egr INFINITI FX35 2004 Service Manual

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[VK45DE]
SERVICE DATA AND SPECIFICATIONS (SDS)
Revision: 2004 November 2004 FX35/FX45
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Standard and LimitABS006IX
GENERAL SPECIFICATIONS
DRIVE BELTS
INTAKE MANIFOLD AND EXHAUST MANIFOLD
Unit: mm (in) Cylinder arrangementV-8
Displacement cm
3 (cu in)4,494 (274.22)
Bore and stroke mm (in)93 x 82.7 (3.66 x 3.256)
Valve arrangementDOHC
Firing order1-8-7-3-6-5-4-2
Number of piston ringsCompression 2
Oil 1
Number of main bearings5
Compression ratio10.5
Compression pressure
kPa (kg/cm
2 , psi)/300 rpmStandard 1,320 (13.5, 191)
Minimum 1,130 (11.5, 164)
Differential limit
between cylinders98 (1.0, 14)
Cylinder number
Va l v e t i m i n g
Unit: degree
abcde f
228240060048
SEM957C
PBIC0187E
Tension of drive belts Auto adjustment by auto tensioner
Items Limit
Surface distortionIntake manifold (upper) 0.1 (0.004)
Intake manifold (lower) 0.1 (0.004)
Exhaust manifold 0.3 (0.012)

FFD-28
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
CAUTION:
Do not install the drive pinion adjusting washer and drive pinion bearing adjusting washer at this
time.
c. Install the companion flange without installing oil seal.
d. Apply oil drive pinion lock nut threads and seating surface, then temporarily install it.
e. Tighten the drive pinion lock nut until it reach standard preload.
CAUTION:
Tighten the drive pinion nut by very small degrees until the
specified preload in achieved. Do not tighten nut more than
necessary.
DIFFERENTIAL CASE INSTALLATION
1. Drive side bearing outer race into the carrier case with tool.
CAUTION:
Do not apply excessive force to the race.
2. Drive side bearing outer race into the side retainer with tool.
3. Apply oil to the bearing portion.
4. Install the deferential case assembly to the carrier case.
CAUTION:
Be careful not to damage the carrier cover mating surface.
5. Install the side bearing adjusting shim to the side retainer, tighten the bolt to specified torque.
CAUTION:
Install removed adjusting shim or same thickness shim.
NOTE:
Do not install O-ring.Tool number : KV40104000(−)
Pinion bearing preload without oil seal
: 0.78 - 1.57 N·m (0.08 - 0.16 kg-m, 7 - 13 in-lb)
SDIA1669E
Tool number : KV31103000 ( – )
SDIA1680E
Tool number : KV31103000 ( – )
SDIA1679E

FFD-34
FRONT FINAL DRIVE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
CAUTION:

Tighten the drive pinion nut by very small degrees until the specified preload in achieved. Do
not tighten nut more than necessary.

First select the thicker washer, then gradually select thinner one.

Do not apply preload more than necessary.
Reassembly of drive pinion assembly
1. The standard preload is obtain when the drive pinion nut is tightened to specified toque, remove the pin-
ion.
2. Remove the companion flange using puller.
3. Drive out the drive pinion from carrier case using copper hammer.
4. Apply gear oil to bearing portion.
5. Install the drive pinion with selected drive pinion adjusting washer and drive pinion bearing adjusting
washer into the carrier case, then install bearing.
6. Apply multi-purpose grease to oil seal lips.
7. Drive oil seal into the final drive using drift.
8. Install companion flange.
9. Apply oil to new drive pinion lock nut threads and seating sur-
face, then install it onto the drive pinion.
CAUTION:
Do not reuse drive pinion lock nut. Always replace nut with
new one.
10. Turn the companion flange more than 20 times to seat bearing.
11. Tighten the drive pinion lock nut to specified torque.
CAUTION:
Do not overtighten the nut.
12. Measure the preload using preload gauge.Drive pinion lock nut torque : 186.2 N·m (19 kg-m, 137 ft-lb)
Pinion bearing preload without oil seal : 0.78 - 1.57 N·m (0.08 - 0.16 kg-m, 7 - 13 in-lb)
When the washer thickness is increased : Preload will decrease.
When the washer thickness is decreased : Preload will increase.
Tool number A: ST33400001 (J26082)
B: KV38102510 ( – )
SDIA1681E
Tool number : KV40104000 (−)
SDIA1669E
Tool number : ST3127S000 (see J25765-A)
Pinion bearing preload without oil seal
: 0.78 - 1.57 N·m (0.08 - 0.16 kg-m, 7 - 13 in-lb)
SDIA1649E

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
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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

FRONT SUSPENSION ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45
5. Place the dent of alignment gauge onto the projection of center
plate and tightly contact them to measure.
CAUTION:

If camber, caster, or kingpin inclination angle is outside
the standard, check front suspension parts for wear and
damage, and replace suspect parts if necessary.

King pin inclination angle is reference value, no inspec-
tion is required.
Toe-In Inspection
Measure toe-in using the following procedure.
WARNING:

Always perform the following procedure on a flat surface.

Make sure that no person is in front of vehicle before push-
ing it.
1. Bounce front of vehicle up and down to stabilize the posture.
2. Push vehicle straight ahead about 5 m (16 ft).
3. Put a mark on base line of the tread (rear side) of both tires at
the same height of hub center. These are measuring points.
4. Measure distance “A” (rear side).
5. Push vehicle slowly ahead to rotate wheels 180 degrees (1/2
turn).
If wheels have rotated more than 180 degrees (1/2 turn), try the
above procedure again from the beginning. Never push vehicle
backward.
6. Measure distance “B” (front side).Camber, caster, kingpin inclination angles:
Refer to FSU-18, "
SERVICE DATA"FSU-18, "SER-
VICE DATA" .
SEIA0241E
SEIA0362E
Total toe-in : Refer to FSU-18, "SERVICE DATA" .
SEIA0363E

FSU-18
SERVICE DATA
Revision: 2004 November 2004 FX35/FX45
SERVICE DATAPFP:00030
Wheel Alignment (Unladen)AES000NC
Ball JointAES000ND
Wheelarch Height (Unladen*)AES000OM
*: Fuel, engine coolant and engine oil full. Spare tire, jack, hand tools and mats are in designated positions.Camber
Degree minute (Decimal degree)Minimum− 1°29′ (− 1.48°)
Nominal− 0°44′ (− 0.73°)
Maximum 0°01′ (0.02°)
Left and right difference 45′ (0.75°) or less
Caster
Degree minute (Decimal degree)Minimum 3°02′ (3.03°)
Nominal 3°47′ (3.78°)
Maximum 4°32′ (4.53°)
Left and right difference 45′ (0.75°) or less
Kingpin inclination
Degree minute (Decimal degree)Minimum 12° 20′ (12.33°)
Nominal 13° 05′ (13.08°)
Maximum 13°50′ (13.83°)
Total toe-in Distance (A – B)Minimum 0.6 mm (0.024 in)
Nominal 1.6 mm (0.063 in)
Maximum 2.6 mm (0.102 in)
Axial end play 0.1 mm (0.004 in)
Swing torque 0.5 − 4.9 N·m (0.06 − 0.49 kg-m, 5 − 43 in-lb)
Measurement on spring balance 0.5 − 4.9 N·m (0.06 − 0.49 kg-m, 5 − 43 in-lb)
Destination USA Canada
Engine VQ35DE VK45DE VQ35DE VK45DE
Axle 2WD AWD AWD
Tire size 265/60R18 265/50R20 265/60R18 265/50R20 265/60R18 265/50R20
Front (Hf)835 mm
(32.87 in)834 mm
(32.83 in)834 mm
(32.83 in)833 mm
(32.80 in)832 mm
(32.76 in)834 mm
(32.83 in)833 mm
(32.80 in)832 mm
(32.76 in)
Rear (Hr)822 mm
(32.36 in)821 mm
(32.32 in)829 mm
(32.64 in)827 mm
(32.56 in)825 mm
(32.48 in)827 mm
(32.56 in)826 mm
(32.52 in)823 mm
(32.40 in)
SFA818A

PRECAUTIONS
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Revision: 2004 November 2004 FX35/FX45
PRECAUTIONSPFP:00001
DescriptionAAS000EV
Observe the following precautions to ensure safe and proper servicing. These precautions are not
described in each individual section.
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
AAS000EW
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 for NVIS/IVIS (NISSAN/INFINITI VEHICLE IMMOBILIZER SYSTEM -
NATS) (If Equipped)
AAS000EX
NVIS/IVIS (NATS) will immobilize the engine if someone tries to start it without the registered key of NVIS/IVIS
(NATS).
Both of the originally supplied ignition key IDs have been NVIS/IVIS (NATS) registered.
The security indicator is located on the instrument panel. The indicator blinks when the immobilizer system is
functioning.
Therefore, NVIS/IVIS (NATS) warns outsiders that the vehicle is equipped with the anti-theft system.

When NVIS/IVIS (NATS) detects trouble, the security indicator lamp lights up while ignition switch is in
"ON" position.
This lighting up indicates that the anti-theft is not functioning, so prompt service is required.

When servicing NVIS/IVIS (NATS) (trouble diagnoses, system initialization and additional registration of
other NVIS/IVIS (NATS) ignition key IDs), CONSULT-II hardware and CONSULT-II NVIS/IVIS (NATS)
software is necessary.
Regarding the procedures of NVIS/IVIS (NATS) initialization and NVIS/IVIS (NATS) ignition key ID regis-
tration, refer to CONSULT-II operation manual, NVIS/IVIS (NATS).
Therefore, CONSULT-II NVIS/IVIS (NATS) software (program card and operation manual) must be kept
strictly confidential to maintain the integrity of the anti-theft function.

When servicing NVIS/IVIS (NATS) (trouble diagnoses, system initialization and additional registration of
other NVIS/IVIS (NATS) ignition key IDs), it may be necessary to re-register original key identification.
Therefore, be sure to receive all keys from vehicle owner. A maximum of four or five key IDs can be regis-
tered into NVIS/IVIS (NATS).

When failing to start the engine first time using the key of NVIS/IVIS (NATS), start as follows.
1. Leave the ignition key in "ON" position for approximately 5 seconds.
2. Turn ignition key to "OFF" or "LOCK" position and wait approximately 5 seconds.
3. Repeat step 1 and 2 again.
4. Restart the engine while keeping the key separate from any others on key-chain.

GI-8
PRECAUTIONS
Revision: 2004 November 2004 FX35/FX45
HOSE CLAMPING

If old rubber hose is re-used, install hose clamp in its original
position (at the indentation where the old clamp was). If there is
a trace of tube bulging left on the old rubber hose, align rubber
hose at that position.

Discard old clamps; replace with new ones.

After installing plate clamps, apply force to them in the direction
of the arrow, tightening rubber hose equally all around.
Precautions for Engine OilsAAS000F3
Prolonged and repeated contact with used engine oil may cause skin cancer. Try to avoid direct skin contact
with used oil.
If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible.
HEALTH PROTECTION PRECAUTIONS

Avoid prolonged and repeated contact with oils, particularly used engine oils.

Wear protective clothing, including impervious gloves where practicable.

Do not put oily rags in pockets.

Avoid contaminating clothes, particularly underpants, with oil.

Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regu-
larly.

First aid treatment should be obtained immediately for open cuts and wounds.

Use barrier creams, applying them before each work period, to help the removal of oil from the skin.

Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Prepa-
rations containing lanolin replace the natural skin oils which have been removed.

Do not use gasoline, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin.

If skin disorders develop, obtain medical advice without delay.

Where practical, degrease components prior to handling.

Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face
shields; in addition an eye wash facility should be provided.
ENVIRONMENTAL PROTECTION PRECAUTIONS
Dispose of used oil and used oil filters through authorized waste disposal contractors to licensed waste dis-
posal sites, or to the waste oil reclamation trade. If in doubt, contact the local authority for advice on disposal
facilities.
It is illegal to pour used oil on to the ground, down sewers or drains, or into water sources.
The regulations concerning pollution vary between regions.
Precautions for Air Conditioning AAS000F4
Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to
ATC/MTC section “HFC-134a (R-134a) Service Procedure”, “REFRIGERANT LINES” for specific instructions.
SMA021D
SMA022D

GI-28
SERVICE INFORMATION FOR ELECTRICAL INCIDENT
Revision: 2004 November 2004 FX35/FX45

Freezing

Water intrusion

Electrical load

Cold or hot start up
Get a thorough description of the incident from the customer. It is important for simulating the conditions of the
problem.
Vehicle Vibration
The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle with
A/C on). In such a case, you will want to check for a vibration related condition. Refer to the following illustra-
tion.
CONNECTORS & HARNESS
Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gently
shake each connector and harness while monitoring the system for the incident you are trying to duplicate.
This test may indicate a loose or poor electrical connection.
HINT
Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector termi-
nals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs inter-
mittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the
terminals on related connectors in the system.
SENSORS & RELAYS
Gently apply a slight vibration to sensors and relays in the system you are inspecting.
This test may indicate a loose or poorly mounted sensor or relay.
ENGINE COMPARTMENT
There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the
things to check for are:

Connectors not fully seated.

Wiring harness not long enough and is being stressed due to engine vibrations or rocking.

Wires laying across brackets or moving components.

Loose, dirty or corroded ground wires.

Wires routed too close to hot components.
To inspect components under the hood, start by verifying the integrity of ground connections. (Refer to Ground
Inspection described later.) First check that the system is properly grounded. Then check for loose connection
by gently shaking the wiring or components as previously explained. Using the wiring diagrams inspect the
wiring for continuity.
BEHIND THE INSTRUMENT PANEL
An improperly routed or improperly clamped harness can become pinched during accessory installation. Vehi-
cle vibration can aggravate a harness which is routed along a bracket or near a screw.
SGI839

GI-52
TERMINOLOGY
Revision: 2004 November 2004 FX35/FX45
TERMINOLOGYPFP:00011
SAE J1930 Terminology List AAS000EO
All emission related terms used in this publication in accordance with SAE J1930 are listed. Accordingly, new
terms, new acronyms/abbreviations and old terms are listed in the following chart.
NEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM
Air cleaner ACL Air cleaner
Barometric pressure BARO ***
Barometric pressure sensor-BCDD BAROS-BCDD BCDD
Camshaft position CMP ***
Camshaft position sensor CMPS Crank angle sensor
Canister *** Canister
Carburetor CARB Carburetor
Charge air cooler CAC Intercooler
Closed loop CL Closed loop
Closed throttle position switch CTP switch Idle switch
Clutch pedal position switch CPP switch Clutch switch
Continuous fuel injection system CFI system ***
Continuous trap oxidizer system CTOX system ***
Crankshaft position CKP ***
Crankshaft position sensor CKPS ***
Data link connector DLC ***
Data link connector for CONSULT-II DLC for CONSULT-II Diagnostic connector for CONSULT-II
Diagnostic test mode DTM Diagnostic mode
Diagnostic test mode selector DTM selector Diagnostic mode selector
Diagnostic test mode I DTM I Mode I
Diagnostic test mode II DTM II Mode II
Diagnostic trouble code DTC Malfunction code
Direct fuel injection system DFI system ***
Distributor ignition system DI system Ignition timing control
Early fuel evaporation-mixture heater EFE-mixture heater Mixture heater
Early fuel evaporation system EFE system Mixture heater control
Electrically erasable programmable read
only memoryEEPROM ***
Electronic ignition system EI system Ignition timing control
Engine control EC ***
Engine control module ECM ECCS control unit
Engine coolant temperature ECT Engine temperature
Engine coolant temperature sensor ECTS Engine temperature sensor
Engine modification EM ***
Engine speed RPM Engine speed
Erasable programmable read only memory EPROM ***
Evaporative emission canister EVAP canister Canister
Evaporative emission system EVAP system Canister control solenoid valve
Exhaust gas recirculation valve EGR valve EGR valve