Page 1

EDITION: AUGUST 2001 REVISION: APRIL 2004 PUBLICATION NO. SM2E-1C33U3

QUICK REFERENCE INDEX

All rights reserved. No part of this Service Manual may be reproduced or stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Nissan Motor Company Ltd., Tokyo, Japan.


FOREWORD This manual contains maintenance and repair procedures for the 2002 INFINITI I35. In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task. All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.

IMPORTANT SAFETY NOTICE The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle. The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately. Service varies with the procedures used, the skills of the technician and the tools and parts available. Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by INFINITI must first be completely satisfied that neither personal safety nor the vehicle’s safety will be jeopardized by the service method selected.


INCH TO METRIC CONVERSION TABLE

METRIC TO INCH CONVERSION TABLE

(Rounded-off for automotive inches mm .100 2.54 .110 2.79 .120 3.05 .130 3.30 .140 3.56 .150 3.81 .160 4.06 .170 4.32 .180 4.57 .190 4.83 .200 5.08 .210 5.33 .220 5.59 .230 5.84 .240 6.10 .250 6.35 .260 6.60 .270 6.86 .280 7.11 .290 7.37 .300 7.62 .310 7.87 .320 8.13 .330 8.38 .340 8.64 .350 8.89 .360 9.14 .370 9.40 .380 9.65 .390 9.91 .400 10.16 .410 10.41 .420 10.67 .430 10.92 .440 11.18 .450 11.43 .460 11.68 .470 11.94 .480 12.19 .490 12.45 .500 12.70 .510 12.95 .520 13.21 .530 13.46 .540 13.72 .550 13.97 .560 14.22 .570 14.48 .580 14.73 .590 14.99 .600 15.24

(Rounded-off for automotive use) mm inches mm 1 .0394 51 2 .079 52 3 .118 53 4 .157 54 5 .197 55 6 .236 56 7 .276 57 8 .315 58 9 .354 59 10 .394 60 11 .433 61 12 .472 62 13 .512 63 14 .551 64 15 .591 65 16 .630 66 17 .669 67 18 .709 68 19 .748 69 20 .787 70 21 .827 71 22 .866 72 23 .906 73 24 .945 74 25 .984 75 26 1.024 76 27 1.063 77 28 1.102 78 29 1.142 79 30 1.181 80 31 1.220 81 32 1.260 82 33 1.299 83 34 1.339 84 35 1.378 85 36 1.417 86 37 1.457 87 38 1.496 88 39 1.535 89 40 1.575 90 41 1.614 91 42 1.654 92 43 1.693 93 44 1.732 94 45 1.772 95 46 1.811 96 47 1.850 97 48 1.890 98 49 1.929 99 50 1.969 100

use) inches .610 .620 .630 .640 .650 .660 .670 .680 .690 .700 .710 .720 .730 .740 .750 .760 .770 .780 .790 .800 .810 .820 .830 .840 .850 .860 .870 .880 .890 .900 .910 .920 .930 .940 .950 .960 .970 .980 .990 1.000 2.000 3.000 4.000 5.000 6.000 7.000 8.000 9.000 10.000 20.000

mm 15.49 15.75 16.00 16.26 16.51 16.76 17.02 17.27 17.53 17.78 18.03 18.29 18.54 18.80 19.05 19.30 19.56 19.81 20.07 20.32 20.57 20.83 21.08 21.34 21.59 21.84 22.10 22.35 22.61 22.86 23.11 23.37 23.62 23.88 24.13 24.38 24.64 24.89 25.15 25.40 50.80 76.20 101.60 127.00 152.40 177.80 203.20 228.60 254.00 508.00

inches 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.031 3.071 3.110 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898 3.937


MAINTENANCE SECTION

MA

GI

EM LC EC

CONTENTS PRECAUTIONS ...............................................................2 Supplemental Restraint System (SRS) ″AIR BAG″ and ″SEAT BELT PRE-TENSIONER″...............2 PREPARATION ...............................................................3 Special Service Tool ....................................................3 Commercial Service Tool.............................................3 GENERAL MAINTENANCE ............................................4 PERIODIC MAINTENANCE ............................................6 Schedule 1...................................................................7 EMISSION CONTROL SYSTEM MAINTENANCE .........7 CHASSIS AND BODY MAINTENANCE ........................8 Schedule 2...................................................................9 EMISSION CONTROL SYSTEM MAINTENANCE .........9 CHASSIS AND BODY MAINTENANCE ......................10 RECOMMENDED FLUIDS AND LUBRICANTS...........11 Fluids and Lubricants ................................................11 SAE Viscosity Number ..............................................11 GASOLINE ENGINE OIL ..........................................11 Anti-freeze Coolant Mixture Ratio .............................12 ENGINE MAINTENANCE ..............................................13 Checking Drive Belts .................................................13 Changing Engine Coolant..........................................14 - DRAINING ENGINE COOLANT - ............................14 - REFILLING ENGINE COOLANT - ...........................15 - FLUSHING COOLING SYSTEM -............................15 Checking Fuel Lines ..................................................16 Changing Air Cleaner Filter .......................................16 VISCOUS PAPER TYPE ...........................................16 Changing Engine Oil..................................................16 Changing Oil Filter.....................................................17 Changing Spark Plugs...............................................18

Checking EVAP Vapor Lines .....................................19 CHASSIS AND BODY MAINTENANCE .......................20 Checking Exhaust System.........................................20 Checking A/T Fluid ....................................................20 Changing A/T Fluid ....................................................21 Balancing Wheels (Bonding Weight Type) ................21 REMOVAL ...............................................................21 WHEEL BALANCE ADJUSTMENT ............................21 Tire Rotation ..............................................................23 Checking Brake Fluid Level and Leaks.....................23 Checking Brake Lines and Cables ............................23 Checking Disc Brake .................................................23 ROTOR ...................................................................23 CALIPER .................................................................24 PAD ........................................................................24 Checking Steering Gear and Linkage .......................24 STEERING GEAR ....................................................24 STEERING LINKAGE ...............................................24 Checking Power Steering Fluid and Lines ................24 Axle and Suspension Parts .......................................25 Drive Shaft .................................................................25 Lubricating Locks, Hinges and Hood Latches...........25 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters...............................................26 SERVICE DATA AND SPECIFICATIONS (SDS) .........27 Engine Maintenance ..................................................27 BELT DEFLECTION AND TENSION ..........................27 SPARK PLUG ..........................................................27 Chassis and Body Maintenance................................27 WHEEL BALANCE ...................................................27

FE AT AX SU BR ST RS BT HA SC EL IDX


PRECAUTIONS Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

NHMA0034

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with a 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. The SRS system composition which is available to INFINITI I35 is as follows: I For a frontal collision The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, crash zone sensor, warning lamp, wiring harness and spiral cable. I For a side collision The Supplemental Restraint System consists of front side air bag module (located in the outer side of front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision). Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: I 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 should be performed by an authorized INFINITI dealer. I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the RS section. I 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 harness connector.

MA-2


PREPARATION Special Service Tool

Special Service Tool

NHMA0002

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

GI

Description

KV10115801 (J38956) Oil filter cap wrench

Removing oil filter a: 64.3 mm (2.531 in)

EM NT375

LC

Commercial Service Tool Tool name (Kent-Moore No.)

NHMA0003

EC

Description

Belt tension gauge (BT3373-F)

Checking drive belt tension

FE AT AX

AMA126

SU BR ST RS BT HA SC EL IDX

MA-3


NHMA0004

GENERAL MAINTENANCE General maintenance includes those items which should be checked during the normal day-to-day operation of the vehicle. They are essential if the vehicle is to continue operating properly. The owners can perform checks and inspections themselves or have their INFINITI dealers do them. OUTSIDE THE VEHICLE The maintenance items listed here should be performed from time to time, unless otherwise specified. Item Tires

Reference page Check the pressure with a gauge, including the spare, at least once a month and always prior to a long distance trips. Adjust to the specified pressure if necessary. Check carefully for damage, cuts or excessive wear.

Wheel nuts

When checking the tires, make sure no nuts are missing, and check for any loose nuts. Tighten if necessary.

Tire rotation

Tires should be rotated every 12,000 km (7,500 miles).

Wheel alignment and balance

MA-21, If the vehicle pulls to either side while driving on a straight and level road, or SU-7, “Preliminary Inspecif you detect uneven or abnormal tire wear, there may be a need for wheel tion” alignment. If the steering wheel or seat vibrates at normal highway speeds, SU-18, “Preliminary wheel balancing may be needed. Inspection”

Windshield wiper blades Doors and engine hood

Lamps

Check for cracks or wear if they do not wipe properly.

MA-23

Check that all doors and the engine hood operate smoothly as well as the trunk lid and back hatch. Also make sure that all latches lock securely. Lubricate if necessary. Make sure that the secondary latch keeps the hood from opening when the primary latch is released. When driving in areas using road salt or other corrosive materials, check lubrication frequently.

MA-25

Make sure that the headlamps, stop lamps, tail lamps, turn signal lamps, and other lamps are all operating properly and installed securely. Also check headlamp aim.

INSIDE THE VEHICLE The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the vehicle, etc. Item

Reference page

Warning lamps and chimes

Make sure that all warning lamps and chimes are operating properly.

Windshield wiper and washer

Check that the wipers and washer operate properly and that the wipers do not streak.

Windshield defroster

Check that the air comes out of the defroster outlets properly and in sufficient quantity when operating the heater or air conditioner.

Steering wheel

Check that it has the specified play. Be sure to check for changes in the steering condition, such as excessive play, hard steering or strange noises. Free play: Less than 35 mm (1.38 in)

Check seat position controls such as seat adjusters, seatback recliner, etc. to make sure they operate smoothly and that all latches lock securely in every position. Check that the head restrains move up and down smoothly and that the locks (if equipped) hold securely in all latched positions. Check that the latches lock securely for folding-down rear seatbacks.

Seat belts

Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters and retractors) operate properly and smoothly and are installed securely. Check the belt webbing for cuts, fraying, wear or damage.

MA-26, RS-9, “Seat Belt Inspection”

Accelerator pedal

Check the pedal for smooth operation and make sure the pedal does not catch or require uneven effort. Keep the floor mats away from the pedal.

Seats

MA-4


GENERAL MAINTENANCE Item

Reference page

Brakes

Check that the brake does not pull the vehicle to one side when applied.

Brake pedal and booster

Check the pedal for smooth operation and make sure it has the proper distance under it when depressed fully. Check the brake booster function. Be sure to keep floor mats away from the pedal.

BR-12, “Brake Pedal and Bracket” and BR-20, “Brake Booster”

Parking brake

Check that the lever has the proper travel and make sure that the vehicle is held securely on a fairly steep hill when only the parking brake is applied.

BR-35, “Parking Brake Control”

Automatic transaxle “Park” mechanism

Check that the lock release button on the selector lever operates properly and smoothly. On a fairly steep hill check that the vehicle is held securely with the selector lever in the “P” position without applying any brakes.

GI

EM LC

UNDER THE HOOD AND VEHICLE The maintenance items listed here should be checked periodically (e.g. each time you check the engine oil or refuel). Item

EC

Reference page

Windshield washer fluid

Check that there is adequate fluid in the tank.

Engine coolant level

Check the coolant level when the engine is cold.

Radiator and hoses

Check the front of the radiator and clean off any dirt, insects, leaves, etc., that may have accumulated. Make sure the hoses have no cracks, deformation, deterioration or loose connections.

— MA-15

FE AT

AX

Brake fluid level

Make sure that the brake fluid level is between the “MAX” and “MIN” lines on the reservoirs.

MA-23

Battery

Check the fluid level in each cell. It should be between the “MAX” and “MIN” lines. Vehicles operated in high temperatures or under severe conditions require frequent checks of the battery fluid level.

SU BR

Engine drive belts

Make sure that no belt is frayed, worn, cracked or oily.

MA-13

Engine oil level

Check the level on the dipstick after parking the vehicle on a level spot and turning off the engine.

MA-16

ST

Power steering fluid level and lines

Check the level on the dipstick with the engine off. Check the lines for improper attachment, leaks, cracks, etc.

MA-24

RS

Automatic transaxle fluid level

Check the level on the dipstick after putting the selector lever in “P” with the engine idling.

MA-20

Exhaust system

Make sure there are no loose supports, cracks or holes. If the sound of the exhaust seems unusual or there is a smell of exhaust fumes, immediately locate the trouble and correct it.

MA-20

Underbody

Fluid leaks

The underbody is frequently exposed to corrosive substances such as those used on icy roads or to control dust. It is very important to remove these substances, otherwise rust will form on the floor pan, frame, fuel lines and around the exhaust system. At the end of winter, the underbody should be thoroughly flushed with plain water, being careful to clean those areas where mud and dirt can easily accumulate.

Check under the vehicle for fuel, oil, water or other fluid leaks after the vehicle has been parked for a while. Water dripping from the air conditioner after use is normal. If you should notice any leaks or gasoline fumes are evident, check for the cause and correct it immediately.

MA-5

BT HA SC EL IDX


NHMA0005

PERIODIC MAINTENANCE Two different maintenance schedules are provided, and should be used, depending upon the conditions in which the vehicle is mainly operated. After 60,000 miles (96,000 km) or 48 months, continue the periodic maintenance at the same mileage/time intervals.

Schedule 1

Follow Periodic Maintenance Schedule 1 if the driving habits frequently include one or more of the following driving conditions: I Repeated short trips of less than 5 miles (8 km). I Repeated short trips of less than 10 miles (16 km) with outside temperatures remaining below freezing. I Operating in hot weather in stop-and-go “rush hour� traffic. I Extensive idling and/or low speed driving for long distances, such as police, taxi or door-to-door delivery use. I Driving in dusty conditions. I Driving on rough, muddy, or salt spread roads. I Towing a trailer, using a camper or a car-top carrier.

Emission Control System Maintenance

Follow Periodic Maintenance Schedule 2 if none of driving conditions shown in Schedule 1 apply to the driving habits.

Emission Control System Maintenance

MA-9

Chassis and Body Maintenance

MA-10

MA-7

Chassis and Body Maintenance MA-8

Schedule 2

MA-6


MAINTENANCE OPERATION

I = Inspect. Correct or replace if necessary.

[ ]: At the mileage intervals only

MAINTENANCE INTERVAL

Perform at number of miles, kilometers or months, whichever comes first.

Miles x 1,000 (km x 1,000) Months

Drive belts

NOTE (1)

Air cleaner filter

NOTE (2)

3.8 (6) 3

7.5 11.3 15 18.8 22.5 26.3 30 33.8 37.5 41.3 45 48.8 52.5 56.3 60 (12) (18) (24) (30) (36) (42) (48) (54) (60) (66) (72) (78) (84) (90) (96) 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48

Reference Section - Page or - Content Title MA-13

[R]

[R]

MA-16

EVAP vapor lines

I*

I*

MA-19

Fuel lines

I*

I*

MA-16

R*

MA-14

Fuel filter

NOTE (3)

Engine coolant

NOTE (4) R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

MA-16

Engine oil filter (Use part No. 1520831U00 or 15208 65F00 or equivalent.)

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

MA-17

MA-7

Spark plugs (PLATINUM-TIPPED type)

Replace every 105,000 miles (169,000 km).

Intake & exhaust valve clearance*

MA-18 EM-56, “Valve Clearance”

NOTE (5)

Schedule 1

Engine oil

PERIODIC MAINTENANCE

I*

EMISSION CONTROL SYSTEM MAINTENANCE

Abbreviations: R = Replace.

NOTE: (1) After 60,000 miles (96,000 km) or 48 months, inspect every 15,000 miles (24,000 km) or 12 months. (2) If operating mainly in dusty conditions, more frequent maintenance may be required. (3) Maintenance-free item. For service procedures, refer to FE section. (4) After 60,000 miles (96,000 km) or 48 months, replace every 30,000 miles (48,000 km) or 24 months. (5) If valve noise increases, inspect valve clearance. ★ Maintenance items and intervals with “*” are recommended by INFINITI for reliable vehicle operation. The owner need not perform such maintenance in order to maintain the emission warranty or manufacturer recall liability. Other maintenance items and intervals are required.

Schedule 1

NHMA0005S01

NHMA0005S0101

GI

EM

LC

EC

FE

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX


Perform at number of miles, kilometers or months, whichever comes first.

MAINTENANCE INTERVAL Miles x 1,000 (km x 1,000) Months

3.8 (6) 3

7.5 11.3 15 18.8 22.5 26.3 30 33.8 37.5 41.3 45 48.8 52.5 56.3 60 (12) (18) (24) (30) (36) (42) (48) (54) (60) (66) (72) (78) (84) (90) (96) 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48

Brake lines & cables

I

Brake pads & rotors Automatic transaxle fluid

I NOTE (1)

Steering gear & linkage, axle & suspension parts

I

I I

I

I

I I

I I

I

I

I

I I

I

I

I

MA-23

I

MA-23

I

MA-20

I

MA-24 MA-25 MA-4 MA-23

NOTE (2)

MA-8

Front drive shaft boots

I

I

I

I

I

I

I

I

MA-25

Exhaust system

I

I

I

I

I

I

I

I

MA-20

Ventilation air filter

I

R

I

R

I

R

I

R

HA-123, “Ventilation Air Filter”

NOTE: (1) If towing a trailer, using a camper or a car-top carrier, or driving on rough or muddy roads, change (not just inspect) oil at every 30,000 miles (48,000 km) or 24 months. (2) Refer to “Tire rotation” under the “General maintenance” heading earlier in this section.

PERIODIC MAINTENANCE

Tire rotation

I

I

Reference Section - Page or - Content Title

Schedule 1 (Cont’d)

MAINTENANCE OPERATION

CHASSIS AND BODY MAINTENANCE

Abbreviations: R = Replace. I = Inspect. Correct or replace if necessary. L = Lubricate.

NHMA0005S0102


MAINTENANCE OPERATION

I = Inspect. Correct or replace if necessary.

[ ]: At the mileage intervals only

MAINTENANCE INTERVAL

I*

MA-13

[R]

[R]

MA-16

EVAP vapor lines

I*

I*

MA-19

Fuel lines

I*

I*

MA-16

R*

MA-14

Miles x 1,000 (km x 1,000) Months

Perform at number of miles, kilometers or months, whichever comes first. Drive belts

7.5 (12) 6

15 (24) 12

22.5 (36) 18

30 (48) 24

37.5 (60) 30

45 (72) 36

52.5 (84) 42

NOTE (1)

Air cleaner filter

Fuel filter

NOTE (2)

Engine coolant

NOTE (3) R

R

R

R

R

R

R

R

MA-16

Engine oil filter (Use part No. 1520831U00 or 15208 65F00 or equivalent.)

R

R

R

R

R

R

R

R

MA-17

Spark plugs (PLATINUM-TIPPED type)

Replace every 105,000 miles (169,000 km).

MA-9

Intake & exhaust valve clearance*

MA-18 EM-56, “Valve Clearance”

NOTE (4)

NOTE: (1) After 60,000 miles (96,000 km) or 48 months, inspect every 15,000 miles (24,000 km) or 12 months. (2) Maintenance-free item. For service procedures, refer to FE section. (3) After 60,000 miles (96,000 km) or 48 months, replace every 30,000 miles (48,000 km) or 24 months. (4) If valve noise increases, inspect valve clearance. ★ Maintenance items and intervals with “*” are recommended by INFINITI for reliable vehicle operation. The owner need not perform such maintenance in order to maintain the emission warranty or manufacturer recall liability. Other maintenance items and intervals are required.

Schedule 2

Engine oil

PERIODIC MAINTENANCE

60 (96) 48

Reference Section - Page or - Content Title

EMISSION CONTROL SYSTEM MAINTENANCE

Abbreviations: R = Replace.

Schedule 2

NHMA0005S02

NHMA0005S0201

GI

EM

LC

EC

FE

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX


Perform at number of miles, kilometers or months, whichever comes first.

MAINTENANCE INTERVAL Miles x 1,000 (km x 1,000) Months

7.5 (12) 6

15 (24) 12

22.5 (36) 18

30 (48) 24

37.5 (60) 30

45 (72) 36

52.5 (84) 42

L = Lubricate.

60 (96) 48

Reference Section - Page or - Content Title

Brake lines & cables

I

I

I

I

MA-23

Brake pads & rotors

I

I

I

I

MA-23

Automatic transaxle fluid

I

I

I

I

MA-20

I

MA-24 MA-25

Steering gear & linkage, axle & suspension parts Tire rotation

MA-4 MA-23

NOTE (1) I

Exhaust system Ventilation air filter

I

I

I R

R

R

MA-10

I

MA-25

I

MA-20

R

HA-123, “Ventilation Air Filter”

NOTE: (1) Refer to “Tire rotation” under the “General maintenance” heading earlier in this section.

PERIODIC MAINTENANCE

Front drive shaft boots

I

Schedule 2 (Cont’d)

MAINTENANCE OPERATION

I = Inspect. Correct or replace if necessary.

CHASSIS AND BODY MAINTENANCE

Abbreviations: R = Replace.

NHMA0005S0202


NHMA0006

RECOMMENDED FLUIDS AND LUBRICANTS Fluids and Lubricants

Fluids and Lubricants

NHMA0006S01

Capacity (Approximate) Recommended Fluids/Lubricants US measure

Imp measure

Liter

4-1/4 qt

3-1/2 qt

4.0

3-7/8 qt

3-1/4 qt

3.7

5-1/4 qt

4-3/8 qt

5.0

8-1/8 qt

6-3/4 qt

7.7

Reservoir

7/8 qt

3/4 qt

0.8

RE4F04B

9 qt

7-1/2 qt

Power steering fluid

Brake fluid Multi-purpose grease

With oil filter change

Engine oil Drain and refill Without oil filter change Dry engine (engine overhaul) Cooling system Automatic transaxle fluid

With reservoir

GI I API Certification Mark*1 I API grade SG/SH, Energy Conserving I & II or API grade SJ, Energy Conserving*1 I ILSAC grade GF-I & GF-II*1

EM

Genuine Nissan Anti-freeze coolant or equivalent

LC

8.5

Nissan Matic “D” (Continental U.S. and Alaska) or Canada NISSAN Automatic Transmission Fluid*2

EC

Power Steering Fluid: Genuine NISSAN PSF II or equivalent*4

FE

Genuine Nissan Brake Fluid*3 or equivalent DOT 3 (US FMVSS No. 116)

AT

NLGI No. 2 (Lithium soap base)

*1: For further details, see “SAE Viscosity Number”. *2: DexronTM III/MerconTM or equivalent may also be used. Outside the continental United States and Alaska contact an INFINITI dealership for more information regarding suitable fluids, including recommended brand(s) of DexronTM III/MerconTM Automatic Transmission Fluid. *3: Available in mainland U.S.A. through your INFINITI dealer. *4: Genuine Nissan PSF, Canada NISSAN Automatic Transmission Fluid, DexronTM III/MerconTM, or equivalent ATF may also be used.

AX SU BR ST

SAE Viscosity Number GASOLINE ENGINE OIL

RS NHMA0006S02 NHMA0006S0203

SAE 5W-30 viscosity oil is preferred for all temperatures. SAE 10W-30 and 10W-40 viscosity oil may be used if the ambient temperature is above −18°C (0°F).

BT HA SC EL IDX

MMA117AA

MA-11


RECOMMENDED FLUIDS AND LUBRICANTS Anti-freeze Coolant Mixture Ratio

Anti-freeze Coolant Mixture Ratio

SMA947CA

NHMA0006S03

The engine cooling system is filled at the factory with a high-quality, year-round, anti-freeze coolant solution. The anti-freeze solution contains rust and corrosion inhibitors. Therefore, additional cooling system additives are not necessary. CAUTION: When adding or replacing coolant, be sure to use only Genuine Nissan anti-freeze coolant or equivalent with the proper mixture ratio of 50% anti-freeze and 50% demineralized water/ distilled water. Other types of coolant solutions may damage your cooling system.

MA-12


ENGINE MAINTENANCE Checking Drive Belts

Checking Drive Belts

NHMA0007

GI

EM LC EC FE AT AX SU SMA172D

BR 1.

Inspect belts for cracks, fraying, wear and oil. If necessary, replace. 2. Inspect drive belt deflection or tension at a point on the belt midway between pulleys. I Check belt tension using belt tension gauge (BT 3373-F or equivalent). I Inspect drive belt deflection or tension when engine is cold. Adjust if belt deflection exceeds the limit or if belt tension is not within specifications. I Drive belt tension can also be checked at other points on the belts. Belt deflection and tension:

RS BT HA SC

Deflection adjustment Unit: mm (in)

Tension adjustment*1 Unit: N (kg, lb)

Used belt

Used belt New belt

Limit

After adjustment

Alternator and air conditioner compressor

7 (0.28)

4.2 - 4.6 (0.165 - 0.181)

Power steering oil pump

11 (0.43)

7.3 - 8 (0.287 - 0.315)

Applied pushing force

ST

New belt Limit

After adjustment

3.7 - 4.1 (0.146 - 0.161)

294 (30, 66)

730 - 818 (74.5 - 83.5, 164 - 184)

838 - 926 (85.45 - 94.43, 188.4 - 208.2)

6.5 - 7.2 (0.256 - 0.283)

196 (20, 44)

495 - 583 (50.5 - 59.5, 111 - 131)

603 - 691 (61.5 - 70.5, 136 - 155)

98 N (10 kg, 22 lb)

—

*1: If the belt tension gauge cannot be installed at check points shown, check drive belt tension at a different location on the belt.

MA-13

EL IDX


ENGINE MAINTENANCE Changing Engine Coolant

Changing Engine Coolant

NHMA0008

WARNING: To avoid the danger of being scalded, never change the coolant when the engine is hot.

— DRAINING ENGINE COOLANT — 1. a. SMA032D

b. 2. I

NHMA0008S01

Set air conditioning system as follows to prevent coolant from remaining in the system. Turn ignition switch ON and set temperature controller to maximum hot position. Wait 10 seconds before turning ignition switch OFF. Open radiator drain plug at the bottom of radiator, and remove radiator cap. Be careful not to allow coolant to contact drive belts.

SMA033D

When draining all the coolant in the system, also perform the two following steps. 1) Remove drain plugs on both sides of cylinder block. 2) Check drained coolant for contaminants such as rust, corrosion or discoloration. If contaminated flush engine cooling system, refer to “FLUSHING COOLING SYSTEM”, MA-15.

SMA191D

MA-14


ENGINE MAINTENANCE Changing Engine Coolant (Cont’d)

— REFILLING ENGINE COOLANT — 1. 2. I

NHMA0008S02

Install reservoir tank if removed, and radiator drain plug. Close and tighten cylinder block drain plugs securely if removed. Apply sealant to the thread of cylinder block drain plugs. Use Genuine Thread Sealant or equivalent. Refer to GI-52. : 60 - 66 N·m (6.1 - 6.7 kg-m, 44 - 48 ft-lb) Left side : 18 - 22 N·m (1.8 - 2.2 kg-m, 13 - 16 ft-lb) Right side

GI

EM 3. I

SMA182B

SMA412B

Fill radiator and reservoir tank to specified level. Use genuine Nissan anti-freeze coolant or equivalent mixed with water (distilled or demineralized). Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-11. Engine coolant capacity (With reservoir tank): 7.7 (8-1/8 US qt, 6-3/4 Imp qt) Reservoir tank capacity: 0.8 (7/8 US qt, 3/4 Imp qt) I Pour coolant through coolant filler neck slowly to allow air in system to escape. 4. Warm up engine to normal operating temperature with radiator cap installed. 5. Run engine at 2,500 rpm for 10 seconds and return to idle speed. I Repeat two or three times. Watch coolant temperature gauge so as not to overheat the engine. 6. Stop engine and cool it down. I Cool down using a fan to reduce the time. I If necessary, refill radiator up to filler neck with coolant. 7. Refill reservoir tank to MAX level line with coolant. 8. Repeat steps 4 through 7 two or more times with radiator cap installed until coolant level no longer drops. 9. Check cooling system for leaks with engine running. 10. Warm up engine, and check for sound of coolant flow while running engine from idle up to 3,000 rpm with heater temperature controller set at several positions between COOL and WARM. I Sound may be noticeable at heater water cock. 11. If sound is heard, bleed air from cooling system by repeating steps 4 through 7 until coolant level no longer drops. I Clean excess coolant from engine.

— FLUSHING COOLING SYSTEM — 1. 2. 3. 4. 5. 6.

NHMA0008S03

Fill radiator and reservoir tank with water and reinstall radiator cap. Run engine and warm it up to normal operating temperature. Rev engine two or three times under no-load. Stop engine and wait until it cools down. Drain water. Repeat steps 1 through 5 until clear water begins to drain from radiator.

MA-15

LC EC FE AT AX SU BR ST RS BT HA SC EL IDX


ENGINE MAINTENANCE Checking Fuel Lines

Checking Fuel Lines

NHMA0009

Inspect fuel lines and tank for improper attachment, leaks, cracks, damage, loose connections, chafing or deterioration. If necessary, repair or replace faulty parts.

SMA803A

CAUTION: Tighten high-pressure rubber hose clamp so that clamp end is 3 mm (0.12 in) from hose end. Tightening torque specifications are the same for all rubber hose clamps. Ensure that screw does not contact adjacent parts.

MMA104A

Changing Air Cleaner Filter VISCOUS PAPER TYPE

NHMA0011 NHMA0011S01

The viscous paper type filter does not need cleaning.

SMA037D

Changing Engine Oil

SMA038D

NHMA0012

WARNING: I Be careful not to burn yourself, as the engine oil is hot. I Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible. 1. Warm up engine, and check for oil leakage from engine components. 2. Stop engine and wait more than 10 minutes. 3. Remove drain plug and oil filler cap. 4. Drain oil and refill with new engine oil. Oil specification and viscosity: I API Certification Mark I API grade SG/SH, Energy Conserving I & II or API grade SJ, Energy Conserving I ILSAC grade GF-I & GF-II I Refer to “RECOMMENDED FLUIDS AND LUBRICANTS�, MA-11. Oil capacity (Approximate):

MA-16


ENGINE MAINTENANCE Changing Engine Oil (Cont’d) Unit: liter (US qt, Imp qt) With oil filter change

4.0 (4-1/4, 3-1/2)

Drain and refill Without oil filter change

3.7 (3-7/8, 3-1/4)

Dry engine (engine overhaul)

5.0 (5-1/4, 4-3/8)

GI

CAUTION: I Be sure to clean drain plug and install with new washer. Oil pan drain plug: : 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb) I

I 5. 6. 7.

The refill capacity depends on the oil temperature and drain time. Use these specifications for reference only. Always use the dipstick to determine when the proper amount of oil is in the engine. Never pull out level gauge while filling engine oil. Warm up engine and check area around drain plug and oil filter for oil leakage. Stop engine and wait more than 10 minutes. Check oil level.

EM LC EC FE AT

SMA954C

Changing Oil Filter

AX NHMA0013

1.

The oil filter is a small full-flow cartridge type and is provided with a relief valve. Refer to LC-8, “Oil Filter”. 2. Remove oil filter with Tool or suitable tool. WARNING: Be careful not to burn yourself, as the engine and the engine oil are hot. SMA039D

3.

Clean oil filter mounting surface on oil cooler. Coat rubber seal of new oil filter with engine oil.

SU BR ST RS BT HA SC EL

SMA010

4. 5.

Screw in the oil filter until a slight resistance is felt, then tighten additionally 2/3 turn. Add engine oil. Oil filter: : 14.7 - 20.5 N·m (1.5 - 2.1 kg-m, 11 - 15 ft-lb) Refer to “Changing Engine Oil”, MA-16.

SMA229B

MA-17

IDX


ENGINE MAINTENANCE Changing Spark Plugs

Changing Spark Plugs 1. 2. 3.

NHMA0014

Remove intake manifold upper and lower, collectors. Disconnect ignition coil harness connectors. Loosen ignition coil fixing bolts and pull out coil from rocker cover.

SMA153D

4. Remove spark plugs with suitable spark plug wrench. Spark plug (Platinum-tipped type): Make

SEM294A

NGK

Standard type

PLFR5A-11

Hot type

PLFR4A-11

Cold type

PLFR6A-11

Use standard type spark plug for normal condition. The hot type spark plug is suitable when fouling may occur with the standard type spark plug such as: I frequent engine starts I low ambient temperatures The cold type spark plug is suitable when spark knock may occur with the standard type spark plug such as: I extended highway driving I frequent high engine revolution Gap (Nominal): 1.1 mm (0.043 in) : 20 - 29 N¡m (2.0 - 3.0 kg-m, 14 - 22 ft-lb)

I I

Do not use a wire brush for cleaning. If plug tip is covered with carbon, spark plug cleaner may be used. Cleaner air pressure: Less than 588 kPa (6 kg/cm2, 85 psi) Cleaning time: Less than 20 seconds

I

Checking and adjusting plug gap is not required between removals. Install in the reverse order of removal.

SMA773C

5.

SMA806CA

MA-18


ENGINE MAINTENANCE Checking EVAP Vapor Lines

Checking EVAP Vapor Lines

NHMA0015

1.

Visually inspect EVAP vapor lines for improper attachment and for cracks, damage, loose connections, chafing and deterioration. 2. Inspect fuel tank filler cap vacuum relief valve for clogging, sticking, etc. Refer to EC-36, “Evaporative Emission System”.

GI

EM LC EC FE AT SMA142D

AX SU BR ST RS BT HA SC EL IDX

MA-19


CHASSIS AND BODY MAINTENANCE Checking Exhaust System

Checking Exhaust System

NHMA0016

Check exhaust pipes, muffler and mounting for improper attachment, leaks, cracks, damage, chafing or deterioration.

SMA211A

Checking A/T Fluid

NHMA0020

1. 2. 3.

SMA053D

SMA051D

Warm up engine. Check for fluid leakage. Before driving, fluid level can be checked at fluid temperatures of 30 to 50°C (86 to 122°F) using “COLD” range on A/T fluid level gauge. a. Park vehicle on level surface and set parking brake. b. Start engine and move selector lever through each gear position. Leave selector lever in “P” position. c. Check fluid level with engine idling. d. Remove A/T fluid level gauge and wipe clean with lint-free paper. e. Re-insert A/T fluid level gauge into charging pipe as far as it will go. f. Remove A/T fluid level gauge and note reading. If reading is at low side of range, add fluid to the charging pipe. Do not overfill. 4. Drive vehicle for approximately 5 minutes in urban areas. 5. Re-check fluid level at fluid temperatures of 50 to 80°C (122 to 176°F) using “HOT” range on A/T fluid level gauge. CAUTION: Firmly fix the A/T fluid level gauge to the A/T fluid charging pipe using a stopper attached.

6. I I

Check fluid condition. If fluid is very dark or smells burned, refer to AT section for checking operation of A/T. Flush cooling system after repair of A/T. If A/T fluid contains frictional material (clutches, bands, etc.), replace radiator and flush cooler line using cleaning solvent and compressed air after repair of A/T. Refer to LC-21, “Radiator”.

SMA853B

MA-20


CHASSIS AND BODY MAINTENANCE Changing A/T Fluid

Changing A/T Fluid 1. 2. 3.

SMA052D

4. 5.

NHMA0021

Warm up A/T fluid. Stop engine. Drain A/T fluid from drain plug and refill with new A/T fluid. Always refill same volume with drained fluid. Fluid grade: Nissan Matic “D” (Continental U.S. and Alaska) or Canada NISSAN Automatic Transmission Fluid Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-11. Fluid capacity (With torque converter): RE4F04B 8.5 (9 US qt, 7-1/2 Imp qt) Drain plug: : 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb) Run engine at idle speed for five minutes. Check fluid level and condition. Refer to “Checking A/T Fluid”. If fluid is still dirty, repeat step 2. through 5.

GI

EM LC EC FE AT

Balancing Wheels (Bonding Weight Type) REMOVAL

AX NHMA0022 NHMA0022S01

1. Remove inner and outer balance weights from the road wheel. CAUTION: Be careful not to scratch the road wheel during removal procedures. 2. Using releasing agent, remove double-faced adhesive tape from the road wheel. CAUTION: I Be careful not to scratch the road wheel during removal. I After removing double-faced adhesive tape, wipe clean traces of releasing agent from the road wheel.

SU

WHEEL BALANCE ADJUSTMENT

BT

I

NHMA0022S02

If a tire balance machine has adhesion balance weight mode settings and drive-in weight mode setting, select and adjust a drive-in weight mode suitable for road wheels. 1. Set road wheel on wheel balancer using the center hole as a guide. Start the tire balance machine. 2. When inner and outer unbalance values are shown on the wheel balancer indicator, multiply outer unbalance value by 1.6 to determine balance weight that should be used. Select the outer balance weight with a value closest to the calculated value above and install it to the designated outer position of, or at the designated angle in relation to the road wheel. CAUTION: I Do not install the inner balance weight before installing the outer balance weight. I Before installing the balance weight, be sure to clean the mating surface of the road wheel.

MA-21

BR ST RS

HA SC EL IDX


CHASSIS AND BODY MAINTENANCE Balancing Wheels (Bonding Weight Type) (Cont’d)

Indicated unbalance value × 1.6 = balance weight to be installed Calculation example: 23 g (0.81 oz) × 1.6 = 38.33 g (1.35 oz) = 40 g (1.41 oz) balance weight (closer to calculated balance weight value) Note that balance weight value must be closer to the calculated balance weight value. Example: 37.4 = 35 g (1.23 oz) 37.5 = 40 g (1.41 oz) SMA054D

a. b.

Install balance weight in the position shown in the figure at left. When installing balance weight to road wheels, set it into the grooved area on the inner wall of the road wheel as shown in the figure at left so that the balance weight center is aligned with the wheel balancer indication position (angle). CAUTION: I Always use genuine Nissan adhesion balance weights. I Balance weights are unreusable; always replace with new ones. I Do not install more than three sheets of balance weight.

SMA055D

c.

SMA056D

If calculated balance weight value exceeds 50 g (1.76 oz), install two balance weight sheets in line with each other (as shown in the figure at left). CAUTION: Do not install one balance weight sheet on top of another. 3. Start wheel balancer again. 4. Install drive-in balance weight on inner side of road wheel in the wheel balancer indication position (angle). CAUTION: Do not install more than two balance weights. 5. Start wheel balancer. Make sure that inner and outer residual unbalance values are 10 g (0.35 oz) each or below. I If either residual unbalance value exceeds 10 g (0.35 oz), repeat installation procedures. Wheel balance (Maximum allowable unbalance): Maximum allowable unbalance

MA-22

Dynamic (At rim flange) Static

10 g (0.35 oz) (one side) 20 g (0.71 oz)


CHASSIS AND BODY MAINTENANCE Tire Rotation

Tire Rotation

NHMA0023

Do not include the T-type spare tire when rotating the tires. Wheel nuts: : 98 - 118 N·m (10.0 - 12.0 kg-m, 72 - 87 ft-lb)

GI

EM SMA829C

Checking Brake Fluid Level and Leaks

NHMA0024

LC

If fluid level is extremely low, check brake system for leaks.

EC FE AT AX

Checking Brake Lines and Cables

NHMA0025

Check brake fluid lines and parking brake cables for improper attachment, leaks, chafing, abrasions, deterioration, etc.

SU BR ST

SBR389C

RS

Checking Disc Brake

NHMA0026

ROTOR

NHMA0026S01

Check condition, wear, and damage.

BT

Unit: mm (in) Front

Rear

Brake model

CLZ25VD

CL9HE

Standard thickness

24.0 (0.94)

9 (0.35)

0.07 (0.0028)

0.07 (0.0028)

22.0 (0.87)

8.0 (0.315)

Maximum runout Minimum thickness (Wear limit)

HA SC EL IDX

MA-23


CHASSIS AND BODY MAINTENANCE Checking Disc Brake (Cont’d)

CALIPER

NHMA0026S02

Check for leakage.

SMA922A

PAD

NHMA0026S03

Check for wear or damage. Unit: mm (in) Brake model

CLZ25VD

CL9HE

Standard thickness

9.5 (0.374)

10 (0.39)

Minimum thickness (Wear limit)

2.0 (0.079)

1.5 (0.059)

BRA0010D

Checking Steering Gear and Linkage STEERING GEAR I I

NHMA0027 NHMA0027S01

Check gear housing and boots for looseness, damage and grease leakage. Check connection with steering column for looseness.

STEERING LINKAGE

NHMA0027S02

Check ball joint, dust cover and other component parts for looseness, wear, damage and grease leakage. SLIA0014E

Checking Power Steering Fluid and Lines

NHMA0028

Check fluid level in reservoir tank with engine off. Use “HOT” range at fluid temperatures of 50 to 80°C (122 to 176°F) or “COLD” range at fluid temperatures of 0 to 30°C (32 to 86°F). CAUTION: I Do not overfill. I Recommended fluid is Genuine NISSAN PSF II or equivalent. Refer to “RECOMMENDED FLUIDS AND LUBRICANTS”, MA-11. SST850C

I I

Check lines for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration. Check rack boots for accumulation of power steering fluid.

SST851C

MA-24


CHASSIS AND BODY MAINTENANCE Axle and Suspension Parts

Axle and Suspension Parts

NHMA0035

Check front and rear axle and suspension parts for excessive play, cracks, wear, or other damage. I Shake each wheel to check for excessive play. I Rotate each wheel to check for abnormal noise. I Check axle and suspension nuts and bolts for looseness. I Check strut (shock absorber) for oil leakage or other damage. I Check suspension ball joint for grease leakage and ball joint dust cover for cracks or other damage.

GI

EM

SMA525A

LC EC FE AT SFA392B

Drive Shaft

AX NHMA0036

Check boot and drive shaft for cracks, wear, damage and grease leakage.

SU BR ST

SFA108A

Lubricating Locks, Hinges and Hood Latches

RS

NHMA0029

BT HA SC EL IDX

SMA049D

MA-25


CHASSIS AND BODY MAINTENANCE Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters

Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters

NHMA0030

SMA042DA

MA-26


SERVICE DATA AND SPECIFICATIONS (SDS) Engine Maintenance

Engine Maintenance BELT DEFLECTION AND TENSION

NHMA0031

Deflection adjustment Unit: mm (in)

Tension adjustment*1 Unit: N (kg, lb)

Used belt

GI

Used belt New belt

Limit

After adjustment

Alternator and air conditioner compressor

7 (0.28)

4.2 - 4.6 (0.165 - 0.181)

Power steering oil pump

11 (0.43)

7.3 - 8 (0.287 - 0.315)

Applied pushing force

New belt Limit

After adjustment

3.7 - 4.1 (0.146 - 0.161)

294 (30, 66)

730 - 818 (74.5 - 83.5, 164 - 184)

838 - 926 (85.45 - 94.43, 188.4 - 208.2)

EM

6.5 - 7.2 (0.256 - 0.283)

196 (20, 44)

495 - 583 (50.5 - 59.5, 111 - 131)

603 - 691 (61.5 - 70.5, 136 - 155)

LC

98 N (10 kg, 22 lb)

—

EC

*1: If the belt tension gauge cannot be installed at check points shown, check drive belt tension at a different location on the belt.

FE

SPARK PLUG

NHMA0032

Platinum-tipped type Make

AT

NGK Standard

PLFR5A-11

Hot

PLFR4A-11

Cold

PLFR6A-11

AX

Type Plug gap (Nominal)

SU

1.1 mm (0.043 in)

Chassis and Body Maintenance WHEEL BALANCE

BR NHMA0033

Dynamic (At rim flange)

10 g (0.35 oz) (one side)

Maximum allowable unbalance Static

ST

20 g (0.71 oz)

RS BT HA SC EL IDX

MA-27


NOTES


ENGINE MECHANICAL SECTION

EM

GI MA

LC EC

CONTENTS PRECAUTIONS ...............................................................3 Parts Requiring Angular Tightening.............................3 Liquid Gasket Application Procedure ..........................3 PREPARATION ...............................................................4 Special Service Tools ..................................................4 Commercial Service Tools ...........................................6 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................................7 NVH Troubleshooting - Engine Noise .........................8 OUTER COMPONENT PARTS .......................................9 Removal and Installation .............................................9 TIGHTENING PROCEDURES ...................................11 MEASUREMENT OF COMPRESSION PRESSURE ....13 OIL PAN.........................................................................14 Components...............................................................14 Removal.....................................................................14 Installation..................................................................17 TIMING CHAIN ..............................................................21 Components...............................................................21 POSITION FOR APPLYING LIQUID GASKET ............23 Removal.....................................................................24 Inspection...................................................................31 Installation..................................................................32 OIL SEAL.......................................................................39 Replacement..............................................................39 VALVE OIL SEAL .....................................................39 FRONT OIL SEAL ....................................................40 REAR OIL SEAL ......................................................41 CYLINDER HEAD..........................................................42 Components...............................................................42 Removal.....................................................................43 Disassembly...............................................................45 Inspection...................................................................46 CYLINDER HEAD DISTORTION ...............................46 CAMSHAFT VISUAL CHECK ....................................46 CAMSHAFT RUNOUT ..............................................46 CAMSHAFT CAM HEIGHT .......................................46 CAMSHAFT JOURNAL CLEARANCE ........................47 CAMSHAFT END PLAY............................................47 CAMSHAFT SPROCKET RUNOUT ...........................47

VALVE GUIDE CLEARANCE ....................................48 VALVE GUIDE REPLACEMENT ................................48 VALVE SEATS .........................................................49 REPLACING VALVE SEAT FOR SERVICE PARTS ....49 VALVE DIMENSIONS ...............................................50 VALVE SPRING .......................................................50 VALVE LIFTER ........................................................50

Assembly ...................................................................51 Installation..................................................................51 Valve Clearance.........................................................56 CHECKING .............................................................56 ADJUSTING ............................................................58 ENGINE ASSEMBLY.....................................................60 Removal and Installation ...........................................60 REMOVAL ...............................................................61 INSTALLATION........................................................63 CYLINDER BLOCK .......................................................64 Components...............................................................64 Removal and Installation ...........................................65 Disassembly...............................................................65 PISTON, CRANKSHAFT AND OIL JET ......................65 Inspection...................................................................66 PISTON AND PISTON PIN CLEARANCE ..................66 PISTON RING SIDE CLEARANCE ............................66 PISTON RING END GAP..........................................66 CONNECTING ROD BEND AND TORSION ...............67 CYLINDER BLOCK DISTORTION AND WEAR ...........67 PISTON-TO-BORE CLEARANCE ..............................68 CRANKSHAFT.........................................................69 BEARING CLEARANCE ...........................................69 CONNECTING ROD BUSHING CLEARANCE (SMALL END) ..........................................................72 DRIVE PLATE RUNOUT ..........................................73

Assembly ...................................................................73 PISTON ..................................................................73 OIL JET ..................................................................74 CRANKSHAFT.........................................................74 KNOCK SENSOR ....................................................76 REPLACEMENT OF PILOT CONVERTER .................77 DRIVE PLATE .........................................................77 SERVICE DATA AND SPECIFICATIONS (SDS) .........78

FE AT AX SU BR ST RS BT HA SC EL IDX


CONTENTS General Specifications...............................................78 Compression Pressure ..............................................78 Cylinder Head ............................................................78 Valve ..........................................................................79 VALVE ....................................................................79 VALVE CLEARANCE................................................79 VALVE SPRING .......................................................79 VALVE LIFTER ........................................................79 VALVE GUIDE .........................................................81 Valve Seat..................................................................82 Camshaft and Camshaft Bearing ..............................83 Cylinder Block............................................................84 Piston, Piston Ring and Piston Pin ...........................85

EM-2

(Cont’d) AVAILABLE PISTON ................................................85 PISTON RING .........................................................86 PISTON PIN ............................................................86

Connecting Rod .........................................................86 Crankshaft..................................................................87 Available Main Bearing..............................................88 UNDERSIZE ............................................................88 Available Connecting Rod Bearing............................89 CONNECTING ROD BEARING .................................89 UNDERSIZE ............................................................89 Miscellaneous Components.......................................89 BEARING CLEARANCE ...........................................89


PRECAUTIONS Parts Requiring Angular Tightening

Parts Requiring Angular Tightening I a) b) c) d) I I I

NHEM0001

Use an angle wrench for the final tightening of the following engine parts: Cylinder head bolts Main bearing cap bolts Connecting rod cap nuts Crankshaft pulley bolt Do not use a torque value for final tightening. The torque value for these parts are for a preliminary step. Ensure thread and seat surfaces are clean and coated with engine oil.

GI MA

LC EC FE AT

Liquid Gasket Application Procedure 1.

2. I

AX NHEM0002

Use a scraper to remove all traces of old liquid gasket from mating surfaces and grooves. Also, completely clean any oil from these areas. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine RTV silicone sealant or equivalent. Refer to GI-52.) Be sure liquid gasket diameter is as specified in this manual.

SEM164F

3. 4. 5.

Apply liquid gasket around the inner side of bolt holes (unless otherwise specified). Assembly should be done within 5 minutes after coating. Wait at least 30 minutes before refilling engine oil and engine coolant.

SU BR ST RS BT HA SC EL

AEM080

IDX

EM-3


PREPARATION Special Service Tools

Special Service Tools

NHEM0003

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name

Description

ST0501S000 ( — ) Engine stand assembly 1 ST05011000 ( — ) Engine stand 2 ST05012000 ( — ) Base

Disassembling and assembling

NT042

KV10106500 ( — ) Engine stand shaft

NT028

KV10117000 (J41262) Engine sub-attachment

KV10117000 has been replaced with KV10117001 (KV10117000 is no longer in production, but it is usable).

NT373

KV10117001 ( — ) Engine sub-attachment

Installing on the cylinder block

NT372

ST10120000 (J24239-01) Cylinder head bolt wrench

Loosening and tightening cylinder head bolt a: 13 (0.51) dia. b: 12 (0.47) c: 10 (0.39) Unit: mm (in)

NT583

KV10116200 (J26336-A) Valve spring compressor 1 KV10115900 (J26336-20) Attachment

Disassembling valve mechanism

NT022

EM-4


PREPARATION Special Service Tools (Cont’d) Tool number (Kent-Moore No.) Tool name

Description

(J39386) Valve oil seal drift

Installing valve oil seal

GI MA

NT024

EM03470000 (J8037) Piston ring compressor

Installing piston assembly into cylinder bore

LC EC

NT044

ST16610001 (J23907) Pilot bushing puller

Removing crankshaft pilot bushing

FE AT

NT045

KV10111100 (J37228) Seal cutter

Removing steel oil pan and rear timing chain case

AX SU NT046

WS39930000 ( — Tube presser

Pressing the tube of liquid gasket )

BR ST

NT052

KV10112100 (BT8653-A) Angle wrench

Tightening bolts for bearing cap, cylinder head, etc.

RS BT HA

NT014

KV10117100 (J3647-A) Heated oxygen sensor wrench

Loosening or tightening heated oxygen sensor For 22 mm (0.87 in) hexagon nut

SC EL IDX

NT379

EM-5


PREPARATION Commercial Service Tools

Commercial Service Tools Tool number (Kent-Moore No.) Tool name

NHEM0004

Description

Spark plug wrench

Removing and installing spark plug

NT047

Valve seat cutter set

Finishing valve seat dimensions

NT048

Piston ring expander

Removing and installing piston ring

NT030

Valve guide drift

Removing and installing valve guide Intake & Exhaust: a = 9.5 mm (0.374 in) dia. b = 5.5 mm (0.217 in) dia. NT015

Valve guide reamer

Reaming valve guide 1 or hole for oversize valve guide 2 Intake & Exhaust: d1 = 6.0 mm (0.236 in) dia. d2 = 10.2 mm (0.402 in) dia. NT016

(J-43897-18) (J-43897-12) Oxygen sensor thread cleaner

Reconditioning the exhaust system threads before installing a new oxygen sensor (Use with anti-seize lubricant shown below.) a = J-43897-18 (18 mm dia.) for zirconia oxygen sensor b = J-43897-12 (12 mm dia.) for titania oxygen sensor

AEM488

Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A907)

Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads

AEM489

EM-6


NHEM0005

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

GI MA

LC EC FE AT AX SU BR ST RS BT HA SC EL IDX

SEM706G

EM-7


NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting — Engine Noise

NVH Troubleshooting — Engine Noise

NHEM0005S01

Use the chart below to help you find the cause of the symptom. 1. Locate the area where noise occurs. 2. Confirm the type of noise. 3. Specify the operating condition of engine. 4. Check specified noise source. If necessary, repair or replace these parts. Operating condition of engine Location of noise Top of engine Rocker cover Cylinder head

Type of noise

Before After When warm-up warm-up starting

When racing

While driving

Source of noise

Check item

Reference page

Ticking or clicking

C

A

A

B

Tappet noise

Valve clearance

Rattle

C

A

A

B

C

Camshaft bearing noise

Camshaft journal clearEM-47, ance EM-46 Camshaft runout

Slap or knock

A

B

B

Piston pin noise

Piston and piston pin clearance Connecting rod bushing clearance

EM-66, EM-72

A

Piston-to-bore clearance Piston ring side clearPiston slap ance noise Piston ring end gap Connecting rod bend and torsion

EM-68, EM-66, EM-66, EM-67

Crankshaft Slap or pulley rap Cylinder block (Side of engine) Oil pan

Front of engine Timing chain cover

When idling

A

B

B

EM-56

Connecting rod bushing clearance (Small EM-72, end) EM-71 Connecting rod bearing clearance (Big end)

Knock

A

B

C

B

B

B

Connecting rod bearing noise

Knock

A

B

A

B

C

Main bearing oil clearMain bearance ing noise Crankshaft runout

EM-69, EM-69

B

Timing chain and chain tensioner noise

EM-31, EM-21

Tapping or ticking

A

A

B

B

Timing chain cracks and wear Timing chain tensioner operation

Squeaking or fizzing

A

B

B

C

Drive belts (Sticking Drive belts deflection or slipping)

Creaking

A

B

A

B

A

B

Drive belts Idler pulley bearing (Slipping) operation

Front of engine

Squall Creak

A: Closely related

A

B: Related

B

C: Sometimes related

B

A

—: Not related

EM-8

B

Water pump noise

Water pump operation

MA section (“Checking Drive Belts”, “ENGINE MAINTENANCE”) LC section (“Water Pump Inspection”, “ENGINE COOLING SYSTEM”)


OUTER COMPONENT PARTS Removal and Installation

Removal and Installation

NHEM0006

GI MA

LC EC FE AT AX SU BR ST RS BT HA SC EL IDX SEM707G

1. 2. 3. 4.

Electronic control throttle actuator Intake manifold upper collector EVAP canister purge volume control solenoid valve Intake manifold lower collector

5. 6. 7. 8.

Power valve VIAS control solenoid valve Fuel tube Fuel damper

EM-9

9. 10. 11. 12.

Fuel damper Vacuum tank Intake manifold Service port


OUTER COMPONENT PARTS Removal and Installation (Cont’d)

SEM708GA

1. 2. 3.

Heated oxygen sensor 1 (front) (bank 1) Exhaust manifold TWC (manifold)

4. 5. 6.

Thermostat with water inlet Exhaust manifold Heated oxygen sensor 1 (front) (bank 2)

EM-10

7. 8. 9.

TWC (manifold) Heated oxygen sensor 2 (rear) (bank 2) Water outlet


OUTER COMPONENT PARTS Removal and Installation (Cont’d)

TIGHTENING PROCEDURES Intake Manifold I 1. 2. I

NHEM0006S01 NHEM0006S0101

Tighten in numerical order shown in the figure. Tighten all bolts and nuts to 4.9 to 9.8 N·m (0.50 to 0.99 kg-m, 44 to 86 in-lb). Finally tighten all bolts and nuts to 26.5 to 31.4 N·m (2.7 to 3.2 kg-m, 20 to 23 ft-lb). Tighten all bolts and nuts to the final torque, evenly dividing the tightening into at least five steps.

GI MA

SEM709G

Fuel Tube I 1. 2.

NHEM0006S0102

Tighten in numerical order shown in the figure. Tighten all bolts to 9.3 to 10.8 N·m (0.95 to 1.1 kg-m, 83 to 95 in-lb). Then tighten all bolts to 20.6 to 26.5 N·m (2.1 to 2.7 kg-m, 16 to 19 ft-lb).

LC EC FE AT

SEM710G

Fuel Damper

AX NHEM0006S0103

Tighten fuel pressure regulator to 2.9 to 3.8 N·m (0.3 to 0.39 kg-m, 26.0 to 33.9 in-lb). I Tighten screws evenly several times to have the fuel damper tightened at the specified torque. I Always replace O-ring with new ones. I Lubricate O-ring with new engine oil.

SU BR ST

SEM952F

Electronic Control Throttle Actuator

SEM711G

RS NHEM0006S0105

I Tighten in numerical order shown in the figure. Tighten all bolts to 7.2 to 9.6 N·m (0.74 to 0.97 kg-m, 64 to 84 inlb). CAUTION: I Perform “Throttle Valve Closed Position Learning” when harness connector of electronic throttle control actuator is disconnected. Refer to “BASIC SERVICE PROCEDURE” in EC section. I Perform “Idle Air Volume Learning” when electronic throttle control actuator is replaced. Refer to “BASIC SERVICE PROCEDURE” in EC section.

BT HA SC EL IDX

EM-11


OUTER COMPONENT PARTS Removal and Installation (Cont’d)

Intake Manifold Upper Collector I

NHEM0006S0108

Tighten in numerical order shown in the figure. Tighten all bolts to 17.6 to 21.6 N·m (1.8 to 2.2 kg-m, 13 to 15 ft-lb).

SEM712G

Intake Manifold Lower Collector

NHEM0006S0107

Tighten bolts and nuts to 17.6 to 21.6 N·m (1.8 to 2.2 kg-m, 13 to 15 ft-lb) in numerical order shown in the figure.

SEM713G

Power Valve I

NHEM0006S0109

Tighten in numerical order shown in the figure. Tighten all bolts to 17.6 to 21.6 N·m (1.8 to 2.2 kg-m, 13 to 15 ft-lb).

SEM714G

Exhaust Manifold

NHEM0006S0110

Tighten nuts to 30 to 32 N·m (3.1 to 3.2 kg-m, 22 to 24 ft-lb) in numerical order shown in the figure.

JEM802G

JEM803G

EM-12


NHEM0007

MEASUREMENT OF COMPRESSION PRESSURE 1. 2. 3. 4. 5. 6.

Warm up engine. Turn ignition switch OFF. Release fuel pressure. Refer to EC-56, “Fuel Pressure Release�. Disconnect ignition coil with power transistor harness connectors, then remove ignition coils. Remove all spark plugs. Remove fuse for fuel injector.

GI MA

SEM087G

7. 8.

Attach a compression tester to No. 1 cylinder. Depress accelerator pedal fully to keep throttle valve wide open. 9. Crank engine and record highest gauge indication. 10. Repeat the measurement on each cylinder as shown above. I Always use a fully-charged battery to obtain specified engine speed.

LC EC FE

Unit: kPa (kg/cm2, psi)/rpm Standard

Minimum

Difference limit between cylinders

AT

1,275 (13.0, 185)/300

981 (10.0, 142)/300

98 (1.0, 14)/300

AX

SEM909E

SEM387C

11. If compression in one or more cylinders is low: a. Pour a small amount of engine oil into cylinders through spark plug holes. b. Retest compression. I If adding oil helps compression, piston rings may be worn or damaged. If so, replace piston rings after checking piston. I If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. (Refer to SDS, EM-79 and EM-82.) If valve or valve seat is damaged excessively, replace them. I If compression stays low in two cylinders that are next to each other: a) The cylinder head gasket may be leaking, or b) Both cylinders may have valve component damage. Inspect and repair as necessary.

SU BR ST RS BT HA SC EL IDX

EM-13


OIL PAN Components

Components

NHEM0008

SEM830G

Removal

NHEM0009

CAUTION: When removing the aluminum oil pan from engine, first remove the crankshaft position sensor (POS) from the assembly. Be careful not to damage sensor edges and signal plate teeth. 1. Remove engine undercover. 2. Drain engine oil.

3.

Remove steel oil pan bolts.

SEM956F

EM-14


OIL PAN Removal (Cont’d)

4. a. I I

Remove steel oil pan. Insert Tool between aluminum oil pan and steel oil pan. Be careful not to damage aluminum mating surface. Do not insert screwdriver, or oil pan flange will be deformed.

GI MA

SEM957F

b. c.

Slide Tool by tapping on the side of the Tool with a hammer. Remove steel oil pan.

LC EC FE AT

SEM960F

5.

Remove oil strainer.

AX SU BR ST

SEM575GA

6.

Remove front exhaust tube and its support. Refer to FE-9, “Removal and Installation”.

RS BT HA SC EL

SEM716G

IDX

EM-15


OIL PAN Removal (Cont’d)

7.

Set a suitable transmission jack under transaxle and hoist engine with engine slinger. 8. Remove crankshaft position sensor (POS) from oil pan. 9. Remove front and rear engine mounting nuts and bolts. 10. Remove center member.

SEM811E

11. Remove drive belts. 12. Remove air conditioner compressor and bracket. Refer to HA-112, “REMOVAL AND INSTALLATION”.

13. Remove rear cover plate.

SEM717G

14. Remove aluminum oil pan bolts in numerical order.

SEM184F

EM-16


OIL PAN Removal (Cont’d)

15. Remove four engine-to-transaxle bolts.

GI MA

SEM718G

16. Remove aluminum oil pan. a. Insert an appropriate size tool into the notch of aluminum oil pan as shown in the figure. I Be careful not to damage aluminum mating surface. I Do not insert screwdriver, or oil pan flange will be deformed. b. Pry off aluminum oil pan by moving the tool up and down. c. Remove aluminum oil pan.

LC EC FE AT

SEM155F

AX

17. Remove O-rings from cylinder block and oil pump body.

SU BR ST SEM819E

Installation 1. a. I I

RS NHEM0010

Install aluminum oil pan. Use a scraper to remove old liquid gasket from mating surfaces. Also remove old liquid gasket from mating surface of cylinder block, front cover and steel oil pan. Remove old liquid gasket from the bolt hole and thread.

BT HA SC EL

MEM108A

b.

Apply sealant to front cover gasket and rear oil seal retainer gasket.

SEM964E

EM-17

IDX


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2002 Infiniti I35 Service Repair Manual  
2002 Infiniti I35 Service Repair Manual  
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