
M A
B
RFD
Revision: 2005 July 2005 FX
INSPECTION AFTER DISASSEMBLY
Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If so, follow the measures
below.
ADJUSTMENT AND SELECTION OF ADJUSTING WASHERS
Differential Side Gear Clearance

Assemble the differential parts if they are disassembled. Refer to RFD-32, "Differential Assembly" .
1. Place differential case straight up so that side gear to be mea- sured comes upward.
Content Conditions and Measures
Hypoid gear

If the gear teeth do not mesh or line-up correctly, determine the cause and adjust or replace as nec-
essary.

If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new
drive gear and drive pinion as a set.
Bearing

If any chipped (by friction), pitted, worn, rusted or scratched mark, or unusual noise from the bearing
is observed, replace as a bearing assembly (as a new set).
Side gear and Pinion mate
gear

If any cracks or damage on the surface of the tooth is found, replace.

If any worn or chipped mark on the contact sides of the thrust washer is found, replace.
Side gear thrust washer and
pinion mate thrust washer

If it is chipped (by friction), damaged, or unusually worn, replace.
Oil seal

Whenever disassembled, replace.

If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace
them.
Differential case

If any wear or crack on the contact sides of the differential case is found, replace.
Companion flange

If any chipped mark (about 0.1 mm, 0.004 in) or other damage on the contact sides of the lips of the
companion flange is found, replace.
PDIA0460E

REAR FINAL DRIVE ASSEMBLY RFD-29
C E F
G H
I
J
K L
M A
B
RFD
Revision: 2005 July 2005 FX
7. Place the J-34309-11 “R200A” pinion height adapter onto the
gauge plate and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean.
8. Position the side bearing discs, J-25269-4, and arbor firmly into the side bearing bores. Install the bearing caps and tighten bear-
ing cap mounting bolts to the specified torque. Refer to RFD-16,
"COMPONENTS" .
9. Select the correct standard pinion height adjusting washer thick- ness. Select by using a standard gauge of 3 mm (0.12 in) and
your J-34309-101 feeler gauge. Measure the distance between
the J-34309-11 pinion height adapter including the standard
gauge and the arbor.
10. Write down exact measurement (the value of feeler gauge).
11. Correct the pinion height washer size by referring to the “pinion head number”.
There are two numbers painted on the drive pinion. The first
one refers to the drive pinion and drive gear as a matched
set. This number should be the same as the number on the
drive gear. The second number is the “pinion head height
number”. It refers to the ideal pinion height from standard
for quietest operation. Use the following chart to determine
the correct pinion height washer.
SPD208A
SPD211A
SPD204A
SPD775
SPD542