Front end INFINITI FX35 2004 Repair Manual

WARNING CHIME
DI-57
C
D
E
F
G
H
I
J
L
MA
B
DI
Revision: 2004 November 2004 FX35/FX45

to Intelligent Key unit terminal 27.
Ground is supplied

to BCM terminal 62

through front door switch (driver side) terminal 1.
Front door switch (driver side) is case grounded.
BCM sends front door switch signal to Intelligent Key unit with CAN communication line.
Intelligent Key unit detects ignition knob return is forgotten, and sends key warning signal to unified meter and
A/C amp. with CAN communication line. Unified meter and A/C amp. sends key warning signal to combination
meter with communication line between unified meter and A/C amp. and combination meter.
When combination meter receives key warning signal, it sounds warning chime.
LIGHT WARNING CHIME
With the key removed from the ignition switch or with the ignition knob is in LOCK (push switch OFF) [with
Intelligent Key], the driver's door open, and the lighting switch in ON position, the warning chime will sound.
[Except when headlamp battery saver control operates (for 5 minutes after ignition switch is turned to OFF or
ACC position) and headlamps do not illuminate.]
Signal is supplied

from combination switch (lighting switch) terminals 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10

to BCM terminals 2, 3, 4, 5, 6, 32, 33, 34, 35 and 36.
NOTE:
BCM detected lighting switch in 1st or 2nd position, refer to BCS-3, "
COMBINATION SWITCH READING
FUNCTION" .
Ground is supplied

to BCM terminal 62

through front door switch (driver side) terminal 1.
Front door switch (driver side) is case grounded.
BCM detects headlamps are illuminated, and sends light warning signal to unified meter and A/C amp. with
CAN communication line. Unified meter and A/C amp. sends light warning signal to combination meter with
communication line between unified meter and A/C amp. and combination meter.
When combination meter receives light warning signal, it sounds warning chime.
SEAT BELT WARNING CHIME
With ignition switch turned ON and seat belt unfastened [seat belt buckle switch (driver side) ON], warning
chime will sound for approximately 6 seconds.
Ground is supplied

to combination meter terminal 9

through seat belt buckle switch (driver side) terminal 60.
Seat belt buckle switch (driver side) terminal 61A is grounded through body grounds B15 and B45.
Combination meter sends seat belt unfastened [seat belt buckle switch (driver side) ON] signal to unified
meter and A/C amp. with communication line between unified meter and A/C amp. and combination meter.
BCM receives seat belt unfastened [seat belt buckle switch (driver side) ON] signal from unified meter and A/
C amp. with CAN communication line, and sends seat belt warning signal to unified meter and A/C amp. with
CAN communication line. Unified meter and A/C amp. sends seat belt warning signal to combination meter
with communication line between unified meter and A/C amp. and combination meter.
When combination meter receives seat belt warning signal, it sounds warning chime.
CAN Communication System DescriptionAKS007Z2
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
tiplex communication line with high data communication speed and excellent error detection ability. Many elec-
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.
CAN Communication UnitAKS007YY
Refer to LAN-6, "CAN Communication Unit" in “LAN SYSTEM”.

PRECAUTIONS
EC-23
[VQ35DE]
C
D
E
F
G
H
I
J
K
L
MA
EC
Revision: 2004 November 2004 FX35/FX45
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
ABS00A2R
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.
On Board Diagnostic (OBD) System of Engine and A/TABS006JZ
The ECM has an on board diagnostic system. It will light up the malfunction indicator lamp (MIL) to warn the
driver of a malfunction causing emission deterioration.
CAUTION:

Be sure to turn the ignition switch OFF and disconnect the negative battery cable before any
repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves,
etc. will cause the MIL to light up.

Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MIL to light up due to the open circuit. (Be sure the connector is free from water, grease,
dirt, bent terminals, etc.)

Certain systems and components, especially those related to OBD, may use a new style slide-
locking type harness connector. For description and how to disconnect, refer to PG-74, "
HAR-
NESS CONNECTOR" .

Be sure to route and secure the harnesses properly after work. The interference of the harness
with a bracket, etc. may cause the MIL to light up due to the short circuit.

Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube
may cause the MIL to light up due to the malfunction of the EVAP system or fuel injection system,
etc.

Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM and
TCM (Transmission control module) before returning the vehicle to the customer.
PrecautionABS006K0

Always use a 12 volt battery as power source.

Do not attempt to disconnect battery cables while engine is
running.

Before connecting or disconnecting the ECM harness con-
nector, turn ignition switch OFF and disconnect negative
battery cable. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition
switch is turned OFF.

Before removing parts, turn ignition switch OFF and then
disconnect negative battery cable.
SEF289H

EC-670
[VK45DE]
PRECAUTIONS
Revision: 2004 November 2004 FX35/FX45
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
ABS00BYX
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.
On Board Diagnostic (OBD) System of Engine and A/TABS00BYY
The ECM has an on board diagnostic system. It will light up the malfunction indicator lamp (MIL) to warn the
driver of a malfunction causing emission deterioration.
CAUTION:

Be sure to turn the ignition switch OFF and disconnect the negative battery cable before any
repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves,
etc. will cause the MIL to light up.

Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MIL to light up due to the open circuit. (Be sure the connector is free from water, grease,
dirt, bent terminals, etc.)

Certain systems and components, especially those related to OBD, may use a new style slide-
locking type harness connector. For description and how to disconnect, refer to PG-74, "
HAR-
NESS CONNECTOR" .

Be sure to route and secure the harnesses properly after work. The interference of the harness
with a bracket, etc. may cause the MIL to light up due to the short circuit.

Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube
may cause the MIL to light up due to the malfunction of the EVAP system or fuel injection system,
etc.

Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM and
TCM (Transmission control module) before returning the vehicle to the customer.
PrecautionABS00BYZ

Always use a 12 volt battery as power source.

Do not attempt to disconnect battery cables while engine is
running.

Before connecting or disconnecting the ECM harness con-
nector, turn ignition switch OFF and disconnect negative
battery cable. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition
switch is turned OFF.

Before removing parts, turn ignition switch OFF and then
disconnect battery ground cable.
SEF289H

EI-1
EXTERIOR & INTERIOR
I BODY
CONTENTS
C
D
E
F
G
H
J
K
L
M
SECTION EI
A
B
EI
Revision: 2004 November 2004 FX35/FX45
EXTERIOR & INTERIOR
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Precautions for Work ................................................ 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 4
SQUEAK AND RATTLE TROUBLE DIAGNOSES ..... 5
Work Flow ................................................................ 5
CUSTOMER INTERVIEW ..................................... 5
DUPLICATE THE NOISE AND TEST DRIVE ....... 6
CHECK RELATED SERVICE BULLETINS ........... 6
LOCATE THE NOISE AND IDENTIFY THE
ROOT CAUSE ...................................................... 6
REPAIR THE CAUSE ........................................... 6
CONFIRM THE REPAIR ....................................... 7
Generic Squeak and Rattle Troubleshooting ........... 7
INSTRUMENT PANEL .......................................... 7
CENTER CONSOLE ............................................. 7
DOORS ................................................................. 7
TRUNK .................................................................. 8
SUNROOF/HEADLINING ..................................... 8
SEATS ................................................................... 8
UNDERHOOD ....................................................... 8
Diagnostic Worksheet .............................................. 9
CLIP AND FASTENER ..............................................11
Clip and Fastener .................................................... 11
FRONT BUMPER ..................................................... 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 16
INSTALLATION ................................................... 16
FRONT FILLET MOLDING ASSEMBLY ............. 17REAR BUMPER ........................................................ 18
Removal and Installation ........................................ 18
REMOVAL ........................................................... 20
INSTALLATION ................................................... 21
REAR BUMPER FASCIA .................................... 21
REAR BUMPER CLOSING ................................. 22
DRAFTER GUARD ............................................. 22
REAR FILLET MOLDING ASSEMBLY ................ 22
FRONT GRILLE ........................................................ 23
Removal and Installation ........................................ 23
REMOVAL ........................................................... 23
INSTALLATION ................................................... 23
COWL TOP ............................................................... 24
Removal and Installation ........................................ 24
REMOVAL ........................................................... 24
INSTALLATION ................................................... 24
FENDER PROTECTOR ............................................ 25
Removal and Installation ........................................ 25
REMOVAL ........................................................... 25
INSTALLATION ................................................... 25
DOOR OUTSIDE MOLDING ..................................... 26
Removal and Installation ........................................ 26
FRONT DOOR OUTSIDE MOLDING .................. 26
REAR DOOR OUTSIDE MOLDING .................... 26
DOOR OUTSIDE LOWER MOLDING ...................... 27
Removal and Installation ........................................ 27
FRONT AND REAR DOOR OUTSIDE LOWER
MOLDING ............................................................ 27
DOOR PARTING SEAL ............................................ 28
Removal and Installation ........................................ 28
REMOVAL ........................................................... 28
INSTALLATION ................................................... 28
CENTER MUD GUARD ............................................ 29
Removal and Installation ........................................ 29
REMOVAL ........................................................... 29
INSTALLATION ................................................... 29
WINDSHIELD MOLDING .......................................... 30
Removal and Installation ........................................ 30
REMOVAL ........................................................... 30
INSTALLATION ................................................... 30

PRECAUTIONS
EI-3
C
D
E
F
G
H
J
K
L
MA
B
EI
Revision: 2004 November 2004 FX35/FX45
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
AIS0057U
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 WorkAIS0057V

After removing and installing the opening/closing parts, be sure to carry out fitting adjustments to check
their operation.

Check the lubrication level, damage, and wear of each part. If necessary, grease or replace it.

EI-16
FRONT BUMPER
Revision: 2004 November 2004 FX35/FX45
REMOVAL
1. Remove front grille. Refer to EI-23, "Removal and Installation" .
2. Remove fillet molding assembly. Only the place connected with
a front bumper fascia is removed.
3. Remove bolts and clips of front undercover.
4. Remove screws and clips of right/left fender protectors on front
side. Refer to EI-25, "
Removal and Installation" .
5. Remove bolts of right/left fender.
6. Insert driver rolled with cloth between bumper fascia and “S”
type clips, and remove bumper fascia.
7. Disconnect harness connector of fog lamps.
8. Remove bumper fascia assembly.
9. Remove bumper energy absorber.
10. Remove bolts and nuts of bumper reinforcement, and remove
bumper reinforcement. Remove bolts and nuts with power tool.
11. Remove ICC sensor with bracket. Refer to Refer to ACS-67,
"REMOVAL AND INSTALLATION" .
12. Remove nuts of bumper stay, and remove bumper stay. Remove
nuts with power tool.
13. Remove nuts of front bumper guard bar, and remove front
bumper guard bar. Remove nuts with power tool.
14. Remove fog lamps located in bumper fascia. Refer to LT- 8 8 ,
"Removal and Installation" .
INSTALLATION
Install in the reverse order of removal.
7. Clip (C205) 8. Bumper fascia assembly 9. Number plate holder
10. Bolt 11. Bolt 12. Bolt
13. Nut 14. Bolt 15. Clip (“S” type)
16. Fillet molding 17. Bolt
PIIA4350E
PIIA4338E
PIIA4331E
PIIA4339E

FRONT BUMPER
EI-17
C
D
E
F
G
H
J
K
L
MA
B
EI
Revision: 2004 November 2004 FX35/FX45
FRONT FILLET MOLDING ASSEMBLY
Removal
1. Remove screws of fillet molding assembly.
2. Remove clips of fillet molding assembly.
3. Remove fillet molding assembly.
Installation
1. Clean adhesive portion of front fender with white gasoline.
2. Strip pattern from the new double adhesive tape and paste on front fender.
3. Fillet molding assembly hold with front fender.
PIIA4350E

FENDER PROTECTOR
EI-25
C
D
E
F
G
H
J
K
L
MA
B
EI
Revision: 2004 November 2004 FX35/FX45
FENDER PROTECTORPFP:63840
Removal and InstallationAIS0037D
REMOVAL
1. Remove bolts of fender protector front.
2. Remove clips of fender protector front.
3. Remove fender protector front.
4. Remove bolt of fender protector rear.
5. Remove clips of fender protector rear.
6. Remove fender protector rear.
INSTALLATION
Install in the reverse order of removal.
PIIA4326E
1. Fender protector front 2. Clip (C103) 3. Screw
4. Bolt 5. Fender protector rear 6. Clip

HEADLINING
EI-43
C
D
E
F
G
H
J
K
L
MA
B
EI
Revision: 2004 November 2004 FX35/FX45
REMOVAL
1. Remove front pillar garnish. Refer to EI-37, "Removal and Installation" .
2. Remove kicking plate (front/rear). Refer to EI-37, "
Removal and Installation" .
3. Remove body side welt. Refer to EI-37, "
Removal and Installation" .
4. Remove seat belt shoulder anchor (front/rear). Refer to SB-4, "
Removal and Installation of Front Seat
Belt" and SB-6, "Removal and Installation of Rear Seat Belt" .
5. Remove center pillar garnish (lower/upper) and luggage side finisher assembly and rear pillar upper gar-
nish assembly. Refer to EI-37, "
Removal and Installation" and EI-44, "Removal and Installation" .
6. Remove assist grip caps and screw. Remove assist grip.
7. Remove sun-visor (drive and passenger), and disconnect harness connector with lamp model.
8. Remove sun-visor holder.
9. Remove DVD display rear. Refer to AV- 1 9 9 , "
Removal and Installation for DVD Display Unit" .
10. Remove map lamp (spot lamp). Refer to LT- 1 5 0 , "
Removal and Installation" .
11. Disconnect harness connector at front left side of headlining.
12. Put front seat to front most and recline seatback to backward.
13. Remove headlining, turn and take out from back door.
CAUTION:

Always remove or install in a pair.

Cover surroundings with waste to avoid scratches or damages.

Do not bend headlining too hard.
14. Remove following parts after removing headlining.

Room lamp

Personal lamp
INSTALLATION
Install in the reverse order of removal.
1. Headlining 2. Assist grip (rear) 3. Assist grip (front)
4. Sun-visor holder (right) 5. Sun-visor (right) 6. Sun-visor cover (right)
7. Map lamp (spot lamp) 8. Sun-visor (left) 9. Sun-visor cover (left)
10. Sun-visor holder (left) 11. Finisher 12. Room lamp
13. Personal lamp 14. Fastener 15. DVD display rear
PIIA4952E

EM-2Revision: 2004 November 2004 FX35/FX45 FUEL INJECTOR AND FUEL TUBE ........................ 45
Removal and Installation ........................................ 45
REMOVAL ........................................................... 46
INSTALLATION .................................................... 47
INSPECTION AFTER INSTALLATION ................ 49
ROCKER COVER ..................................................... 51
Removal and Installation ........................................ 51
REMOVAL ........................................................... 51
INSTALLATION .................................................... 52
FRONT TIMING CHAIN CASE ................................. 54
Removal and Installation ........................................ 54
REMOVAL ........................................................... 54
INSTALLATION .................................................... 58
INSPECTION AFTER INSTALLATION ................ 62
TIMING CHAIN .......................................................... 63
Removal and Installation ........................................ 63
REMOVAL ........................................................... 64
INSPECTION AFTER REMOVAL ........................ 71
INSTALLATION .................................................... 71
INSPECTION AFTER INSTALLATION ................ 80
CAMSHAFT ............................................................... 82
Removal and Installation ........................................ 82
REMOVAL ........................................................... 83
INSPECTION AFTER REMOVAL ........................ 84
INSTALLATION .................................................... 87
Valve Clearance ...................................................... 89
INSPECTION ....................................................... 89
ADJUSTMENT .................................................... 92
OIL SEAL .................................................................. 94
Removal and Installation of Valve Oil Seal ............. 94
REMOVAL ........................................................... 94
INSTALLATION .................................................... 94
Removal and Installation of Front Oil Seal ............. 95
REMOVAL ........................................................... 95
INSTALLATION .................................................... 96
Removal and Installation of Rear Oil Seal .............. 96
REMOVAL ........................................................... 96
INSTALLATION .................................................... 96
CYLINDER HEAD ..................................................... 98
On-Vehicle Service ................................................. 98
CHECKING COMPRESSION PRESSURE ......... 98
Removal and Installation ........................................ 99
REMOVAL ........................................................... 99
INSPECTION AFTER REMOVAL ......................100
INSTALLATION ..................................................101
Disassembly and Assembly ..................................102
DISASSEMBLY .................................................103
ASSEMBLY .......................................................103
Inspection After Disassembly ...............................104
VALVE DIMENSIONS ........................................104
VALVE GUIDE CLEARANCE ............................105
VALVE GUIDE REPLACEMENT .......................105
VALVE SEAT CONTACT ...................................107
VALVE SEAT REPLACEMENT .........................107
VALVE SPRING SQUARENESS .......................108
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD ..............................109
ENGINE ASSEMBLY ...............................................110
Removal and Installation .......................................110
2WD MODEL .....................................................110
REMOVAL .......................................................... 111
INSTALLATION ..................................................113
INSPECTION AFTER INSTALLATION ..............113
AWD MODEL .....................................................115
REMOVAL ..........................................................115
INSTALLATION ..................................................118
INSPECTION AFTER INSTALLATION ..............118
CYLINDER BLOCK .................................................120
Disassembly and Assembly ..................................120
DISASSEMBLY ..................................................121
ASSEMBLY ........................................................126
How to Select Piston and Bearing ........................131
DESCRIPTION ..................................................131
HOW TO SELECT PISTON ...............................131
HOW TO SELECT CONNECTING ROD BEAR-
ING .....................................................................132
HOW TO SELECT MAIN BEARING ..................133
Inspection After Disassembly ................................136
CRANKSHAFT END PLAY ................................136
CONNECTING ROD SIDE CLEARANCE .........136
PISTON TO PISTON PIN OIL CLEARANCE .....136
PISTON RING SIDE CLEARANCE ...................137
PISTON RING END GAP ..................................137
CONNECTING ROD BEND AND TORSION .....138
CONNECTING ROD BEARING HOUSING
DIAMETER (BIG END) ......................................138
CONNECTING ROD BUSHING OIL CLEAR-
ANCE (SMALL END) .........................................138
CYLINDER BLOCK DISTORTION ....................139
MAIN BEARING HOUSING INNER DIAMETER .140
PISTON TO CYLINDER BORE CLEARANCE ..140
CRANKSHAFT MAIN JOURNAL DIAMETER ...141
CRANKSHAFT PIN JOURNAL DIAMETER ......142
CRANKSHAFT OUT-OF-ROUND AND TAPER .142
CRANKSHAFT RUNOUT ..................................142
CONNECTING ROD BEARING OIL CLEAR-
ANCE .................................................................142
MAIN BEARING OIL CLEARANCE ...................143
MAIN BEARING CRUSH HEIGHT ....................144
CONNECTING ROD BEARING CRUSH
HEIGHT .............................................................144
MAIN BEARING CAP BOLT OUTER DIAMETER .144
CONNECTING ROD BOLT OUTER DIAMETER .144
DRIVE PLATE ....................................................145
OIL JET ..............................................................145
OIL JET RELIEF VALVE ....................................145
SERVICE DATA AND SPECIFICATIONS (SDS) ....146
Standard and Limit ................................................146
GENERAL SPECIFICATIONS ...........................146
DRIVE BELT ......................................................147
INTAKE MANIFOLD COLLECTOR, INTAKE