engine INFINITI M35 2006 Factory Service Manual

EM-270
[VK45DE]
CYLINDER BLOCK
Revision: 2006 January2006 M35/M45
Measure the distortion on the cylinder block upper face at some
different points in six directions with straightedge and feeler
gauge.
If it exceeds the limit, replace cylinder block.
MAIN BEARING HOUSING INNER DIAMETER
Install main bearing caps and main bearing without installing
main bearings, and tighten main bearing cap bolts to the speci-
fied torque. Refer to EM-254, "
ASSEMBLY" for the tightening
procedure.
Measure the inner diameter of main bearing housing with bore
gauge.
If out of the standard, replace cylinder block and main bearing
caps as assembly.
NOTE:
Cylinder block cannot be replaced as a single part, because it is
machined together with main bearing caps.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter
Using bore gauge, measure cylinder bore for wear, out-of-round
and taper at six different points on each cylinder. (“X” and “Y”
directions at “A”, “B” and “C”) (“X” is in longitudinal direction of
engine)
If the measured value exceeds the limit, or if there are scratches
and/or seizure on the cylinder inner wall, hone or re-bore the
inner wall.
Oversize piston is provided. When using oversize piston, re-
bore cylinder so that the clearance of the piston-to-cylinder bore
satisfies the standard.
CAUTION:
When using oversize piston, use oversize pistons for all
cylinders with oversize piston rings.Limit : 0.1 mm (0.004 in)
SEM123C
Standard : 68.944 - 68.968 mm (2.7143 - 2.7153 in)
PBIC1643E
Standard inner diameter:
93.000 - 93.030 mm (3.6614 - 3.6626 in)
Wear limit:
0.2 mm (0.008 in)
Out-of-round (Difference between “X” and “Y”):
0.015 mm (0.0006 in)
Taper limit (Difference between “A” and “C”):
0.01 mm (0.0004 in)
Oversize (OS) : 0.2 mm (0.008 in)
PBIC3827E
PBIC0124E

EX-1
EXHAUST SYSTEM
B ENGINE
CONTENTS
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SECTION EX
A
EX
Revision: 2006 January2006 M35/M45
EXHAUST SYSTEM
PREPARATION ........................................................... 2
Special Service Tools ............................................... 2
Commercial Service Tools ........................................ 2
EXHAUST SYSTEM ................................................... 3
Checking Exhaust System ....................................... 3
Components ............................................................. 4
Removal and Installation .......................................... 5
REMOVAL ........................................................
..... 5INSTALLATION ..................................................... 5
INSPECTION AFTER INSTALLATION .................. 5
Components ............................................................. 6
Removal and installation .......................................... 7
REMOVAL ........................................................
..... 7
INSTALLATION ..................................................... 7
INSPECTION AFTER INSTALLATION .................. 7

EXHAUST SYSTEM
EX-5
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Revision: 2006 January2006 M35/M45
Removal and InstallationNBS005RL
CAUTION:
Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat
resistance, corrosion resistance, and shape.
Perform the operation with the exhaust system fully cooled down because the system will be hot
just after engine stops.
Be careful not to cut your hand on the heat insulator edge.
REMOVAL
Disconnect each joint and mounting using power tool.
Remove heated oxygen sensor 2 as follows:
–Using heated oxygen sensor wrench (SST), removal heated
oxygen sensor 2.
CAUTION:
Be careful not to damage heated oxygen sensor 2.
INSTALLATION
Note the following, and install in the reverse order of removal.
When installing, heated oxygen sensor 2 is identified by the color of the connector.
Check for deformation of the grommets (18 and 20 of Components).
Insert the collar (17 of Components) vertically.
Install the collar (5 of Components) with its lower surface horizontal.
Temporarily tighten nuts and bolts when installing exhaust pipe assembly. Tighten them to the specified
torque when connecting the vehicle rear to the vehicle front.
CAUTION:
Always replace exhaust tube gaskets with new ones when reassembling.
Discard any heated oxygen sensor which has been dropped onto a hard surface such as a con-
crete floor; use a new one.
Before installing a new heated oxygen sensor, clean exhaust system threads using the heated
oxygen sensor thread cleaner [commercial service tool: J-43897-18 or J-43897-12], and apply the
anti-seize lubricant (commercial service tool).
Do not over torque heated oxygen sensor. Doing so may cause damage to heated oxygen sensor,
resulting in the “MIL” coming on.
If heat insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the heat
insulator, remove them.
When installing heat insulator avoid large gaps or interference between heat insulator and each
exhaust pipe.
Remove deposits from the sealing surface of each connection. Connect them securely to avoid
gases leakage.
Temporarily tighten mounting nuts on the exhaust manifold side and mounting bolts on the vehi-
cle side. Check each part for unusual interference, and then tighten them to the specified torque.
When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/
left directions.
INSPECTION AFTER INSTALLATION
Make sure clearance between tail tube and rear bumper is even.
PBIC2298E
Bank 1 : Blue
Bank 2 : Green

EX-6
EXHAUST SYSTEM
Revision: 2006 January2006 M35/M45
With engine running, check exhaust tube joints for gas leakage and unusual noises.
Check to ensure that mounting brackets and mounting rubbers are installed properly and free from undue
stress. Improper installation could result in excessive noise and vibration.
ComponentsNBS005RM
VK45DE
Refer to GI-11, "Components" for symbol marks in the figure.
PBIC3307E
1. Mounting bracket 2. Main muffler (RH) 3. Main muffler (LH)
4. Mounting rubber 5. Collar 6. Ring gasket
7. Dynamic damper 8. Wire bonding 9. Mounting bracket
10. Mounting rubber 11. Center muffler 12. Gasket
13. Exhaust front tube 14. Heated oxygen sensor 2 (bank 2) 15. Ring gasket
16. Mounting bracket 17. Heated oxygen sensor 2 (bank 1) 18. Mounting bracket
19. Exhaust mounting bracket

EXHAUST SYSTEM
EX-7
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Revision: 2006 January2006 M35/M45
Removal and installationNBS005RN
CAUTION:
Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat
resistance, corrosion resistance, and shape.
Perform the operation with the exhaust system fully cooled down because the system will be hot
just after engine stops.
Be careful not to cut your hand on the heat insulator edge.
REMOVAL
Disconnect each joint and mounting using power tool.
Remove heated oxygen sensor 2 as follows:
–Using heated oxygen sensor wrench (SST), removal heated
oxygen sensor 2.
CAUTION:
Be careful not to damage heated oxygen sensor 2.
INSTALLATION
Note the following, and install in the reverse order of removal.
When installing, heated oxygen sensor 2 is identified by the color of the connector.
Install the collar (5 of Components) with its lower surface horizontal.
Temporarily tighten nuts and bolts when installing exhaust pipe assembly. Tighten them to the specified
torque when connecting the vehicle rear to the vehicle front.
CAUTION:
Always replace exhaust tube gaskets with new ones when reassembling.
Discard any heated oxygen sensor which has been dropped onto a hard surface such as a con-
crete floor; use a new one.
Before installing a new heated oxygen sensor, clean exhaust system threads using the heated
oxygen sensor thread cleaner [commercial service tool: J-43897-18 or J-43897-12], and apply the
anti-seize lubricant (commercial service tool).
Do not over torque heated oxygen sensor. Doing so may cause damage to heated oxygen sensor,
resulting in the “MIL” coming on.
If heat insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the heat
insulator, remove them.
When installing heat insulator avoid large gaps or interference between heat insulator and each
exhaust pipe.
Remove deposits from the sealing surface of each connection. Connect them securely to avoid
gases leakage.
Check each part for unusual interference, and then tighten them to the specified torque.
When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/
left directions.
INSPECTION AFTER INSTALLATION
Make sure clearance between tail tube and rear bumper is even.
With engine running, check exhaust tube joints for gas leakage and unusual noises.
Check to ensure that mounting brackets and mounting rubbers are installed properly and free from undue
stress. Improper installation could result in excessive noise and vibration.
PBIC2334E
Bank 1 : Green
Bank 2 : Blue

DESCRIPTION
FFD-7
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FFD
Revision: 2006 January2006 M35/M45
DESCRIPTIONPFP:00000
Cross-Sectional ViewNDS000EP
1. Side retainer 2. Side bearing 3. Differential case
4. Drive gear 5. Pinion mate shaft 6. Pinion mate gear
7. Side gear 8. Side shaft 9. Gear carrier
10. Drive pinion 11. Companion flange 12. Pinion front bearing
13. Pinion rear bearing 14. Extension tube retainer 15. Engine assembly
PDIA0647E

FFD-8
DIFFERENTIAL GEAR OIL
Revision: 2006 January2006 M35/M45
DIFFERENTIAL GEAR OILPFP:KLD30
Changing Differential Gear OilNDS000EQ
DRAINING
1. Stop engine.
2. Remove drain plug (1) and drain gear oil.
3. Set a gasket on drain plug (1) and install it to final drive assem-
bly and tighten to the specified torque. Refer to FFD-15, "
COM-
PONENTS" .
CAUTION:
Do not reuse gasket.
FILLING
1. Remove filler plug (1). Fill with new gear oil until oil level reaches
the specified level near filler plug mounting hole.
2. After refilling oil, check oil level. Set a gasket to filler plug (1),
then install it to final drive assembly. Refer to FFD-15, "
COMPO-
NENTS" .
CAUTION:
Do not reuse gasket.
Checking Differential Gear OilNDS000ER
OIL LEAKAGE AND OIL LEVEL
Make sure that oil is not leaking from final drive assembly or around it.
Remove filler plug (1) and check oil level from filler plug mount-
ing hole as shown in the figure.
CAUTION:
Do not start engine while checking oil level.
Set a gasket on filler plug (1) and install it on final drive assem-
bly. Refer to FFD-15, "
COMPONENTS" .
CAUTION:
Do not reuse gasket.
PDIA0781J
Oil grade and Viscosity:
Refer to MA-12, "
Fluids and Lubricants" .
Oil capacity:
Approx. 0.65 (1-3/8 US pt, 1-1/8 Imp pt)
PDIA0782J
PDIA0782J

SIDE OIL SEAL
FFD-11
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FFD
Revision: 2006 January2006 M35/M45
SIDE OIL SEALPFP:33142
Removal and InstallationNDS000ET
NOTE:
Left side oil seal is attached to engine assembly. Replace it after removing front final drive assembly
from vehicle.
REMOVAL
Right Side:
1. Remove the front drive shaft. Refer to FAX-11, "Removal and Installation" .
2. Remove the side oil seal using a puller.
CAUTION:
Be careful not to damage gear carrier.
Left Side:
1. Remove the front final drive assembly from vehicle with power tool. Refer to FFD-13, "Removal and Instal-
lation" .
2. Remove the side oil seal using a flat-bladed screwdriver.
CAUTION:
Be careful not to damage gear carrier.
INSTALLATION
Right Side:
1. Apply multi-purpose grease to sealing lips of side oil seal.
2. Using the drift, press-fit side oil seal so that its surface comes
face to face with the end surface of the side retainer.
CAUTION:
Do not reuse oil seal.
When installing, do not incline oil seal.
3. Install the front drive shaft. Refer to FAX-11, "
Removal and
Installation" .
4. When oil leaks while removing, check oil level after the installa-
tion. Refer to FFD-8, "
Checking Differential Gear Oil" .
Left Side:
1. Apply multi-purpose grease to sealing lips of side oil seal.
2. Using the drift, press-fit side oil seal so that its surface comes
face to face with the end surface of the gear carrier.
CAUTION:
Do not reuse oil seal.
When installing, do not incline oil seal.
3. Install the front final drive assembly on vehicle. Refer toFFD-13,
"Removal and Installation" .
4. Install the front drive shaft. Refer to FAX-11, "
Removal and
Installation" . Tool number A: KV381054S0 (J-34286)
PDIA0838J
Tool number A: ST33400001 (J-26082)
PDIA0787J
Tool number A: KV38102100 (J-25803-01)
PDIA0788J

FRONT FINAL DRIVE ASSEMBLY
FFD-13
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FFD
Revision: 2006 January2006 M35/M45
FRONT FINAL DRIVE ASSEMBLYPFP:38500
Removal and InstallationNDS000EU
COMPONENTS
REMOVAL
1. Remove front drive shaft both. Refer to FA X - 11 , "Removal and Installation" .
2. Remove front crossbar with power tool.
3. Separate steering outer socket and steering knuckle. Refer to PS-18, "
POWER STEERING GEAR" .
4. Remove side shaft.
5. Remove three way catalyst (right bank) with power tool. Refer to EX-3, "
EXHAUST SYSTEM" .
6. Remove front propeller shaft. Refer to PR-5, "
Removal and Installation" .
7. Separate EPS solenoid valve connector.
8. Separate power steering hydraulic line.
9. Remove stabilizer assembly with power tool. Refer to FSU-35, "
Removal and Installation" .
10. Separate steering lower joint and steering gear assembly. Refer to PS-18, "
POWER STEERING GEAR" .
11. Set a suitable jack to engine.
12. Remove front suspension member with power tool. Refer to FSU-26, "
Removal and Installation" .
13. Remove breather hose and tube.
14. Remove engine mounting bracket (RH) (Lower) and engine mounting insulator (RH) with power tool.
Refer to EM-118, "
Removal and Installation (AWD Models)" .
15. Remove front final drive assembly with power tool.
1. Front final drive assembly 2. Side shaft 3. Bushing
4. Front propeller shaft 5. Breather hose 6. Breather tube
7. Breather connector 8. Engine mounting bracket (RH)
(Lower)9. Engine mounting insulator (RH)
Refer to GI-11, "
Components" , for the symbols in the figure.
PDIA0789J

FL-1
FUEL SYSTEM
B ENGINE
CONTENTS
C
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F
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SECTION FL
A
FL
Revision: 2006 January2006 M35/M45
FUEL SYSTEM
PREPARATION ........................................................... 2
Commercial Service Tools ........................................ 2
FUEL SYSTEM ........................................................... 3
Checking Fuel Lines ............................................ ..... 3
General Precautions ................................................ 3
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND
FUEL PUMP ASSEMBLY ........................................... 4
Components ............................................................. 4
Removal and Installation .......................................... 4
REMOVAL ........................................................
..... 4
INSTALLATION ..................................................... 6
INSPECTION AFTER INSTALLATION ................. 7Components ............................................................. 8
Disassembly and Assembly ...................................... 8
DISASSEMBLY ..................................................... 8
ASSEMBLY ........................................................... 9
FUEL TANK .............................................................. 10
Components ........................................................... 10
Removal and Installation ........................................ 10
REMOVAL ........................................................
... 10
INSTALLATION ................................................... 11
INSPECTION AFTER INSTALLATION ................ 11
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 13
Standard and Limit .................................................. 13
FUEL TANK ...................................................... ... 13