Revers INFINITI QX56 2004 Factory Service Manual

EX-4Revision: August 2007
EXHAUST SYSTEM
2004 QX56
REMOVAL
Remove exhaust system components using power tool.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:

Always replace exhaust gaskets with new ones when reassembling.

Before installing a new heated oxygen sensor, clean and lube the exhaust tube threads using tool.

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; install a new one.

Do not over-torque the heated oxygen sensor. Doing so may damage the heated oxygen sensor,
resulting in the MIL coming on.

If any mounting insulator is badly deformed, repair or replace it. If deposits such as mud pile up on
the mounting insulators, clean and inspect them.

Temporarily tighten the mounting nuts on the exhaust manifold side and the mounting bolts on the
vehicle side. Check each part for interference with other components, and then tighten the nuts
and bolts to specification.
INSPECTION AFTER INSTALLATION

With the 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. Tool number
A : — (J-43897-18)
B : — (J-43897-12)

FAX-6
WHEEL HUB
Revision: August 20072004 QX56
4. Put alignment mark on disc rotor and wheel hub and bearing
assembly, then remove disc rotor.
5. Remove cotter pin, then remove lock nut from drive shaft using power tool. Refer to FA X -7 , "
Removal and
Installation" .
6. Remove drive shaft from wheel hub and bearing assembly. Refer to FAX-7, "
Removal and Installation" .
7. Remove wheel sensor. Refer to BRC-64, "
Removal and Installation" .

Inspect the wheel sensor O-ring, replace the wheel sensor assembly if damaged.

Clean the wheel sensor hole and mounting surface with a suitable brake cleaner and clean lint-free
shop rag. Be careful that dirt and debris do not enter the axle bearing area.

Apply a coat of suitable grease to the wheel sensor O-ring and mounting hole.
CAUTION:
Do not pull on the wheel sensor harness.
8. Remove wheel hub and bearing assembly bolts using power tool.
9. Remove splash guard and wheel hub and bearing assembly from steering knuckle.
INSPECTION AFTER REMOVAL
Check for deformity, cracks and damage on each part, replace if necessary.
INSTALLATION
Installation is in the reverse order of removal.

Use new bolts when installing the wheel hub and bearing assembly.

When installing disc rotor on wheel hub and bearing assembly,
position the disc rotor according to alignment mark.
(When not using the alignment mark, refer to BR-22, "
Removal
and Installation of Brake Caliper and Disc Rotor" .)

When installing wheel and tire. Refer to WT-6, "Rotation" .
WDIA0044E
WDIA0044E

FAX-8
DRIVE SHAFT
Revision: August 20072004 QX56
INSTALLATION
Installation is in the reverse order of removal.

Tighten wheel nuts to specification. Refer to WT-6, "Rotation" .
Disassembly and AssemblyEDS001B6
DISASSEMBLY
Final Drive Side
1. Mount the drive shaft in a vise.
CAUTION:
When mounting the drive shaft in a vise, use copper or aluminum plates between the vise and the
drive shaft.
2. Remove the boot bands.
3. Remove the stopper ring with a flat-bladed screwdriver as
shown, and pull the housing off.
1. Sliding joint housing 2. Snap ring 3. Ball cage, steel ball, inner race assembly
4. Stopper ring 5. Boot band 6. Boot
7. Drive shaft 8. Circlip 9. Joint sub-assembly
WDIA0054E
SRA2 49 A

FFD-10
SIDE OIL SEALS
Revision: August 20072004 QX56
SIDE OIL SEALSPFP:33142
Removal and InstallationEDS0035K
REMOVAL
1. Remove front final drive. Refer to FFD-12, "REMOVAL" .
2. Remove differential side shaft and side flange using suitable
tool.
3. Place a small hole in seal case, using suitable tool.
4. Install slide hammer tool as shown and remove seal.
5. Installation is in the reverse order of removal.
BDIA0006E
LDIA0129E
LDIA0130E

FRONT FINAL DRIVE ASSEMBLY
FFD-15
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E
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B
FFD
Revision: August 20072004 QX56
ASSEMBLY INSPECTION AND ADJUSTMENT

Before inspection and adjustment, drain gear oil.
Total Preload Torque
1. Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
2. Rotate drive pinion at least 20 times to check for smooth operation of the bearing.
3. Measure total preload with preload gauge.

If measured value is out of the specification, disassemble it to
check and adjust each part. Adjust the pinion bearing preload
and side bearing preload.
Adjust the pinion bearing preload first, then adjust the side bear-
ing preload.
Tooth Contact
1. Remove rear cover. Refer to FFD-11, "REMOVAL" .
2. Thoroughly clean drive gear and drive pinion teeth.
3. Lightly apply a mixture of powdered ferric oxide and oil or the
equivalent. Apply it to 3 or 4 teeth of drive gear drive side.
4. Rotate drive gear back and forth several times, check drive pin-
ion gear to drive gear tooth contact.
CAUTION:
Check tooth contact on drive side and reverse side.
34. Bushing 35. Bearing 36 Screw
37 Dowel pin
Tool number : ST3127S000 (J-25765-A)
Total preload (with oil seal):
2.98 - 4.76 N·m (0.31 - 0.48 kg-m, 27 - 42 in-lb)
SDIA2220E
When the preload torque is large
On pinion bearings: Replace the collapsible spacer.
On side bearings: Loosen the side bearing adjust nuts at the same force on each side.
When the preload is small
On pinion bearings: Tighten the drive pinion nut.
On side bearings: Tighten the side bearing adjust nuts at the same force on each side.
SDIA2248E
SDIA2249E

FL-8Revision: August 2007
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
2004 QX56
11. Remove the lock ring using Tool.
12. Remove the fuel level sensor, fuel filter, and fuel pump assem-
bly.
CAUTION:

Do not bend the float arm during removal.

Avoid impacts such as dropping when handling the com-
ponents.
INSTALLATION
Installation is in the reverse order of removal.

Connect the quick connector as follows:
–Check the connection for any damage or foreign materials.
–Align the connector with the pipe, then insert the connector straight into the pipe until a click is heard.
–After connecting the quick connector, make sure that the con-
nection is secure by checking as follows:
–Pull the tube and the connector to make sure they are securely
connected.
–Visually inspect the connector to make sure the two retainer tabs
are securely connected.
INSPECTION AFTER INSTALLATION
1. Turn the ignition switch ON but do not start engine, then check the fuel pipes and hose connections for
leaks while applying fuel pressure to the system.
2. Start the engine and rev it above idle speed, then check that there are no fuel leaks at any of the fuel pipe
and hose connections.Tool number : — (J-46536)
LBIA0389E
PBIC1653E

FUEL TANK
FL-13
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MA
FL
Revision: August 20072004 QX56
19. Remove the fuel tank strap bolts while supporting the fuel tank
with a suitable lift jack.
20. Disconnect the EVAP hose from the molded clip in the top of the fuel tank while lowering the fuel tank.
21. Lower the fuel tank using a suitable lift jack and remove it.
22. If necessary, remove the lock ring using Tool.
23. If necessary, remove the fuel level sensor, fuel filter, and fuel
pump assembly.
CAUTION:

Do not bend the float arm during removal.

Avoid impacts such as dropping when handling the com-
ponents.
INSTALLATION
Installation is in the reverse order of removal.

Connect the quick connector as follows:
–Check the connection for any damage or foreign materials.
–Align the connector with the pipe, then insert the connector straight into the pipe until a click is heard.
–After connecting the quick connector, make sure that the con-
nection is secure by checking as follows:
–Pull the tube and the connector to make sure they are securely
connected.
–Visually inspect the connector to make sure the two retainer tabs
are securely connected.
INSPECTION AFTER INSTALLATION
1. Turn the ignition switch ON but do not start engine, then check the fuel pipe and hose connections for
leaks while applying fuel pressure.
2. Start the engine and rev it above idle, then check that there are no fuel leaks at any of the fuel pipe and
hose connections.
LBIA0387E
Tool number : — (J-46536)
LBIA0389E
PBIC1653E

FSU-10
COIL SPRING AND SHOCK ABSORBER
Revision: August 20072004 QX56
COIL SPRING AND SHOCK ABSORBERPFP:56210
Removal and InstallationEES0010K
REMOVAL
1. Remove the wheel and tire using power tool.
2. Remove the shock absorber lower bolt using power tool.
3. Remove the three shock absorber upper mounting nuts using
power tool.
4. Remove the coil spring and shock absorber assembly.

Turn steering knuckle out to gain enough clearance for
removal.
INSTALLATION
Installation is in the reverse order of removal.

The step in the shock absorber assembly lower seat faces outside of vehicle.

Tighten all nuts and bolts to specification. Refer to FSU-5, "Components" .

When installing wheel and tire, refer to WT-6, "Rotation" .
Disassembly and AssemblyEES0010L
DISASSEMBLY
1. Set the shock absorber in a vise, then loosen (without removing)
the piston rod lock nut as shown.
CAUTION:
Do not remove piston rod lock nut at this time.
2. Compress the spring using commercial service tool until the
shock absorber mounting insulator can be turned by hand.
WAR NIN G:
Make sure that the pawls of the two spring compressors are
firmly hooked on the spring. The spring compressors must
be tightened alternately and evenly so as not to tilt the
spring.
3. Remove the piston rod lock nut.

Discard the piston rod lock nut, use a new nut for assembly.
INSPECTION AFTER DISASSEMBLY
Shock Absorber Assembly

Check for smooth operation through a full stroke, both compression and extension.

Check for oil leakage on welded or gland packing portions.

Check piston rod for cracks, deformation or other damage and replace if necessary.
Mounting Insulator and Rubber Parts
Check cemented rubber-to-metal portion for separation or cracks. Check rubber parts for deterioration and
replace if necessary.
LEIA0093E
SSU0 02
SSU0 03

FSU-12
STABILIZER BAR
Revision: August 20072004 QX56
STABILIZER BARPFP:54611
Removal and InstallationEES0010M
REMOVAL
1. Remove engine under cover using power tool.
2. Remove stabilizer bar mounting bracket bolts and connecting
rod nuts as shown, using power tool.
3. Remove bushings from stabilizer bar.
INSPECTION AFTER REMOVAL

Check stabilizer bar for twist and deformation. Replace if necessary.

Check rubber bushing for cracks, wear and deterioration. Replace if necessary.
INSTALLATION
Installation is in the reverse order of removal.

Tighten all nuts and bolts to specification. Refer to FSU-5, "Components" .
LEIA0094E

UPPER LINK
FSU-13
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FSU
Revision: August 20072004 QX56
UPPER LINKPFP:54524
Removal and InstallationEES0010N
REMOVAL
1. Remove the wheel and tire using power tool.
2. Remove wheel opening shield.
3. Remove cotter pin and nut from upper link ball joint.
4. Separate upper link ball joint stud from steering knuckle using
Tool.

Support lower link with jack.
5. Remove upper link mounting bolts and nuts.
INSPECTION AFTER REMOVAL
Upper Link
Check for deformation and cracks. Replace if necessary.
Upper Link Ball Joint
Check for distortion and damage. Replace if necessary.
INSTALLATION
Installation is in the reverse order of removal.

Tighten all nuts and bolts to specification. Refer to FSU-5, "Components" .

When installing wheel and tire, refer to WT-6, "Rotation" .

After installation, check that the front wheel alignment is within specification. Refer to FSU-6, "Front
Wheel Alignment" . Tool number : ST29020001 (J24319-01)
LEIA0095E
LEIA0096E