gas INFINITI FX35 2004 Workshop Manual

OVERHEATING CAUSE ANALYSIS
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Revision: 2004 November 2004 FX35/FX45
OVERHEATING CAUSE ANALYSISPFP:00012
Troubleshooting ChartABS004UZ
Symptom Check items
Cooling sys-
tem parts
malfunctionPoor heat transferWater pump malfunction Worn or loose drive belt
— Thermostat stuck closed —
Damaged finsDust contamination or
paper clogging
Physical damage
Clogged radiator cooling
tubeExcess foreign material
(rust, dirt, sand, etc.)
Reduced air flowCooling fan does not oper-
ate
Fan assembly — High resistance to fan rota-
tion
Damaged fan blades
Damaged radiator shroud — — —
Improper engine coolant
mixture ratio—— —
Poor engine coolant quality — Engine coolant density —
Insufficient engine coolantEngine coolant leaksCooling hoseLoose clamp
Cracked hose
Water pump Poor sealing
Radiator capLoose
Poor sealing
RadiatorO-ring for damage, deterio-
ration or improper fitting
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Overflowing reservoir tankExhaust gas leaks into
cooling systemCylinder head deterioration
Cylinder head gasket dete-
rioration

WATER PUMP
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Revision: 2004 November 2004 FX35/FX45
c. Install timing chain tensioner (primary).
d. Remove stopper pin.
4. Install chain tensioner cover and water pump cover.
a. Before installing, remove all traces of liquid gasket from mating
surface of water pump cover and chain tensioner cover using a
scraper. Also remove traces of liquid gasket from the mating sur-
face of front timing chain case.
b. Apply a continuous bead of liquid gasket to mating surface of
chain tensioner cover and water pump cover with tube presser
[SST: WS39930000 ( – )].
Use Genuine RTV Silicone Sealant or equivalent. GI-48,
"RECOMMENDED CHEMICAL PRODUCTS AND SEAL-
ANTS".
5. Install water drain plug (front) of cylinder block.

Apply liquid gasket to the thread of water drain plug (front).
Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "
RECOMMENDED CHEMICAL
PRODUCTS AND SEALANTS".
6. Install in the reverse order of removal for remaining parts.

After starting engine, let idle for three minutes, then rev engine up to 3,000 rpm under no load to
purge air from the high-pressure chamber of chain tensioner. Engine may produce a rattling
noise. This indicates that air still remains in the chamber and is not a matter of concern.
INSPECTION AFTER INSTALLATION

Check for leaks of engine coolant using radiator cap tester adapter [SST: EG17650301 (J-33984-A)] and
radiator cap tester (commercial service tool). Refer to CO-11, "
CHECKING COOLING SYSTEM FOR
LEAKS" .

Start and warm up engine. Visually make sure that there is no leaks of engine coolant and A/T fluid.
SLC448B
SLC446B
PBIC1283E

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WATER INLET AND THERMOSTAT ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
WATER INLET AND THERMOSTAT ASSEMBLYPFP:21200
Removal and InstallationABS009RF
REMOVAL
1. Remove front engine undercover using power tool.
2. Drain engine coolant from radiator. Refer to CO-11, "
Changing Engine Coolant" .
CAUTION:

Perform this step when engine is cold.

Do not spill engine coolant on drive belts.
3. Remove air duct and air cleaner case. Refer to EM-17, "
AIR CLEANER AND AIR DUCT" .
4. Remove water drain plug (front) of cylinder block.
5. Disconnect radiator hose (upper) and oil cooler hose from water inlet and thermostat assembly.
6. Remove water inlet and thermostat assembly.

Do not disassemble water inlet and thermostat assembly.
Replace them as a unit, if necessary.
1. Water inlet and thermostat assembly 2. Gasket
SBIA0483E
PBIC0846E
SLC962AB

WATER INLET AND THERMOSTAT ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45
INSPECTION AFTER REMOVAL
1. Check valve seating condition at ordinary room temperatures. It should seat tightly.
2. Check valve operation.
INSTALLATION
Note to the following, and install in the reverse order of removal.

Be careful not to spill engine coolant over engine room. Use rag to absorb engine coolant.

Install water drain plug (front) of cylinder block.
–Apply liquid gasket to the thread of water drain plug (front).
Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "
RECOMMENDED CHEMICAL
PRODUCTS AND SEALANTS".
INSPECTION AFTER INSTALLATION

Check for leaks of engine coolant using radiator cap tester adapter [SST: EG17650301 (J-33984-A)] and
radiator cap tester (commercial service tool). Refer to CO-11, "
CHECKING COOLING SYSTEM FOR
LEAKS" .

Start and warm up engine. Visually make sure that there is no leaks of engine coolant.
Thermostat Standard
Valve opening temperature 76 - 79°C (169 - 174°F)
Maximum valve lift More than 8.6 mm / 90°C (0.339 in / 194°F)
Valve closing temperature More than 71 °C (160 °F)
SLC949A

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WATER OUTLET AND WATER PIPING
Revision: 2004 November 2004 FX35/FX45
WATER OUTLET AND WATER PIPINGPFP:11060
Removal and InstallationABS007ZU
REMOVAL
1. Remove front engine undercover with power tool.
2. Drain engine coolant from drain plug and water drain plugs on radiator and both sides of cylinder block.
Refer to CO-11, "
Changing Engine Coolant" .
CAUTION:
Perform when engine is cold.
3. Remove engine cover with power tool. Refer to EM-19, "
INTAKE MANIFOLD COLLECTOR" .
4. Remove air duct and air cleaner case assembly. Refer to EM-17, "
AIR CLEANER AND AIR DUCT" .
5. Disconnect radiator upper hose, heater hose and water hose.
6. Remove water outlet and water piping.
INSTALLATION
Note to the following, and install in the reverse order of removal.

Securely insert each hose, and install a clamp at a position where it does not interfere with the pipe bulge.

When inserting a water pipe into water outlet, apply neutral detergent to O-ring.
INSPECTION AFTER INSTALLATION

Check for leaks of engine coolant using radiator cap tester adapter [SST: EG17650301 (J-33984-A)] and
radiator cap tester (commercial service tool). Refer to CO-11, "
CHECKING COOLING SYSTEM FOR
LEAKS" .

Start and warm up engine. Visually make sure that there is no leaks of engine coolant and A/T fluid.
1. Harness bracket 2. Water hose 3. Water bypass hose
4. Engine coolant temperature sensor 5. Gasket 6. Water outlet
7. Heater hose 8. Water pipe 9. Radiator upper hose
10. Heater pipe 11. Washer 12. O-ring
SBIA0484E

PREPARATION
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Revision: 2004 November 2004 FX35/FX45
PREPARATIONPFP:00002
Special Service ToolsABS006JD
The actual shapes of Kent-Moore tools may from those of special service tools illustrated here.
Commercial Service ToolsABS006JE
Tool number
(Kent-Moore No.)
Tool nameDescription
EG17650301
(J33984-A)
Radiator cap tester adapterAdapting radiator cap tester to radiator cap
and thermostat housing filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
KV99103510
(—)
Radiator plate pliers AInstalling radiator upper and lower tanks
KV99103520
(—)
Radiator plate pliers BRemoving radiator upper and lower tanks
WS39930000
(—)
Tube pressurePressing the tube of liquid gasket
S-NT564
S-NT224
S-NT225
S-NT052
Tool nameDescription
Power toolLoosening bolts and nuts
Radiator cap tester Checking radiator and radiator cap
PBIC0190E
PBIC1982E

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OVERHEATING CAUSE ANALYSIS
Revision: 2004 November 2004 FX35/FX45
OVERHEATING CAUSE ANALYSISPFP:00012
Troubleshooting ChartABS006JF
Symptom Check items
Cooling sys-
tem parts
malfunctionPoor heat transferWater pump malfunction Worn or loose drive belt
— Thermostat stuck closed —
Damaged finsDust contamination or
paper clogging
Physical damage
Clogged radiator cooling
tubeExcess foreign material
(rust, dirt, sand, etc.)
Reduced air flowCooling fan does not oper-
ate
Fan assembly — High resistance to fan rota-
tion
Damaged fan blades
Damaged radiator shroud — — —
Improper engine coolant
mixture ratio—— —
Poor engine coolant quality — Engine coolant density —
Insufficient engine coolantEngine coolant leaksCooling hoseLoose clamp
Cracked hose
Water pump Poor sealing
Radiator capLoose
Poor sealing
RadiatorO-ring for damage, deterio-
ration or improper fitting
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Overflowing reservoir tankExhaust gas leaks into
cooling systemCylinder head deterioration
Cylinder head gasket dete-
rioration

WATER PUMP
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Revision: 2004 November 2004 FX35/FX45
WAT E R P U MPPFP:21020
Removal and InstallationABS006JO
CAUTION:

When removing water pump, be careful not to get engine coolant on drive belt.

Water pump can not be disassembled and should be replaced as a unit.
REMOVAL
1. Drain engine coolant from drain plugs on radiator and both side of cylinder block. Refer to CO-36, "Chang-
ing Engine Coolant" and EM-241, "DISASSEMBLY" .
CAUTION:

Perform this step when engine is cold.

Do not spill engine coolant on drive belts.
2. Remove following parts:

Engine front undercover

Air duct (inlet); Refer to EM-172, "AIR CLEANER AND AIR DUCT" .

Alternator, water pump and A/C compressor belt; Refer to EM-169, "DRIVE BELTS" .
3. Remove fan coupling with cooling fan, and then water pump pulley.
4. Remove water pump.

Engine coolant will leak from the cylinder block, so have a receptacle ready under vehicle.
CAUTION:

Handle the water pump vane so that it does not contact any other parts.

Do not disassemble water pump.
INSPECTION AFTER REMOVAL

Visually check that there is no significant dirt or rusting on water
pump body and vane.

Make sure there is no looseness in vane shaft, and that it turns
smoothly when rotated by hand.

If anything is found, replace water pump.
1. Water pump pulley 2. Water pump 3. Gasket
PBIC1538E
PBIC1539E

THERMOSTAT AND WATER CONTROL VALVE
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Revision: 2004 November 2004 FX35/FX45
THERMOSTAT AND WATER CONTROL VALVEPFP:21200
Removal and InstallationABS006JP
REMOVAL
1. Drain engine coolant from drain plugs on radiator and both side of cylinder block. Refer to CO-36, "Chang-
ing Engine Coolant" and EM-241, "DISASSEMBLY" .
CAUTION:

Perform this step when engine is cold.

Do not spill engine coolant on drive belts.
2. Remove engine cover with power tool. Refer to EM-168, "
ENGINE ROOM COVER" .
3. Remove air duct (inlet). Refer to EM-172, "
AIR CLEANER AND AIR DUCT" .
4. Disconnect water suction hose from water inlet.
5. Remove water inlet and thermostat.
CAUTION:
Do not disassemble thermostat.
6. Remove intake manifolds (upper and lower). Refer to EM-174, "
INTAKE MANIFOLD" .
1. Water connector 2. O-ring 3. Rubber ring
4. Heater hose 5. Water control valve 6. Water outlet
7. Gasket 8. O-ring 9. Water outlet pipe
10. Thermostat housing 11. Radiator cap 12. Radiator hose (upper)
13. Thermostat 14. Rubber ring 15. Water inlet
16. Water suction hose 17. Water suction pipe 18. Radiator hose (lower)
19. Gasket 20. O-ring 21. Heater pipe
22. Heater hose 23. Water hose 24. Water hose
PBIC1561E

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ENGINE CONTROL SYSTEM
Revision: 2004 November 2004 FX35/FX45
Multiport Fuel Injection (MFI) SystemABS006K7
INPUT/OUTPUT SIGNAL CHART
*1: This sensor is not used to control the engine system under normal conditions.
*2: This signal is sent to the ECM through CAN communication line.
*3: ECM determines the start signal status by the signals of engine speed and battery voltage.
SYSTEM DESCRIPTION
The amount of fuel injected from the fuel injector is determined by the ECM. The ECM controls the length of
time the valve remains open (injection pulse duration). The amount of fuel injected is a program value in the
ECM memory. The program value is preset by engine operating conditions. These conditions are determined
by input signals (for engine speed and intake air) from both the crankshaft position sensor and the mass air
flow sensor.
VARIOUS FUEL INJECTION INCREASE/DECREASE COMPENSATION
In addition, the amount of fuel injected is compensated to improve engine performance under various operat-
ing conditions as listed below.


During warm-up

When starting the engine

During acceleration

Hot-engine operation

When selector lever is changed from N to D

High-load, high-speed operation


During deceleration

During high engine speed operation
Sensor Input Signal to ECM ECM function Actuator
Crankshaft position sensor (POS)
Engine speed*
3
Piston position
Fuel injection
& mixture ratio
controlFuel injector Camshaft position sensor (PHASE)
Mass air flow sensor Amount of intake air
Engine coolant temperature sensor Engine coolant temperature
Heated oxygen sensor 1 Density of oxygen in exhaust gas
Throttle position sensor Throttle position
Accelerator pedal position sensor Accelerator pedal position
Park/neutral position (PNP) switch Gear position
Knock sensor Engine knocking condition
Battery
Battery voltage*
3
Power steering pressure sensor Power steering operation
Heated oxygen sensor 2*
1Density of oxygen in exhaust gas
Air conditioner switch*
2Air conditioner operation
Wheel sensor*
2Vehicle speed