stall INFINITI M35 2006 Factory Service Manual

FFD-32
FRONT FINAL DRIVE ASSEMBLY
Revision: 2006 January2006 M35/M45
9. Install drive gear on the mounting bolts, and then tighten to the
specified torque. Refer to FFD-15, "
COMPONENTS" .
CAUTION:
Tighten bolts in a crisscross fashion.
10. Press side bearing inner races to differential case, using the drift
and the base.
CAUTION:
Do not reuse side bearing inner race.
11. Press-fit side bearing outer race into side retainer with the drift
and the drift bar.
CAUTION:
At first, using a hammer, tap bearing outer race until it
becomes flat to side retainer.
Do not reuse side bearing outer race.
12. Press-fit side bearing outer race into gear carrier with the drift
and the drift bar.
CAUTION:
At first, using a hammer, tap bearing outer race until it
becomes flat to gear carrier.
Do not reuse side bearing outer race.
13. Place the differential case assembly into gear carrier.
14. Measure side bearing preload. If necessary, select the appropri-
ate side bearing adjusting shim. Refer to FFD-25, "
Side Bearing
Preload" .
SDIA0247J
Tool number A: ST33230000 (J-25805-01)
B: ST33061000 (J-8107-2)
PDIA0810J
Tool number A: ST30611000 (J-25742-1)
B: KV31103000 (J-38982)
PDIA0811J
Tool number A: ST30611000 (J-25742-1)
B: KV31103000 (J-38982)
PDIA0812J
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FRONT FINAL DRIVE ASSEMBLY
FFD-33
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FFD
Revision: 2006 January2006 M35/M45
15. Install selected side bearing adjusting shim (1).
16. Apply multi-purpose grease to O-ring (2), and install it to side
retainer.
CAUTION:
Do not reuse O-ring.
17. Install side retainer assembly to gear carrier.
18. Install side retainer mounting bolts to the specified torque. Refer
to FFD-15, "
COMPONENTS" .
19. Using the drift, press-fit side oil seal so that its surface comes
face to face with the end surface of the side retainer.
CAUTION:
Do not reuse oil seal.
When installing, do not incline oil seal.
Apply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of oil seal.
20. Using the drift, press-fit side oil seal so that its surface comes
face to face with the end surface of gear carrier.
CAUTION:
Do not reuse oil seal.
When installing, do not incline oil seal.
Apply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of oil seal.
21. Apply multi-purpose grease to O-ring, and install it to gear car-
rier.
CAUTION:
Do not reuse O-ring.
22. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and total preload
torque. Refer to FFD-17, "
Drive Gear Runout" , FFD-17, "Tooth Contact" , FFD-19, "Backlash" , FFD-16,
"Total Preload Torque" .
Recheck above items. Readjust the above description, if necessary.
PDIA0813E
PDIA0669E
Tool number A: ST33400001 (J-26082)
PDIA0787J
Tool number A: KV38102100 (J-25803-01)
PDIA0788J

FFD-34
FRONT FINAL DRIVE ASSEMBLY
Revision: 2006 January2006 M35/M45
23. Apply sealant to mating surface of carrier cover.
Use Genuine Silicone RTV or equivalent. Refer to GI-48,
"Recommended Chemical Products and Sealants" .
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
24. Install carrier cover on gear carrier and tighten mounting bolts
with the specified torque. Refer to FFD-15, "
COMPONENTS" .
Side Shaft Assembly
1. Using the drift, install side shaft oil seal.
CAUTION:
Do not reuse oil seal.
When installing, do not incline oil seal.
Apply multi-purpose grease onto oil seal lips, and gear
oil onto the circumference of oil seal.
2. Install dust sealed.
3. Support side shaft bearing with the drift, then press side shaft
(1) into the side shaft bearing using a press.
4. Apply multi-purpose grease to O-ring, and install it to extension
tube retainer.
CAUTION:
Do not reuse O-ring.
PDIA0742E
SDIA1648E
Tool number A: KV38100200 ( — )
PDIA0814J
Tool number A: ST30032000 (J-26010-01)
PDIA0815J

FL-1
FUEL SYSTEM
B ENGINE
CONTENTS
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SECTION FL
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FL
Revision: 2006 January2006 M35/M45
FUEL SYSTEM
PREPARATION ........................................................... 2
Commercial Service Tools ........................................ 2
FUEL SYSTEM ........................................................... 3
Checking Fuel Lines ............................................ ..... 3
General Precautions ................................................ 3
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND
FUEL PUMP ASSEMBLY ........................................... 4
Components ............................................................. 4
Removal and Installation .......................................... 4
REMOVAL ........................................................
..... 4
INSTALLATION ..................................................... 6
INSPECTION AFTER INSTALLATION ................. 7Components ............................................................. 8
Disassembly and Assembly ...................................... 8
DISASSEMBLY ..................................................... 8
ASSEMBLY ........................................................... 9
FUEL TANK .............................................................. 10
Components ........................................................... 10
Removal and Installation ........................................ 10
REMOVAL ........................................................
... 10
INSTALLATION ................................................... 11
INSPECTION AFTER INSTALLATION ................ 11
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 13
Standard and Limit .................................................. 13
FUEL TANK ...................................................... ... 13

FUEL SYSTEM
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FUEL SYSTEMPFP:17503
Checking Fuel LinesNBS005R8
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 PrecautionsNBS005R9
WAR NING :
When replacing fuel line parts, be sure to observe the following.
Put a “CAUTION: FLAMMABLE” 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:
Use gasoline required by the regulations for octane number. Refer to GI-6, "Precautions for Fuel
(Unleaded Premium Gasoline Required)" .
Before removing fuel line parts, perform 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-98, "FUEL PRESSURE RELEASE" (VQ35DE)
or EC-809, "
FUEL PRESSURE RELEASE" (VK45DE).
–Disconnect the battery cable from the negative 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-39, "
EVAPORATIVE EMISSION SYSTEM" (VQ35DE) or
EC-749, "
EVAPORATIVE EMISSION SYSTEM" (VK45DE).
For servicing“On Board Refueling Vapor Recovery (ORVR)”
parts, refer to EC-46, "
ON BOARD REFUELING VAPOR
RECOVERY (ORVR)" (VQ35DE) or EC-756, "ON BOARD
REFUELING VAPOR RECOVERY (ORVR)" (VK45DE).
SMA803A
SBIA0504E

FL-4
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
Revision: 2006 January2006 M35/M45
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLYPFP:17042
ComponentsNBS005RA
Removal and InstallationNBS005RB
REMOVAL
WAR NING :
Read “General Precautions” when working on the fuel system. Refer to FL-3, "
General Precautions" .
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 fuel gauge indicates level as shown in the fig-
ure 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-98, "
FUEL PRESSURE RELEASE" (VQ35DE)
or EC-809, "
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
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FL-6
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
Revision: 2006 January2006 M35/M45
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: Green
SBIA0504E
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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
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Fuel hose
When installing fuel hose connector insert them fully until a click
sound of full stopper engagement is heard.
Main and Sub Fuel Level Sensor Unit
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
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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
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ASSEMBLY
1. Check for damage of fuel level sensor unit installation position on the side of fuel filter and fuel pump
assembly.
2. Slide fuel level sensor unit until it aligns to installation groove, then insert it until it stops.
After inserting, apply force in reverse direction (removal direction) to ensure it cannot be pulled out.
3. Connect the black (A) and white (B) harnesses so that they are
in the positions shown in the figure.
Securely insert harness connector until it stops.
PBIC3387E

FL-10
FUEL TANK
Revision: 2006 January2006 M35/M45
FUEL TANKPFP:17202
ComponentsNBS005RE
Removal and InstallationNBS005RF
REMOVAL
WAR NING :
Be sure to read “General Precautions” when working on the fuel system. Refer to FL-3, "
General Pre-
cautions" .
Drain fuel from fuel tank if necessary. Refer to FL-4, "REMOVAL" .
Perform work on level place.
1. Perform steps 2 to 7 of “REMOVAL” in “ FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP
ASSEMBLY” on main and sub fuel level sensor units. Refer to FL-4, "
REMOVAL" .
2. Remove exhaust front tube, center muffler and main muffler. Refer to EX-3, "
EXHAUST SYSTEM" .
3. Remove propeller shaft. Refer to PR-6, "
REAR PROPELLER SHAFT" .
4. Remove parking rear brake cables. Refer to PB-3, "
PARKING BRAKE CONTROL" .
5. Remove rear suspension assembly. Refer to RSU-5, "
REAR SUSPENSION ASSEMBLY" .
6. Remove fuel tank protector.
1. Grommet 2. Fuel filler cap 3. Fuel tank mounting band
4. Fuel tank protector 5. Insulator 6. Fuel tank
7. Vent tube 8. Vent hose 9. Fuel filler tube
10. Fuel filler hose 11. EVAP hose 12. Vent hose
PBIC3201E