lan s INFINITI FX35 2004 Service Manual

CYLINDER BLOCK
EM-139
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Revision: 2004 November 2004 FX35/FX45
Piston Pin Outer Diameter
Measure outer diameter of piston pin.
Connecting Rod Bushing Oil Clearance (Small End)
(Connecting rod bushing oil clearance) = (Piston pin bushing inner diameter) – (Piston pin outer diameter)

If the measured value exceeds the standard, replace connecting rod assembly and/or piston and piston
pin assembly.

If replacing piston and piston pin assembly, refer to EM-140, "PISTON TO CYLINDER BORE CLEAR-
ANCE" .

If replacing connecting rod assembly, refer to EM-142, "CON-
NECTING ROD BEARING OIL CLEARANCE" .
Factory installed parts grading:
Service parts apply only to grade “0”.
Unit: mm (in)
*: After installing in connecting rod
CYLINDER BLOCK DISTORTION

Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon,
or other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.Standard : 21.989 - 22.001 mm (0.8657 - 0.8662 in)
PBIC0117E
Standard : 0.005 - 0.017 mm (0.0002 - 0.0007 in)
Limit : 0.030 mm (0.0012 in)
PBIC0809E
Grade 0 1
Piston pin bushing inner
diameter* 22.000 - 22.006
(0.8661 - 0.8664) 22.006 - 22.012
(0.8664 - 0.8666)
Piston pin hole diameter 21.993 - 21.999
(0.8659 - 0.8661) 21.999 - 22. 005
(0.8661 - 0.8663)
Piston pin outer diameter 21.989 - 21.995
(0.8657- 0.8659) 21.995 - 22.001
(0.8659 - 0.8662)
PBIC0812E

PRECAUTIONS
EM-159
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Revision: 2004 November 2004 FX35/FX45
[VK45DE]PRECAUTIONSPFP:00001
Precautions Necessary for Steering Wheel Rotation After Battery DisconnectABS00DAO
NOTE:

This Procedure is applied only to models with Intelligent Key system and NVIS/IVIS (NISSAN/INFINITI
VEHICLE IMMOBILIZER SYSTEM - NATS).

Remove and install all control units after disconnecting both battery cables with the ignition knob in the
″LOCK″ position.

Always use CONSULT-II to perform self-diagnosis as a part of each function inspection after finishing
work. If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NVIS/IVIS, an electrically controlled steering lock
mechanism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the
steering lock will be released.
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT-II.
Precautions for Drain Engine CoolantABS006HV
Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingABS006HW

Before starting work, make sure no fire or spark producing items are in the work area.

Release fuel pressure before disconnecting and disassembly.

After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and DisassemblyABS006HX

When instructed to use special service tools, use specified tools. Always be careful to work safely, avoid
forceful or uninstructed operations.

Exercise maximum care to avoid damage to mating or sliding surfaces.

Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.

Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly.

When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be
used where noted in the step.
Precautions for Inspection, Repair and ReplacementABS006HY
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and InstallationABS006HZ

Use torque wrench to tighten bolts or nuts to specification.

EM-160
[VK45DE]
PRECAUTIONS
Revision: 2004 November 2004 FX35/FX45

When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.

Replace with new gasket, packing, oil seal or O-ring.

Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.

Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.

Release air within route when refilling after draining engine coolant.

After repairing, start engine and increase engine speed to check engine coolant, fuel, oil, and exhaust
systems for leakage.
Parts Requiring Angle TighteningABS006I0

Use angle wrench [SST: KV10112100 (BT8653-A)] for the final tightening of the following engine parts:
–Cylinder head bolts
–Main bearing cap bolts
–Connecting rod cap nuts
–Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle
tightening)

Do not use a torque value for final tightening.

The torque value for these parts are for a preliminary step.

Ensure thread and seat surfaces are clean and coated with engine oil.
Precautions for Liquid GasketABS006I1
REMOVAL OF LIQUID GASKET SEALING

After removing mounting bolts and nuts, separate the mating
surface using seal cutter (SST) and remove old liquid gasket
sealing.
CAUTION:
Be careful not to damage the mating surfaces.

In areas where seal cutter (SST) is difficult to use, use plastic
hammer to lightly tap the areas where liquid gasket is applied.
CAUTION:
If for some unavoidable reason tool such as a flat-blade
screwdriver is used, be careful not to damage the mating
surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using scraper, remove old liquid gasket adhering to the liquid
gasket application surface and the mating surface.

Remove liquid gasket completely from the groove of the liquid
gasket application surface, mounting bolts, and bolt holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
PBIC0002E
PBIC0003E

PRECAUTIONS
EM-161
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Revision: 2004 November 2004 FX35/FX45
3. Attach liquid gasket tube to tube presser [SST: WS39930000
(—)].
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-48, "
RECOMMENDED CHEMICAL PRODUCTS AND
SEALANTS" .
4. Apply liquid gasket without breaks to the specified location with the specified dimensions.

If there is a groove for the liquid gasket application, apply liquid gasket to the groove.

As for the bolt holes, normally apply liquid gasket inside the
holes. Occasionally, it should be applied outside the holes.
Make sure to read the text of this manual.

Within five minutes of liquid gasket application, install the mat-
ing component.

If liquid gasket protrudes, wipe it off immediately.

Do not retighten after the installation.

Wait 30 minutes or more after installation before refilling
engine with engine oil and engine coolant.
CAUTION:
If there are specific instructions in this manual, observe
them.
EMA0622D
SEM159F

EM-170
[VK45DE]
DRIVE BELTS
Revision: 2004 November 2004 FX35/FX45
5. Remove alternator, water pump and A/C compressor belt.
Power Steering Oil Pump Belt
1. Remove air duct (inlet). Refer to EM-172, "AIR CLEANER AND AIR DUCT" .
2. Front engine undercover with power tool
3. Remove alternator, water pump and A/C compressor belt. Refer to EM-169, "
Alternator, Water Pump and
A/C Compressor Belt" .
4. While securely holding the hexagonal protrusion part of auto
tensioner pulley with box wrench, move wrench handle in the
direction of arrow (loosening direction of tensioner).
CAUTION:
Avoid placing hand in a location where pinching may occur
if holding tool accidentally comes off.
5. Under the above condition, insert a metal bar of approximately 6
mm (0.24 in) in diameter (hexagonal bar wrench shown as
example in the figure) through the holding boss to lock auto ten-
sioner pulley arm.

Leave auto tensioner pulley arm locked until belt is installed
again.
6. Remove power steering oil pump belt.
INSTALLATION
Note to the following, and install in the reverse order of removal.
CAUTION:

Make sure belt is securely installed around all pulleys.

Make sure belt is correctly engaged with the pulley groove.

Check for engine oil and engine coolant are not adhered belt and pulley groove.

Check that belt tension is within the allowable working range, using indicator notch on auto ten-
sioner. Refer to EM-169, "
Checking Drive Belts" .
PBIC1543E

EM-174
[VK45DE]
INTAKE MANIFOLD
Revision: 2004 November 2004 FX35/FX45
INTAKE MANIFOLDPFP:14003
Removal and InstallationABS006IC
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain the engine coolant when the engine is hot.
1. PCV tube 2. Engine cover rear bracket 3.EVAP canister purge control sole-
noid valve
4. EVAP hose 5. EVAP tube 6. EVAP hose
7. Vacuum gallery 8. Engine cover front bracket 9. Vacuum tank
10. VIAS control solenoid valve 11. Water gallery 12. Gasket
13. Intake manifold (lower) 14. Gasket 15. Water hose
16. Intake manifold adapter 17. Electric throttle control actuator 18. Gasket
19. Intake manifold (upper) 20. Resonator 21. EVAP service port
PBIC3502E

INTAKE MANIFOLD
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Revision: 2004 November 2004 FX35/FX45
1. Remove engine cover with power tool. Refer to EM-168, "ENGINE ROOM COVER" .
2. Release fuel pressure. Refer to EC-700, "
FUEL PRESSURE RELEASE" .
3. Drain engine coolant. Refer to CO-36, "
Changing Engine Coolant" .
4. 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" .
5. Disconnect fuel feed hose quick connector on engine side.
Refer to EM-188, "
FUEL INJECTOR AND FUEL TUBE" .
6. Remove fuel damper and fuel hose assembly. Refer to EM-188, "
FUEL INJECTOR AND FUEL TUBE" .
CAUTION:

While hoses are disconnected, plug them to prevent fuel from draining.

Do not separate fuel damper and fuel hose.
7. Remove or disconnect harnesses, brackets, vacuum hose, vacuum gallery and PCV hose and tube from
intake manifold (upper).
8. Remove electric throttle control actuator as follows:
a. Disconnect harness connector.
b. Loosen mounting bolts diagonally.
CAUTION:

Handle carefully to avoid any shock to electric throttle control actuator.

Do not disassemble.
9. Disconnect water hoses from water gallery.
10. Remove intake manifold adaptor and water gallery.
11. Loosen bolts in reverse order as shown in the figure to remove
intake manifold (upper) with power tool.
12. Remove vacuum tank form intake manifold (lower).
13. Remove fuel injector and fuel tube assembly. Refer to EM-188, "
FUEL INJECTOR AND FUEL TUBE" .
14. Loosen bolts in reverse order as shown in the figure to remove
intake manifold (lower) with power tool.
SBIA0353E
PBIC0014E
PBIC0015E

EM-178
[VK45DE]
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

EM-180
[VK45DE]
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
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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