fuel INFINITI QX56 2004 Factory Service Manual

EM-6Revision: August 2007
PREPARATION
2004 QX56
KV10115600
(J-38958)
Valve oil seal driftInstalling valve oil seal
Use side A.
a: 20 (0.79) dia. d: 8 (0.31) dia.
b: 13 (0.51) dia. e: 10.7 (0.421) dia.
c: 10.3 (0.406) dia. f: 5 (0.20) dia.
Unit: mm (in)
EM03470000
(J-8037)
Piston ring compressorInstalling piston assembly into cylinder bore
ST16610001
(J-23907)
Pilot bushing pullerRemoving crankshaft pilot bushing
WS39930000
(—)
Tube presserPressing the tube of liquid gasket
—
(J-47245)
Ring gear stopperRemoving and installing crankshaft pulley
16441 6N210
(J-45488)
Quick connector releaseRemoving fuel tube quick connectors in en-
gine room
—
(J-46535)
Drive belt tension releaserReleasing drive belt tension Tool number
(Kent-Moore No.)
Tool nameDescription
S-NT603
S-NT044
S-NT045
S-NT052
LBIA0451E
PBIC0198E
W BIA0536E

INTAKE MANIFOLD
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INTAKE MANIFOLDPFP:14003
Removal and InstallationEBS00ILF
REMOVAL
1. Partially drain the engine coolant. Refer to MA-12, "DRAINING ENGINE COOLANT" .
WAR NIN G:
To avoid the danger of being scalded, never drain the engine coolant when the engine is hot.
2. Remove the engine room cover using power tool. Refer to EM-11, "
REMOVAL" .
3. Release the fuel pressure. Refer to EC-46, "
FUEL PRESSURE RELEASE" .
4. Remove the air duct and resonator assembly. Refer to EM-14, "
REMOVAL" .
5. Disconnect the fuel tube quick connector on the engine side.
1. Intake manifold 2. PCV hose 3. Gasket
4. Electric throttle control actuator 5. Water hose 6. Water hose
7. PCV hose 8. EVAP hose 9. EVAP canister purge control sole-
noid valve
10. Bracket 11. Gasket
KBIA2461E
LBIA0395E

EM-16Revision: August 2007
INTAKE MANIFOLD
2004 QX56

Perform the following steps to disconnect the quick connector
using Tool.
a. Remove quick connector cap (engine side only).
b. With the sleeve side of Tool facing quick connector, install Tool
onto fuel tube.
c. Insert Tool into quick connector until sleeve contacts and goes
no further. Hold the Tool in that position.
CAUTION:
Inserting the Tool hard will not disconnect quick connector.
Hold Tool where it contacts and goes no further.
d. Draw and pull out quick connector straight from fuel tube.
CAUTION:

Pull quick connector holding A position in illustration.

Do not pull with lateral force applied. O-ring inside quick connector may be damaged.

Prepare container and cloth beforehand as fuel will leak out.

Avoid fire and sparks.

Be sure to cover openings of disconnected pipes with plug or plastic bag to avoid fuel leakage
and entry of foreign materials.
6. Remove or disconnect harnesses, brackets, vacuum hose, vacuum gallery and PCV hose and tube from
intake manifold.
7. Remove electric throttle control actuator by loosening bolts diagonally.
CAUTION:

Handle carefully to avoid any damage to the electric throttle control actuator.

Do not disassemble.
8. Remove the fuel injectors and fuel tube assembly. Refer to EM-29, "
Removal and Installation" .
9. Loosen the bolts in reverse order shown using power tool.
10. Remove the intake manifold.
CAUTION:
Cover engine openings to avoid entry of foreign materials.Tool number : 16441 6N210 (J-45488)
SBIA0354E
WBIA0604E
KBIA2462E

INTAKE MANIFOLD
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INSTALLATION
Installation is in the reverse order of removal.

Tighten the intake manifold bolts in numerical order as shown.

Install the EVAP canister purge control solenoid valve connector with it facing front of engine.

Tighten the electronic throttle control actuator bolts of the electric throttle control actuator equally and
diagonally in several steps.

After installation perform procedure in EM-18, "INSPECTION AFTER INSTALLATION" .

Install the water hose so that its overlap width for connection is between 27 mm (1.06 in) and 32 mm (1.26
in) (target: 27 mm 1.06 in).
Connecting Quick Connector of Fuel Tube
Install quick connector as follows (the steps are the same for quick connectors on both engine side and vehi-
cle side except for the quick connector cap).
1. Make sure no foreign substances are deposited in and around tube and quick connector, and they are not
damaged.
2. Thinly apply new engine oil around the fuel tube from tip end to the spool end.
3. Align center to insert quick connector straight into fuel tube.

Insert until the paint mark for engagement identification
(white) goes completely inside quick connector so that you
cannot see it from the straight side of the connected part. Use
a mirror to check this where it is not possible to view directly
from the straight side, such as quick connector on vehicle
side.

Insert fuel tube into quick connector until top spool is com-
pletely inside quick connector, and 2nd level spool exposes
right below quick connector on engine side.
CAUTION:

Hold A position in illustration when inserting fuel tube
into quick connector.

Carefully align center to avoid inclined insertion to pre-
vent damage to O-ring inside quick connector.

Insert until you hear a “click” sound and actually feel
the engagement.

To avoid misidentification of engagement with a similar
sound, be sure to perform the next step.
4. Pull quick connector by hand holding A position. Make sure it is completely engaged (connected) so that it
does not come out from fuel tube.
NOTE:
Recommended pulling force is 50 N (5.1 kg, 11.2 lb).
KBIA2462E
PBIC0017E
KBIA0272E

EM-18Revision: August 2007
INTAKE MANIFOLD
2004 QX56
5. Install the quick connector cap on the quick connector joint (on
engine side only).
6. Install the fuel hose and tube to hose clamps.
7. Refill the engine coolant. Refer to MA-13, "
REFILLING ENGINE
COOLANT" .
INSPECTION AFTER INSTALLATION

After installing fuel tubes, make sure there is no fuel leakage at connections in the following steps.
–Apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then check for
fuel leaks at connections.
–Start the engine and rev it up and check for fuel leaks at connections.

Perform procedures for “Throttle Valve Closed Position Learning” after finishing repairs. Refer to EC-44,
"Throttle Valve Closed Position Learning" .

If electric throttle control actuator is replaced, perform procedures for “Idle Air Volume Learning” after fin-
ishing repairs. Refer to EC-44, "
Idle Air Volume Learning" .
SBIA0354E

EXHAUST MANIFOLD AND THREE WAY CATALYST
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EXHAUST MANIFOLD AND THREE WAY CATALYSTPFP:14004
Removal and InstallationEBS00ILG
REMOVAL
WA RN ING:
Perform the work when the exhaust and cooling system have cooled sufficiently.
1. Remove air duct and resonator assembly. Refer to EM-14, "
REMOVAL" .
2. Drain engine coolant from the radiator. Refer to MA-12, "
DRAINING ENGINE COOLANT" .
3. Remove engine undercover using power tool.
4. Remove the radiator and radiator hoses. Refer to CO-10, "
RADIATOR" .
5. Remove the drive belts. Refer to EM-12, "
Removal" .
6. Remove the air fuel ratio A/F sensors (right bank, left bank), using the following steps.
a. Remove engine room cover using power tool. Refer to EM-11, "
REMOVAL" .
b. Remove harness connector of each air fuel ratio A/F sensors, and harness from bracket and middle
clamp.
1. Air fuel ratio (A/F) sensor 1 (bank 2) 2. Exhaust manifold cover (bank 2) 3. Exhaust manifold (bank 2)
4. Gaskets 5. Exhaust manifold (left bank 1) 6. Exhaust manifold cover (bank 1)
7. Air fuel ratio (A/F) sensor 1 (bank 1)
WBIA0466E

EM-20Revision: August 2007
EXHAUST MANIFOLD AND THREE WAY CATALYST
2004 QX56
c. Remove the air fuel ratio A/F sensors from both left and right
exhaust manifolds using Tool.
CAUTION:

Be careful not to damage the air fuel ratio A/F sensors

Discard any air fuel ratio A/F sensor which has been
dropped from a height of more than 0.5m (19.7 in) onto a
hard surface such as a concrete floor. Replace it with a
new one.
7. Remove the front cross bar.
8. Remove the exhaust manifold (left bank) using the following
steps.
a. Remove the exhaust front tube using power tool. Refer to EX-3,
"Removal and Installation" .
b. Remove the exhaust manifold cover.
c. Loosen the nuts in reverse order shown using power tool.
d. Remove the exhaust studs from positions 2, 4, 6, 8 and remove
the left exhaust manifold.
9. Remove the exhaust manifold (right bank) using the following
steps.
a. Remove the exhaust front tube using power tool. Refer to EX-3,
"Removal and Installation" .
b. Remove the oil level gauge guide. Refer to EM-22, "
OIL PAN
AND OIL STRAINER" .
c. Remove the exhaust manifold cover.
d. Loosen the nuts in reverse order shown using power tool.
e. Remove the exhaust studs from positions 2, 4, 6, 8 and remove the right exhaust manifold.
INSPECTION AFTER REMOVAL
Surface Distortion

Use a reliable straightedge and feeler gauge to check the flat-
ness of each exhaust manifold flange surface.

If flatness exceeds the limit, replace the exhaust manifold.
INSTALLATION
Installation is in the reverse order of removal.

Install a new exhaust manifold gasket with the top of the triangu-
lar up mark on it facing up and its coated face (gray side) toward
the exhaust manifold side.Tool number : — (J-44626)
WBIA0630E
KBIA2464E
Flatness limit : 0.3 mm (0.012 in)
KBIA2504E
KBIA2553E

EXHAUST MANIFOLD AND THREE WAY CATALYST
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Tighten the exhaust manifold nuts in the numerical order shown.
Then recheck the torque of the nuts.

Before installing new air fuel ration A/F sensors, clean the exhaust system threads using Tool and apply
anti-seize lubricant.
CAUTION:

Do not over tighten the air fuel ratio A/F sensors. Doing so may cause damage to the sensor,
resulting in the MIL coming on.
KBIA2464E
Tool number : ( — ) J-43879-12
: ( — ) J-43897-18

FUEL INJECTOR AND FUEL TUBE
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Removal and InstallationEBS00ILK
CAUTION:
Do not remove or disassemble parts unless instructed as shown.
REMOVAL
1. Remove the engine room cover using power tool. Refer to EM-11, "REMOVAL" .
2. Release the fuel pressure. Refer to EC-46, "
FUEL PRESSURE RELEASE" .
3. Disconnect the negative battery terminal.
4. Disconnect the fuel injector harness connectors.
5. Disconnect the fuel hose assembly from the fuel tubes (right bank and left bank).
CAUTION:

Plug the fuel hoses to prevent fuel from draining.

Do not separate the fuel connector and fuel hose.
6. Remove the fuel injectors with the fuel tube assembly.
1. Fuel tube (right bank) 2. Cap 3. Fuel damper
4. O-ring 5. O-ring (Blue) 6. Fuel injector
7. Clip 8. O-ring (Brown) 9. O-ring
10. Fuel hose assembly 11. Fuel tube (left bank)
KBIA2472E

EM-30Revision: August 2007
FUEL INJECTOR AND FUEL TUBE
2004 QX56
7. Remove the fuel injector from the fuel tube using the following
steps.
a. Spread open and remove the clip.
b. Remove the fuel injector from the fuel tube by pulling straight
out.
CAUTION:

Be careful with remaining fuel that may leak out from fuel
tube.

Do not damage injector nozzles during removal.

Do not bump or drop fuel injectors.

Do not disassemble fuel injectors.
8. Remove the fuel damper from each fuel tube.
INSTALLATION
1. Install the fuel damper to each fuel tube using the following
steps.
a. Apply engine oil to the new O-ring and set it into the cap of the
fuel tube.
CAUTION:

Handle O-ring with bare hands. Never wear gloves.

Lubricate new O-ring with new engine oil.

Do not clean O-ring with solvent.

Make sure that O-ring and its mating part are free of for-
eign material.

When installing O-ring, do not scratch it with tool or fin-
gernails.

Do not twist or stretch the O-ring.
b. Make sure that the backup spacer is in the O-ring connecting surface of the fuel damper.
NOTE:
The backup spacer is part of the fuel damper assembly.
c. Insert the fuel damper until it seats on the fuel tube.
CAUTION:

Insert straight, making sure that the axis is lined up.

Do not pressure-fit with excessive force.
d. Install the cap, and then tighten the bolts evenly.

After tightening the bolts, make sure that there is no gap between the cap and fuel tube.
2. Install new O-rings to the fuel injector paying attention to the items below.
CAUTION:

Upper and lower O-ring are different.
KBIA2506E
Reference value :130 N (13.3 kg, 29.2 lb)
KBIA2473E