INFINITI FX35 2004 Service Manual

EM-176
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INTAKE MANIFOLD
Revision: 2004 November 2004 FX35/FX45
15. Remove intake manifold gaskets.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
INSPECTION AFTER REMOVAL
Surface Distortion

Check the surface distortion of both the intake manifold (upper
and lower) mating surfaces with straightedge and feeler gauge.

If it exceeds the limit, replace intake manifolds (lower and/or
upper).
INSTALLATION
Note to the following, and install in the reverse order of removal:
Intake Manifold (Lower)
Tighten in numerical order as shown in the figure.

There are two types of mounting bolts. Refer to the following for
locating bolts.
Intake Manifold (Upper)
Tighten in numerical order as shown in the figure.

There are two types of mounting bolts. Refer to the following for
locating bolts
Electric Throttle Control Actuator

Install intake manifold adapter gasket and electric throttle control actuator gasket so that three protrusions
for installation identification do not face downward.

Tighten mounting bolts of electric throttle control actuator equally and diagonally in several steps.

After installation perform procedure in EM-177, "INSPECTION AFTER INSTALLATION" .
Water Hose
Insert hose by 27 to 32 mm (1.06 to 1.26 in) from connector end.
Vacuum Hose
Refer to EC-677, "Vacuum Hose Drawing" . Limit : 0.1 mm (0.004 in)
PBIC0016E
M8 × 90 mm (3.54 in) : 7, 8
M8 × 35 mm (1.38 in) Except the above
PBIC0015E
M8 × 80 mm (3.15 in) : 4, 5, 6, 7
M8 × 25 mm (0.98 in) : Except the above
PBIC0014E

INTAKE MANIFOLD
EM-177
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Revision: 2004 November 2004 FX35/FX45
INSPECTION AFTER INSTALLATION

Perform the “Throttle Valve Closed Position Learning” when harness connector of electric throttle control
actuator is disconnected. Refer to EC-698, "
Throttle Valve Closed Position Learning" .

Perform the “Idle Air Volume Learning” and “Throttle Valve Closed Position Learning” when electric throt-
tle control actuator is replaced. Refer to EC-698, "
Idle Air Volume Learning" .

EM-178
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EXHAUST MANIFOLD AND THREE WAY CATALYST
Revision: 2004 November 2004 FX35/FX45
EXHAUST MANIFOLD AND THREE WAY CATALYSTPFP:14004
Removal and InstallationABS006ID
REMOVAL
WARNING:
Perform the work, when the exhaust and cooling system have completely cooled down.
1. Remove engine cover with power tool. Refer to EM-168, "
ENGINE ROOM COVER" .
2. Remove front and rear engine undercovers with power tool.
3. Remove air duct (inlet), air cleaner case and mass air flow sensor assembly, air duct and resonator
assembly. Refer to EM-172, "
AIR CLEANER AND AIR DUCT" .
4. Remove front cross bar. Refer to FSU-6, "
FRONT SUSPENSION ASSEMBLY" .
5. Drain engine coolant from radiator. Refer to CO-36, "
Changing Engine Coolant" .
CAUTION:

Perform this step when engine is cold.

Do not spill engine coolant on drive belts.
6. Remove radiator. Refer to CO-39, "
RADIATOR" .
7. Remove drive belts. Refer to EM-169, "
DRIVE BELTS" .
8. Remove heated oxygen sensors as follows:
a. Disconnect harness connector of each heated oxygen sensors.
1. Heated oxygen sensor 1 (bank 2) 2. Exhaust manifold cover (right bank) 3. Exhaust manifold (right bank)
4. Gasket 5. Exhaust manifold (left bank) 6. Exhaust manifold cover (left bank)
7. Heated oxygen sensor 1 (bank 1) 8. Three way catalyst cover (right bank) 9. Three way catalyst (right bank)
10. Heated oxygen sensor 2 (bank 2) 11. Gasket 12. Three way catalyst cover (left bank)
13. Heated oxygen sensor 2 (bank 1) 14. Three way catalyst (left bank) 15. Mounting bracket
16. Mounting bracket
PBIC3503E

EXHAUST MANIFOLD AND THREE WAY CATALYST
EM-179
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Revision: 2004 November 2004 FX35/FX45
b. Remove heated oxygen sensor 1 and 2 on both bank with
heated oxygen sensor wrench (SST).

Put marks to identify installation positions of each heated oxy-
gen sensor.
CAUTION:

Be careful not to damage heated oxygen sensor.

Discard any heated oxygen sensor which has been
dropped from a height of more than 0.5 m (19.7 in) onto a
hard surface such as a concrete floor; replace with a new
one.
9. Remove exhaust mounting bracket between three way catalysts (right and left bank) and transmission.
Refer to EX-3, "
EXHAUST SYSTEM" .
10. Disconnect A/C piping from A/C compressor, then remove A/C compressor with power tool. Refer to AT C -
139, "Components" .
11. Remove alternator and bracket. Refer to SC-23, "
CHARGING SYSTEM" .
12. Remove exhaust front tube with power tool. Refer to EX-3, "
EXHAUST SYSTEM" .
13. Remove steering lower joint at power steering gear assembly side, and release steering lower shaft.
Refer to PS-19, "
POWER STEERING GEAR AND LINKAGE" .
14. Remove three way catalysts (right and left bank).
15. Remove exhaust manifold covers. (right and left bank)
16. Loosen mounting nuts in reverse order as shown in the figure to
remove exhaust manifold.
NOTE:
Disregard the numerical order No. 9 to 12 in removal.
17. Remove exhaust manifold gaskets.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
PBIC2333E
PBIC2334E
PBIC1549E

EM-180
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EXHAUST MANIFOLD AND THREE WAY CATALYST
Revision: 2004 November 2004 FX35/FX45
INSPECTION AFTER REMOVAL
Surface Distortion

Check the surface distortion of the each exhaust manifold flange
mating surface with straightedge and feeler gauge.

If it exceeds the limit, replace exhaust manifold.
INSTALLATION
Note the following, and install in the reverse order of removal.
Exhaust Manifold Gasket
Install exhaust manifold gasket with its directional protrusion set upward.
Refer to the figure of components on former page. Refer to EM-178, "
Removal and Installation" .
Exhaust Manifold

Install exhaust manifold in numerical order as shown in the fig-
ure.
NOTE:
Tighten mounting nuts No. 1 to 4 in two steps. The numerical
order No. 9 to 12 shown second steps.
Heated Oxygen Sensor

Install heated oxygen sensors in the original position.

Install referring the following if the installation positions cannot
be identified.
*: The length of glass tube of bank 2 is longer than the one
of bank 1.
CAUTION:

Before installing a new heated oxygen sensor, clean
exhaust system threads using oxygen sensor thread
cleaner (commercial service tool: J-43897-18 or J-43897-12), and apply anti-seize lubricant (com-
mercial service tool).

Do not over torque heated oxygen sensor. Doing so may cause damage to the heated oxygen sen-
sor, resulting in “MIL” coming on.Limit : 0.3 mm (0.012 in)
PBIC1550E
PBIC1549E
Glass tube color
Heated oxygen sensor 1* : Black
Heated oxygen sensor 2 : White
PBIC2652E

OIL PAN AND OIL STRAINER
EM-181
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Revision: 2004 November 2004 FX35/FX45
OIL PAN AND OIL STRAINERP F P : 1111 0
Removal and InstallationABS006IE
REMOVAL
WARNING:
To avoid the danger of being scalded, do not drain engine oil when engine is hot.
1. Remove front tire.
2. Remove hood assembly. Refer to BL-14, "
HOOD" .
3. Remove engine cover with power tool. Refer to EM-168, "
ENGINE ROOM COVER" .
4. Remove front and rear engine undercovers with power tool.
5. Drain engine oil. Refer to LU-26, "
Changing Engine Oil" .
6. Drain engine coolant. Refer to CO-36, "
Changing Engine Coolant" .
CAUTION:

Perform this step when engine is cold.

Do not spill engine coolant on drive belts.
7. Remove drive belts. Refer to EM-169, "
DRIVE BELTS" .
1. Oil pan 2. O-ring 3. Crankshaft position sensor (POS)
4. O-ring 5. Oil pressure switch 6. Gasket
7. Oil strainer 8. Drain plug 9. Drain plug washer
10. O-ring 11. Oil cooler 12. Connector bolt
13. Oil filter 14. O-ring 15. Axle pipe
16. O-ring 17. Rear plate cover 18. Relief valve
PBIC1552E

EM-182
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OIL PAN AND OIL STRAINER
Revision: 2004 November 2004 FX35/FX45
8. Remove auto tensioner of power steering oil pump belt. Refer to EM-171, "Drive Belt Auto Tensioner and
Idler Pulley" .
9. Remove power steering oil pump with piping connected, and temporarily secure it aside with ropes or
equivalent. Refer to PS-31, "
POWER STEERING OIL PUMP" .
10. Remove A/C compressor with piping connected, and temporarily secure it aside with ropes or equivalent.
Refer to ATC-139, "
Components" .
11. Remove A/C compressor fitting bolts, and install A/C compressor temporarily on vehicle side with ropes or
equivalent.
12. Remove harness of lower side of oil pan.
13. Remove crankshaft position sensor (POS) from transmission.
CAUTION:

Handle carefully to avoid dropping and shocks.

Do not disassemble it.

Do not allow metal powder to adhere to magnetic part at sensor tip.

Do not place sensors in a location where they are exposed to magnetism.
14. Install engine slinger and hang engine assembly to secure position. Refer to EM-236, "
ENGINE ASSEM-
BLY" .
15. Remove front suspension member with power tool. Refer to FSU-17, "
FRONT SUSPENSION MEMBER" .
16. Remove front final drive assembly. Refer to FFD-10, "
FRONT FINAL DRIVE ASSEMBLY" .
17. Remove oil filter. Refer to LU-28, "
OIL FILTER" .
18. Disconnect oil cooler water hoses, and remove oil cooler water pipe and oil cooler. Refer to LU-29, "
OIL
COOLER" .
19. Remove oil pan as the follows:
a. Remove rear plate cover.
b. Remove transmission joint bolts which pierce oil pan. Refer to AT- 2 6 9 , "
Removal and Installation (AWD
models)" .
c. Loosen oil pan bolts with power tool in reverse order as shown
in the figure.
NOTE:
Disregard the numerical order No. 11 and No. 17 in removal.
d. Insert seal cutter (SST) between oil pan and cylinder block.
Slide seal cutter by tapping on the side of seal cutter with ham-
mer. Remove oil pan.
CAUTION:

Be careful not to damage the mating surface.

Do not insert flat-blade screwdriver, this will damage the
mating surface.
e. Remove O-rings from bottom of oil pump and front cover.
20. As necessary, pull axle pipe from oil pan.

Hold pipes and pull them out to front drive shaft (left) installing side.
21. Remove oil strainer.
PBIC0194E
SEM365E

OIL PAN AND OIL STRAINER
EM-183
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Revision: 2004 November 2004 FX35/FX45
INSPECTION AFTER REMOVAL
Clean oil strainer if any object attached.
INSTALLATION
1. Install oil strainer.
2. Install axle pipe to oil pan, if removed.

Lubricate O-ring groove of axle pipe, O-ring, and O-ring joint
of oil pan with new engine oil.

Right/left O-ring diameters differ from each other. O-ring with
identification paint mark is installed on front drive shaft (left)
installing side.

Install axle pipe to oil pan from (left) side.
CAUTION:
Insert it with care to prevent O-ring from sliding.
3. Install oil pan as follows:
a. Install new O-rings to oil pump and front cover side.
b. Apply a continuous bead of liquid gasket with tube presser [SST:
WS39930000 ( — )] to the cylinder block mating surface of
oil pan to a limited portion as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-48, "
RECOMMENDED CHEMICAL PRODUCTS AND SEAL-
ANTS".
CAUTION:
Attaching should be done within 5 minutes after coating.
c. Install oil pan.

Tighten bolts in numerical order as shown in the figure.
NOTE:
Tighten bolts No. 1 and No. 2 in two steps. The numerical
order No. 11 and No. 17 shown second steps.

There are three types of mounting bolts. Refer to the following
for locating bolts.
d. Tighten transmission joint bolts. Refer to AT- 2 6 9 , "
Removal and
Installation (AWD models)" .
e. Install rear plate cover.
4. Install oil pan drain plug with new drain plug washer.

Refer to the figure of components of former page for installation direction of drain plug washer. Refer to
EM-181, "
Removal and Installation" .
5. Install in the reverse order of removal after this step.
NOTE:
At least 30 minutes after oil pan is installed, pour engine oil.
INSPECTION AFTER INSTALLATION
1. Check engine oil level and add engine oil. Refer to LU-25, "ENGINE OIL" .
2. Start engine, and check there is no leak of engine oil.
3. Stop engine and wait for 15 minutes.
PBIC2336E
PBIC0195E
M6 × 30 mm (1.18 in) : 18, 19
M8 × 100 mm (3.94 in) : 5, 9
M8 × 45 mm (1.77 in) : Except the above
PBIC0194E

EM-184
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OIL PAN AND OIL STRAINER
Revision: 2004 November 2004 FX35/FX45
4. Check engine oil level again. Refer to LU-25, "ENGINE OIL" .

IGNITION COIL
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Revision: 2004 November 2004 FX35/FX45
IGNITION COILPFP:22448
Removal and InstallationABS006IF
REMOVAL
1. Remove engine cover with power tool. Refer to EM-168, "ENGINE ROOM COVER" .
2. Remove air duct (inlet), air cleaner case and mass air flow sensor assembly, air duct and resonator
assembly. Refer to EM-172, "
AIR CLEANER AND AIR DUCT" .
3. Disconnect harness connector from ignition coil.
4. Remove ignition coil.
CAUTION:
Do not shock it.
INSTALLATION
Install in the reverse order of removal.
1. Ignition coil 2. Spark plug
PBIC1589E