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QUICK REFERENCE INDEX Edition: November 2005 A GENERAL INFORMATION Revision: November 2005 Publication No. SM6E-1F50U0 B ENGINE

C TRANSMISSION/ TRANSAXLE D DRIVELINE/AXLE

E SUSPENSION

F BRAKES

G STEERING H RESTRAINTS

I BODY

J AIR CONDITIONER K ELECTRICAL

GI EM LU CO EC FL EX ACC AT

Engine Mechanical Engine Lubrication System Engine Cooling System Engine Control System Fuel System Exhaust System Accelerator Control System Automatic Transmission

PR RFD FAX RAX FSU RSU WT SCS BR PB BRC PS STC SB SRS

Propeller Shaft Rear Final Drive Front Axle Rear Axle Front Suspension Rear Suspension Road Wheels & Tires Suspension Control System Brake System Parking Brake System Brake Control System Power Steering System Steering Control System Seat Belts Supplemental Restraint System (SRS) Body, Lock & Security System Glasses, Window System & Mirrors Roof Exterior & Interior Instrument Panel Seat Automatic Air Conditioner

BL GW RF EI IP SE ATC SC LT DI WW LAN AV

MA

Starting & Charging System Lighting System Driver Information System Wiper, Washer & Horn LAN System Audio, Visual,Navigation & Telephone System Auto Cruise Control System Power Supply, Ground & Circuit Elements Maintenance

IDX

Alphabetical Index

ACS PG

L MAINTENANCE M INDEX

General Information

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, recording or otherwise, without the prior written permission of Nissan Motor Company Ltd., Tokyo, Japan.

A B C D E F G H I J K L M


This manual contains maintenance and repair procedure for the 2006 INFINITI Q45. 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 NISSAN must first be completely satisfied that neither personal safety nor the vehicle’s safety will be jeopardized by the service method selected.


QUICK REFERENCE CHART Q45 QUICK REFERENCE CHART Q45 ENGINE TUNE-UP DATA (VK45DE) Engine model

2006 PFP:00000 ELS0003W

VK45DE

Firing order

1-8-7-3-6-5-4-2

Idle speed A/T (In “P” or “N” position)

650±50

rpm

Ignition timing (BTDC at idle speed)

12°±5°

Tensions of drive belts

Auto adjustment by auto tensioner

Radiater cap relief pressure Standard

78-98 (0.8-1.0 , 11-14)

kPa (kg/cm2 , psi)

Cooling system leakage testing pressure 157(1.6, 23)

kPa (kg/cm2 , psi) Compression pressure Standard

1,320 (13.5, 191) /300

kPa (kg/cm2 , psi)/rpm

Minimum Spark plug

1,130 (11.5, 164)/300 Standard type

PLFR5A - 11

Hot type

PLFR4A - 11

Cold type

PLFR6A - 11

FRONT WHEEL ALIGNMENT (Unladen* ) Camber

Degree minute (Decimal degree) Caster

Degree minute (Decimal degree) Kingpin inclination Degree minute (Decimal degree)

ELS0003X

Minimum

– 1° 30′ (– 1.50°)

Nominal

– 0° 45′ (– 0.75°)

Maximum

0° 00′ (0.00°)

Left and right difference

45′ (0.75°) or less

Minimum

5° 25′ (5.42°)

Nominal

6° 10′ (6.17°)

Maximum

6° 55′ (6.92°)

Left and right difference

45′ (0.75°) or less

Minimum

13° 15′ (13.25°)

Nominal

14° 00′ (14.00°)

Maximum

14° 45′ (14.75°)

Nominal

1 (0.04)

Minimum

0′ (0°)

Nominal

3′ (0.05°)

Maximum

6′ (0.10°)

Minimum

39° 45′ (39.75°)

Total toe-in Distance (A – B) mm (in) Angle (left plus right) Degree minute (Decimal degree) Wheel turning angle (Full turn) Inside

Degree minute (Decimal degree)

Outside

Degree minute

Nominal

42° 45′ (42.75°)

Maximum

43° 45′ (43.75°)

Nominal

33° 50′ (33.83°)

(Decimal degree) * : Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.


QUICK REFERENCE CHART Q45

2006

REAR WHEEL ALIGNMENT (Unladen*) Tire Camber Degree minute (Decimal degree)

Total toe-in

Distance (A–B) mm (in) Angle (left plus right) Degree minute (Decimal degree)

ELS0003Y

17 inch

18 inch

19 inch

Minimum

– 0° 55′ (– 0.92°)

– 1° 05′ (– 1.08°)

– 1° 10′ (– 1.17°)

Nominal

– 0° 25′ (– 0.42°)

– 0° 35′ (– 0.58°)

– 0° 40′ (– 0.67°)

Maximum

0° 05′ (0.08°)

– 0° 05′ (–0.08°)

– 0° 10′ (–0.17°)

Minimum

– 2.0 (– 0.079)

– 1.6 (– 0.063)

– 1.2 (– 0.047)

Nominal

0.8 (0.031)

1.2 (0.047)

1.6 (0.063)

Maximum

3.6 (0.142)

4.0 (0.157)

4.4 (0.173)

Minimum

– 5′ (0.08°)

– 4′ (0.07°)

– 3′ (0.05°)

Nominal

2′ (0.03°)

3′ (0.05°)

4′ (0.07°)

Maximum

9′ (0.15°)

10′ (0.17°)

11′ (0.18°)

* : Fuel, radiator coolant and oil full. Spare tire, jack, hand tools and mats in designated positions.

BRAKE

ELS0003Z

Unit : mm ( in ) Front brake Pad wear limit

2.0 (0.079)

Rotor repair limit

26.0 (1.02)

Rear brake Pad wear limit

2.0 (0.079)

Rotor repair limit

14.0 (0.551)

Pedal free height

192.4 - 202.4 (7.57 - 7.97)

Pedal depressed height*

90 (3.54) or more

* : Under force of 490 N(50 kg, 110 lb) with engine running.

REFILL CAPACITIES

ELS00040

UNIT

Liter

US measure

80

21 - 1/8 gal

10.3

10 - 7/8 qt

With oil filter change

5.6

5 - 7/8 qt

Without oil filter change

5.0

5 - 1/4 qt

Dry engine (overhall)

6.7

7 - 1/8 qt

A/T

10.3

10 - 7/8 qt

Differential carrier

1.4

3 pt

Power steering system

1.0

1 - 1/8 qt

0.18

6.0 fl oz

0.60 kg

1.32 lb

Fuel tank Coolant (With reservoir tank) Drain and refill Engine*

Transmission

Air conditioning system

Compressor oil Refrigerant

* : For further details, see “Changing Engine Oil” in MA section.


GENERAL INFORMATION

A GENERAL INFORMATION

SECTION

GI

GENERAL INFORMATION

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D

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CONTENTS PRECAUTIONS .......................................................... 3 Description ............................................................... 3 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 3 Precautions for NVIS/IVIS (NISSAN/INFINITI VEHICLE IMMOBILIZER SYSTEM - NATS) (If Equipped) ................................................................. 3 General Precautions ................................................ 4 Precautions for Three Way Catalyst ......................... 5 Precautions for Fuel (Unleaded Premium Gasoline Required) ................................................................. 5 Precautions for Multiport Fuel Injection System or Engine Control System ............................................ 6 Precautions for Hoses .............................................. 6 HOSE REMOVAL AND INSTALLATION ............... 6 HOSE CLAMPING ................................................ 6 Precautions for Engine Oils ...................................... 7 HEALTH PROTECTION PRECAUTIONS ............. 7 ENVIRONMENTAL PROTECTION PRECAUTIONS ................................................................... 7 Precautions for Air Conditioning ............................... 7 HOW TO USE THIS MANUAL ................................... 8 Description ............................................................... 8 Terms ....................................................................... 8 Units ......................................................................... 8 Contents ................................................................... 8 Components ............................................................. 9 SYMBOLS ............................................................. 9 How to Follow Trouble Diagnoses .......................... 10 DESCRIPTION .................................................... 10 HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES ............................................... 10 HARNESS WIRE COLOR AND CONNECTOR NUMBER INDICATION ........................................11 KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES ............................... 12 How to Read Wiring Diagrams ............................... 14 CONNECTOR SYMBOLS ................................... 14 SAMPLE/WIRING DIAGRAM - EXAMPL - ......... 15

Revision: 2005 November

DESCRIPTION .................................................... 16 Abbreviations .......................................................... 22 SERVICE INFORMATION FOR ELECTRICAL INCIDENT ......................................................................... 23 How to Check Terminal ........................................... 23 CONNECTOR AND TERMINAL PIN KIT ............ 23 HOW TO PROBE CONNECTORS ...................... 23 How to Perform Efficient Diagnosis for an Electrical Incident ................................................................... 26 WORK FLOW ...................................................... 26 INCIDENT SIMULATION TESTS ........................ 26 CIRCUIT INSPECTION ....................................... 29 Control Units and Electrical Parts ........................... 34 PRECAUTIONS .................................................. 34 CONSULT-II CHECKING SYSTEM .......................... 35 Description .............................................................. 35 Function and System Application ........................... 35 Nickel Metal Hydride Battery Replacement ............ 35 Checking Equipment .............................................. 36 CONSULT-II Start Procedure .................................. 36 CONSULT-II Data Link Connector (DLC) Circuit ... 37 INSPECTION PROCEDURE .............................. 37 CIRCUIT DIAGRAM ............................................ 38 LIFTING POINT ......................................................... 39 Commercial Service Tools ...................................... 39 Garage Jack and Safety Stand ............................... 39 2-pole Lift ................................................................ 40 Board-on Lift ........................................................... 41 TOW TRUCK TOWING ............................................. 42 Tow Truck Towing ................................................... 42 Vehicle Recovery (Freeing a Stuck Vehicle) ........... 43 TIGHTENING TORQUE OF STANDARD BOLTS ... 44 Tightening Torque Table ......................................... 44 RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ............................................................... 45 Recommended Chemical Products and Sealants... 45 IDENTIFICATION INFORMATION ............................ 46 Model Variation ....................................................... 46 IDENTIFICATION NUMBER ................................ 46 IDENTIFICATION PLATE .................................... 47

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ENGINE SERIAL NUMBER ................................ 47 AUTOMATIC TRANSMISSION NUMBER ........... 47 Dimensions ............................................................. 48 Wheels & Tires ....................................................... 48

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TERMINOLOGY ........................................................49 SAE J1930 Terminology List ...................................49

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PRECAUTIONS PRECAUTIONS Description

PFP:00001

GI NAS0003H

Observe the following precautions to ensure safe and proper servicing. These precautions are not described in each individual section.

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

B

NAS0003I

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● 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 SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors.

Precautions for NVIS/IVIS (NISSAN/INFINITI VEHICLE IMMOBILIZER SYSTEM NATS) (If Equipped)

NAS0003J

NVIS/IVIS (NATS) will immobilize the engine if someone tries to start it without the registered key of NVIS/IVIS (NATS). Both of the originally supplied ignition key IDs have been NVIS/IVIS (NATS) registered. The security indicator is located on the instrument panel. The indicator blinks when the immobilizer system is functioning. Therefore, NVIS/IVIS (NATS) warns outsiders that the vehicle is equipped with the anti-theft system. ● When NVIS/IVIS (NATS) detects trouble, the security indicator lamp lights up while ignition switch is in "ON" position. This lighting up indicates that the anti-theft is not functioning, so prompt service is required. ● When servicing NVIS/IVIS (NATS) (trouble diagnoses, system initialization and additional registration of other NVIS/IVIS (NATS) ignition key IDs), CONSULT-II hardware and CONSULT-II NVIS/IVIS (NATS) software is necessary. Regarding the procedures of NVIS/IVIS (NATS) initialization and NVIS/IVIS (NATS) ignition key ID registration, refer to CONSULT-II operation manual, NVIS/IVIS (NATS). Therefore, CONSULT-II NVIS/IVIS (NATS) software (program card and operation manual) must be kept strictly confidential to maintain the integrity of the anti-theft function. ● When servicing NVIS/IVIS (NATS) (trouble diagnoses, system initialization and additional registration of other NVIS/IVIS (NATS) ignition key IDs), it may be necessary to re-register original key identification. Therefore, be sure to receive all keys from vehicle owner. A maximum of four or five key IDs can be registered into NVIS/IVIS (NATS). ● When failing to start the engine first time using the key of NVIS/IVIS (NATS), start as follows. 1. Leave the ignition key in "ON" position for approximately 5 seconds. 2. Turn ignition key to "OFF" or "LOCK" position and wait approximately 5 seconds. 3. Repeat step 1 and 2 again. 4. Restart the engine while keeping the key separate from any others on key-chain.

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PRECAUTIONS General Precautions ●

NAS0003K

Do not operate the engine for an extended period of time without proper exhaust ventilation. Keep the work area well ventilated and free of any inflammable materials. Special care should be taken when handling any inflammable or poisonous materials, such as gasoline, refrigerant gas, etc. When working in a pit or other enclosed area, be sure to properly ventilate the area before working with hazardous materials. Do not smoke while working on the vehicle. SGI285

Before jacking up the vehicle, apply wheel chocks or other tire blocks to the wheels to prevent the vehicle from moving. After jacking up the vehicle, support the vehicle weight with safety stands at the points designated for proper lifting before working on the vehicle. These operations should be done on a level surface. When removing a heavy component such as the engine or transaxle/transmission, be careful not to lose your balance and drop them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder. SGI231

Before starting repairs which do not require battery power: Turn off ignition switch. Disconnect the negative battery terminal. If the battery terminals are disconnected, recorded memory of radio and each control unit is erased.

SEF289H

● ● ●

● ●

To prevent serious burns: Avoid contact with hot metal parts. Do not remove the radiator cap when the engine is hot. Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner. Do not attempt to top off the fuel tank after the fuel pump nozzle shuts off automatically. Continued refueling may cause fuel overflow, resulting in fuel spray and possibly a fire. Clean all disassembled parts in the designated liquid or solvent SGI233 prior to inspection or assembly. Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones. Replace inner and outer races of tapered roller bearings and needle bearings as a set. Arrange the disassembled parts in accordance with their assembled locations and sequence. Do not touch the terminals of electrical components which use microcomputers (such as ECM). Static electricity may damage internal electronic components. After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection. Use only the fluids and lubricants specified in this manual.

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PRECAUTIONS ● ●

Use approved bonding agent, sealants or their equivalents when required. Use hand tools, power tools (disassembly only) and recommended special tools where specified for safe and efficient service repairs. When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks.

GI

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PBIC0190E

Before servicing the vehicle: Protect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons do not scratch paint.

D

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F

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SGI234

H

WARNING: To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness connectors which are related to the engine control system and TCM (transmission control module) system. The connectors should be disconnected only when working according to the WORK FLOW of TROUBLE DIAGNOSES in EC and AT sections.

I

Precautions for Three Way Catalyst

J

NAS0003L

If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To prevent this, follow the instructions. ● Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst. ● When checking for ignition spark or measuring engine compression, make tests quickly and only when necessary. ● Do not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to the catalyst. Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three way catalyst.

Precautions for Fuel (Unleaded Premium Gasoline Required)

NAS0003M

Use unleaded premium gasoline with an octane rating of at least 91 AKI (Anti-Knock Index) number (Research octane number 96). If unleaded premium gasoline is not available, unleaded regular gasoline with an octane rating of at least 87 AKI number (Research octane number 91) can be used, but only under the following precautions: ● have the fuel tank filled only partially with unleaded regular gasoline, and fill up with unleaded premium gasoline as soon as possible. ● avoid full throttle driving and abrupt acceleration. However, for maximum vehicle performance, the use of unleaded premium gasoline is recommended. CAUTION: Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Do not use E-85 fuel (85% fuel ethanol, 15% unleaded gasoline) unless the vehicle is specifically designed for E-85 fuel Revision: 2005 November

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PRECAUTIONS (i.e. Flexible Fuel Vehicle - FFV models). Using a fuel other than that specified could adversely affect the emission control devices and systems, and could also affect the warranty coverage validity.

Precautions for Multiport Fuel Injection System or Engine Control System ●

NAS0003N

Before connecting or disconnecting any harness connector for the multiport fuel injection system or ECM: Turn ignition switch to “OFF” position. Disconnect negative battery terminal. Otherwise, there may be damage to ECM. Before disconnecting pressurized fuel line from fuel pump to injectors, be sure to release fuel pressure. Be careful not to jar components such as ECM and mass air flow sensor. SGI787

Precautions for Hoses

NAS0003O

HOSE REMOVAL AND INSTALLATION ●

To prevent damage to rubber hose, do not pry off rubber hose with tapered tool or screwdriver.

SMA019D

To reinstall the rubber hose securely, make sure that hose insertion length and orientation is correct. (If tube is equipped with hose stopper, insert rubber hose into tube until it butts up against hose stopper.)

SMA020D

HOSE CLAMPING ●

If old rubber hose is re-used, install hose clamp in its original position (at the indentation where the old clamp was). If there is a trace of tube bulging left on the old rubber hose, align rubber hose at that position. Discard old clamps; replace with new ones.

SMA021D

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PRECAUTIONS ●

After installing plate clamps, apply force to them in the direction of the arrow, tightening rubber hose equally all around.

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D

Precautions for Engine Oils

NAS0003P

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.

E

HEALTH PROTECTION PRECAUTIONS ● ● ● ● ●

● ● ●

● ● ● ●

Avoid prolonged and repeated contact with oils, particularly used engine oils. Wear protective clothing, including impervious gloves where practicable. Do not put oily rags in pockets. Avoid contaminating clothes, particularly underpants, with oil. Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. First aid treatment should be obtained immediately for open cuts and wounds. Use barrier creams, applying them before each work period, to help the removal of oil from the skin. Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. Do not use gasoline, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin. If skin disorders develop, obtain medical advice without delay. Where practical, degrease components prior to handling. Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided.

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ENVIRONMENTAL PROTECTION PRECAUTIONS Dispose of used oil and used oil filters through authorized waste disposal contractors to licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt, contact the local authority for advice on disposal facilities. It is illegal to pour used oil on to the ground, down sewers or drains, or into water sources. The regulations concerning pollution vary between regions.

Precautions for Air Conditioning

NAS0003Q

Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to ATC section “HFC-134a (R-134a) Service Procedure”, “REFRIGERANT LINES” for specific instructions.

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HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL Description

PFP:00008 NAS0003R

This volume explains “Removal, Disassembly, Installation, Inspection and Adjustment” and “Trouble Diagnoses”.

Terms ●

NAS0003S

The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury and/or damage to some part of the vehicle. WARNING indicates the possibility of personal injury if instructions are not followed. CAUTION indicates the possibility of component damage if instructions are not followed. BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful information. Standard value:Tolerance at inspection and adjustment. Limit value:The maximum or minimum limit value that should not be exceeded at inspection and adjustment.

Units ●

NAS0003T

The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit), and alternatively expressed in the metric system and in the yard/pound system. Also with regard to tightening torque of bolts and nuts, there are descriptions both about range and about the standard tightening torque. “Example” Range Outer Socket Lock Nut

: 59 - 78 N·m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)

Standard Drive Shaft Installation Bolt

: 44.3 N·m (4.5 kg-m, 33 ft-lb)

Contents

NAS0003U

ALPHABETICAL INDEX is provided at the end of this manual so that you can rapidly find the item and page you are searching for.

A QUICK REFERENCE INDEX, a black tab (e.g. ) is provided on the first page. You can quickly find the first page of each section by matching it to the section's black tab. THE CONTENTS are listed on the first page of each section. THE TITLE is indicated on the upper portion of each page and shows the part or system. THE PAGE NUMBER of each section consists of two or three letters which designate the particular section and a number (e.g. “BR-5”). THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools, knacks of work and hidden or tricky steps which are not shown in the previous large illustrations. Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle or transmission, etc. are presented in a step-by-step format where necessary.

● ● ●

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HOW TO USE THIS MANUAL Components â—?

NAS0003V

THE LARGE ILLUSTRATIONS are exploded views (see the following) and contain tightening torques, lubrication points, section number of the PARTS CATALOG (e.g. SEC. 440) and other information necessary to perform repairs. The illustrations should be used in reference to service matters only. When ordering parts, refer to the appropriate PARTS CATALOG . Components shown in an illustration may be identified by a circled number. When this style of illustration is used, the text description of the components will follow the illustration.

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SFIA2959E

1.

Union bolt

2.

Copper washer

3.

Brake hose

4.

Cap

5.

Bleed valve

6.

Sliding pin bolt

7.

Piston seal

8.

Piston

9.

Piston boot

10.

Cylinder body

11.

Sliding pin

12.

Torque member mounting bolt

13.

Washer

14.

Sliding pin boot

15.

Bushing

16.

Torque member

17.

Inner shim cover

18.

Inner shim

19.

Inner pad

20.

Pad retainer

21.

Pad wear sensor

22.

Outer pad

23.

Outer shim

24.

Outer shim cover

1: PBC (Poly Butyl Cuprysil) grease or silicone-based grease

2: Rubber grease

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: Brake fluid

Refer to GI section for additional symbol definitions.

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SYMBOLS

SAIA0749E

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HOW TO USE THIS MANUAL How to Follow Trouble Diagnoses

NAS0003W

DESCRIPTION NOTICE: Trouble diagnoses indicate work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing. 1. Before performing trouble diagnoses, read the “Preliminary Check”, the “Symptom Chart” or the “Work Flow”. 2. After repairs, re-check that the problem has been completely eliminated. 3. Refer to Component Parts and Harness Connector Location for the Systems described in each section for identification/location of components and harness connectors. 4. Refer to the Circuit Diagram for quick pinpoint check. If you need to check circuit continuity between harness connectors in more detail, such as when a sub-harness is used, refer to Wiring Diagram in each individual section and Harness Layout in PG section for identification of harness connectors. 5. When checking circuit continuity, ignition switch should be OFF. 6. Before checking voltage at connectors, check battery voltage. 7. After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as they were.

HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES

SAIA0256E

1. 2.

Work and diagnostic procedure Start to diagnose a problem using procedures indicated in enclosed test groups. Questions and required results Questions and required results are indicated in bold type in test group. The meaning of are as follows:

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HOW TO USE THIS MANUAL a. Battery voltage → 11 - 14V or approximately 12V b. Voltage : Approximately 0V → Less than 1V 3.

4.

GI

Symbol used in illustration Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with each symbol. Refer to "Connector Symbols" in GI Section and "KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES" below. Action items Next action for each test group is indicated based on result of each question. Test group number is shown in the left upper portion of each test group.

HARNESS WIRE COLOR AND CONNECTOR NUMBER INDICATION

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There are two types of harness wire color and connector number indication.

TYPE 1: Harness Wire Color and Connector Number are Shown in Illustration ●

E

Letter designations next to test meter probe indicate harness wire color. Connector numbers in a single circle (e.g. M33) indicate harness connectors. Connector numbers in a double circle (e.g. F211) indicate component connectors.

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HOW TO USE THIS MANUAL TYPE 2: Harness Wire Color and Connector Number are Shown in Text

SGI144A

KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES

SAIA0750E

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HOW TO USE THIS MANUAL GI

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HOW TO USE THIS MANUAL How to Read Wiring Diagrams

NAS0003X

CONNECTOR SYMBOLS Most of connector symbols in wiring diagrams are shown from the terminal side. ● Connector symbols shown from the terminal side are enclosed by a single line and followed by the direction mark. ● Connector symbols shown from the harness side are enclosed by a double line and followed by the direction mark. ● Certain systems and components, especially those related to OBD, may use a new style slide-locking type harness connector. For description and how to disconnect, refer to PG section, “Description”, “HARNESS CONNECTOR”.

SAIA0257E

Male and female terminals Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams.

SGI363

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HOW TO USE THIS MANUAL SAMPLE/WIRING DIAGRAM - EXAMPL ●

GI

For detail, refer to following “DESCRIPTION”.

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SGI091A

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HOW TO USE THIS MANUAL Optional Splice

SGI942

DESCRIPTION Number

Item

1

Power condition

2

Fusible link

3

Fusible link/fuse location

4

Fuse

5

6

Current rating

Connectors

Description ●

This shows the condition when the system receives battery positive voltage (can be operated).

The double line shows that this is a fusible link.

The open circle shows current flow in, and the shaded circle shows current flow out.

This shows the location of the fusible link or fuse in the fusible link or fuse box. For arrangement, refer to PG section, POWER SUPPLY ROUTING.

The single line shows that this is a fuse.

The open circle shows current flow in, and the shaded circle shows current flow out.

This shows the current rating of the fusible link or fuse.

This shows that connector E3 is female and connector M1 is male.

The G/R wire is located in the 1A terminal of both connectors.

Terminal number with an alphabet (1A, 5B, etc.) indicates that the connector is SMJ connector. Refer to PG section, SMJ (SUPER MULTIPLE JUNCTION).

7

Optional splice

The open circle shows that the splice is optional depending on vehicle application.

8

Splice

The shaded circle shows that the splice is always on the vehicle.

9

Page crossing

This arrow shows that the circuit continues to an adjacent page.

The A will match with the A on the preceding or next page.

10

Common connector

The dotted lines between terminals show that these terminals are part of the same connector.

11

Option abbreviation

This shows that the circuit is optional depending on vehicle application.

12

Relay

This shows an internal representation of the relay. For details, refer to PG section, STANDARDIZED RELAY.

13

Connectors

This shows that the connector is connected to the body or a terminal with bolt or nut.

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HOW TO USE THIS MANUAL Number

Item

Description ●

14

Wire color

GI

This shows a code for the color of the wire. BR = Brown OR or O = Orange P = Pink PU or V (Violet) = Purple GY or GR = Gray SB = Sky Blue CH = Dark Brown DG = Dark Green

B = Black W = White R = Red G = Green L = Blue Y = Yellow LG = Light Green

B

C

When the wire color is striped, the base color is given first, followed by the stripe color as shown below: Example: L/W = Blue with White Stripe 15

Option description

16

Switch

17

Assembly parts

18

19

20

Cell code

This shows a description of the option abbreviation used on the page.

This shows that continuity exists between terminals 1 and 2 when the switch is in the A position. Continuity exists between terminals 1 and 3 when the switch is in the B position.

Connector terminal in component shows that it is a harness incorporated assembly.

This identifies each page of the wiring diagram by section, system and wiring diagram page number.

Arrow indicates electric current flow, especially where the direction of standard flow (vertically downward or horizontally from left to right) is difficult to follow.

A double arrow “ cuit operation.

Current flow arrow

System branch

E

F

H

This shows that the system branches to another system identified by cell code (section and system).

This arrow shows that the circuit continues to another page identified by cell code.

I

Page crossing

The C will match with the C on another page within the system other than the next or preceding pages.

22

Shielded line

The line enclosed by broken line circle shows shield wire.

23

Component box in wave line

This shows that another part of the component is also shown on another page (indicated by wave line) within the system.

24

Component name

This shows the name of a component.

This shows the connector number.

The letter shows which harness the connector is located in.

Example: M : main harness. For detail and to locate the connector, refer to PG section "Main Harness", “Harness Layout”. A coordinate grid is included for complex harnesses to aid in locating connectors.

The line spliced and grounded under wire color shows that ground line is spliced at the grounded connector.

This shows the ground connection. For detailed ground distribution information, refer to "Ground Distribution" in PG section.

This area shows the connector faces of the components in the wiring diagram on the page.

Connectors enclosed in broken line show that these connectors belong to the same component.

This shows a code for the color of the connector. For code meaning, refer to wire color codes, Number 14 of this chart.

This shows the arrangement of fusible link(s) and fuse(s), used for connector views of "POWER SUPPLY ROUTING" in PG section. The open square shows current flow in, and the shaded square shows current flow out.

This shows that more information on the Super Multiple Junction (SMJ) and Joint Connectors (J/C) exists on the PG section. Refer to "Reference Area" for details.

Connector number

26

Ground (GND)

27

Ground (GND)

28

Connector views

29

Common component

30

Connector color

31

Fusible link and fuse box

32

Reference area

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” shows that current can flow in either direction depending on cir-

21

25

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HOW TO USE THIS MANUAL Harness Indication ●

Letter designations next to test meter probe indicate harness (connector) wire color. Connector numbers in a single circle M33 indicate harness connectors.

AGI070

Component Indication Connector numbers in a double circle F211 indicate component connectors.

Switch Positions Switches are shown in wiring diagrams as if the vehicle is in the “normal” condition. A vehicle is in the “normal” condition when: ● ignition switch is “OFF”, ● doors, hood and trunk lid/back door are closed, ● pedals are not depressed, and ● parking brake is released.

SGI860

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HOW TO USE THIS MANUAL Detectable Lines and Non-Detectable Lines GI

In some wiring diagrams, two kinds of lines, representing wires, with different weight are used. ● A line with regular weight (wider line) represents a “detectable line for DTC (Diagnostic Trouble Code)”. A “detectable line for DTC” is a circuit in which ECM can detect its malfunctions with the on board diagnostic system. ● A line with less weight (thinner line) represents a “non-detectable line for DTC”. A “non-detectable line for DTC” is a circuit in which ECM cannot detect its malfunctions with the on board diagnostic system.

B

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SGI862-B

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HOW TO USE THIS MANUAL Multiple Switch The continuity of multiple switch is described in two ways as shown below. ● The switch chart is used in schematic diagrams. ● The switch diagram is used in wiring diagrams.

SGI875

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HOW TO USE THIS MANUAL Reference Area The Reference Area of the wiring diagram contains references to additional electrical reference pages at the GI end of the manual. If connector numbers and titles are shown in the Reference Area of the wiring diagram, these connector symbols are not shown in the Connector Area. B

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SGI092A

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HOW TO USE THIS MANUAL Abbreviations

NAS0003Y

The following ABBREVIATIONS are used: ABBREVIATION

DESCRIPTION

A/C

Air Conditioner

A/T

Automatic Transaxle/Transmission

ATF

Automatic Transmission Fluid

D1

Drive range 1st gear

D2

Drive range 2nd gear

D3

Drive range 3rd gear

D4

Drive range 4th gear

FR, RR

Front, Rear

LH, RH

Left-Hand, Right-Hand

M/T

Manual Transaxle/Transmission

OD

Overdrive

P/S

Power Steering

SAE

Society of Automotive Engineers, Inc.

SDS

Service Data and Specifications

SST

Special Service Tools

2WD

2-Wheel Drive

22

2nd range 2nd gear

21

2nd range 1st gear

12

1st range 2nd gear

11

1st range 1st gear

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT SERVICE INFORMATION FOR ELECTRICAL INCIDENT How to Check Terminal

PFP:00000

GI NAS0003Z

CONNECTOR AND TERMINAL PIN KIT Use the connector and terminal pin kits listed below when replacing connectors or terminals. The connector and terminal pin kits contain some of the most commonly used NISSAN/INFINITI connectors and terminals. For detailed connector and terminal pin replacement procedures, refer to the latest NISSAN/ INFINITI CONNECTOR AND TERMINAL PIN SERVICE MANUAL.

C

Tool number (Kent-Moore No.) Tool name (J38751-95NI) Connector and terminal pin kit (NISSAN) (J38751-95INF) Connector and terminal pin kit (INFINITI) (J42992-98KIT) OBD and terminal repair kit (J42992-2000UPD) OBD-II Connector Kit Update

B

Description

D

E

F

G WAIA0004E

WAIA0005E

H

HOW TO PROBE CONNECTORS Connector damage and an intermittent connection can result from improperly probing of the connector during circuit checks. The probe of a digital multimeter (DMM) may not correctly fit the connector cavity. To correctly probe the connector, follow the procedures below using a “T” pin. For the best contact grasp the “T” pin using an alligator clip.

I

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Probing from Harness Side Standard type (not waterproof type) connector should be probed from harness side with “T” pin. ● If the connector has a rear cover such as a ECM connector, remove the rear cover before probing the terminal. ● Do not probe waterproof connector from harness side. Damage to the seal between wire and connector may result.

K

L

M

SGI841

Probing from Terminal Side FEMALE TERMINAL ● There is a small notch above each female terminal. Probe each terminal with the “T” pin through the notch. Do not insert any object other than the same type male terminal into female terminal.

SEL265V

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT ●

Some connectors do not have a notch above each terminal. To probe each terminal, remove the connector retainer to make contact space for probing.

SEL266V

MALE TERMINAL Carefully probe the contact surface of each terminal using a “T” pin. Do not bend terminal.

SEL267V

How to Check Enlarged Contact Spring of Terminal An enlarged contact spring of a terminal may create intermittent signals in the circuit. If the intermittent open circuit occurs, follow the procedure below to inspect for open wires and enlarged contact spring of female terminal. 1. Assemble a male terminal and approx. 10 cm (3.9 in) of wire. Use a male terminal which matches the female terminal. 2. Disconnect the suspected faulty connector and hold it terminal side up.

SEL270V

3.

While holding the wire of the male terminal, try to insert the male terminal into the female terminal. Do not force the male terminal into the female terminal with your hands.

SEL271V

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT 4.

While moving the connector, check whether the male terminal can be easily inserted or not.

GI

B

C SEL272V

D ●

If the male terminal can be easily inserted into the female terminal, replace the female terminal. E

F

G SEL273V

Waterproof Connector Inspection

H

If water enters the connector, it can short interior circuits. This may lead to intermittent problems. Check the following items to maintain the original waterproof characteristics. I

RUBBER SEAL INSPECTION ● Most waterproof connectors are provided with a rubber seal between the male and female connectors. If the seal is missing, the waterproof performance may not meet specifications. ● The rubber seal may come off when connectors are disconnected. Whenever connectors are reconnected, make sure the rubber seal is properly installed on either side of male or female connector.

J

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L SEL275V

M

WIRE SEAL INSPECTION The wire seal must be installed on the wire insertion area of a waterproof connector. Be sure that the seal is installed properly.

Terminal Lock Inspection Check for unlocked terminals by pulling wire at the end of connector. An unlocked terminal may create intermittent signals in the circuit.

SEL330V

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT How to Perform Efficient Diagnosis for an Electrical Incident

NAS00040

WORK FLOW

SGI838

STEP

DESCRIPTION Get detailed information about the conditions and the environment when the incident occurred. The following are key pieces of information required to make a good analysis:

STEP 1

STEP 2

WHAT

Vehicle Model, Engine, Transmission/Transaxle and the System (i.e. Radio).

WHEN

Date, Time of Day, Weather Conditions, Frequency.

WHERE

Road Conditions, Altitude and Traffic Situation.

HOW

System Symptoms, Operating Conditions (Other Components Interaction). Service History and if any After Market Accessories have been installed.

Operate the system, road test if necessary. Verify the parameter of the incident. If the problem cannot be duplicated, refer to “Incident Simulation Tests”. Get the proper diagnosis materials together including: ●

Power Supply Routing

System Operation Descriptions

Applicable Service Manual Sections

Check for any Service Bulletins

STEP 3

Identify where to begin diagnosis based upon your knowledge of the system operation and the customer comments. STEP 4

Inspect the system for mechanical binding, loose connectors or wiring damage. Determine which circuits and components are involved and diagnose using the Power Supply Routing and Harness Layouts.

STEP 5

Repair or replace the incident circuit or component.

STEP 6

Operate the system in all modes. Verify the system works properly under all conditions. Make sure you have not inadvertently created a new incident during your diagnosis or repair steps.

INCIDENT SIMULATION TESTS Introduction Sometimes the symptom is not present when the vehicle is brought in for service. If possible, re-create the conditions present at the time of the incident. Doing so may help avoid a No Trouble Found Diagnosis. The following section illustrates ways to simulate the conditions/environment under which the owner experiences an electrical incident. The section is broken into the six following topics: ● Vehicle vibration ● Heat sensitive Revision: 2005 November

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT Freezing GI Water intrusion ● Electrical load ● Cold or hot start up B Get a thorough description of the incident from the customer. It is important for simulating the conditions of the problem. ● ●

Vehicle Vibration

C

The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle with A/C on). In such a case, you will want to check for a vibration related condition. Refer to the following illustration. CONNECTORS & HARNESS Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gently shake each connector and harness while monitoring the system for the incident you are trying to duplicate. This test may indicate a loose or poor electrical connection. HINT Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector terminals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs intermittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the terminals on related connectors in the system. SENSORS & RELAYS Gently apply a slight vibration to sensors and relays in the system you are inspecting. This test may indicate a loose or poorly mounted sensor or relay.

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SGI839

ENGINE COMPARTMENT There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the things to check for are: ● Connectors not fully seated. ● Wiring harness not long enough and is being stressed due to engine vibrations or rocking. ● Wires laying across brackets or moving components. ● Loose, dirty or corroded ground wires. ● Wires routed too close to hot components. To inspect components under the hood, start by verifying the integrity of ground connections. (Refer to Ground Inspection described later.) First check that the system is properly grounded. Then check for loose connection by gently shaking the wiring or components as previously explained. Using the wiring diagrams inspect the wiring for continuity. BEHIND THE INSTRUMENT PANEL An improperly routed or improperly clamped harness can become pinched during accessory installation. Vehicle vibration can aggravate a harness which is routed along a bracket or near a screw.

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT UNDER SEATING AREAS An unclamped or loose harness can cause wiring to be pinched by seat components (such as slide guides) during vehicle vibration. If the wiring runs under seating areas, inspect wire routing for possible damage or pinching.

Heat Sensitive The customer's concern may occur during hot weather or after car has sat for a short time. In such cases you will want to check for a heat sensitive condition. To determine if an electrical component is heat sensitive, heat the component with a heat gun or equivalent. Do not heat components above 60°C (140°F). If incident occurs while heating the unit, either replace or properly insulate the component.

SGI842

Freezing The customer may indicate the incident goes away after the car warms up (winter time). The cause could be related to water freezing somewhere in the wiring/electrical system. There are two methods to check for this. The first is to arrange for the owner to leave his car overnight. Make sure it will get cold enough to demonstrate his complaint. Leave the car parked outside overnight. In the morning, do a quick and thorough diagnosis of those electrical components which could be affected. The second method is to put the suspect component into a freezer long enough for any water to freeze. Reinstall the part into the car and check for the reoccurrence of the incident. If it occurs, repair or replace the component.

SGI843

Water Intrusion The incident may occur only during high humidity or in rainy/snowy weather. In such cases the incident could be caused by water intrusion on an electrical part. This can be simulated by soaking the car or running it through a car wash. Do not spray water directly on any electrical components.

SGI844

Electrical Load The incident may be electrical load sensitive. Perform diagnosis with all accessories (including A/C, rear window defogger, radio, fog lamps) turned on.

SGI845

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT Cold or Hot Start Up On some occasions an electrical incident may occur only when the car is started cold, or it may occur when GI the car is restarted hot shortly after being turned off. In these cases you may have to keep the car overnight to make a proper diagnosis. B CIRCUIT INSPECTION

Introduction In general, testing electrical circuits is an easy task if it is approached in a logical and organized method. Before beginning it is important to have all available information on the system to be tested. Also, get a thorough understanding of system operation. Then you will be able to use the appropriate equipment and follow the correct test procedure. You may have to simulate vehicle vibrations while testing electrical components. Gently shake the wiring harness or electrical component to do this. OPEN

A circuit is open when there is no continuity through a section of the circuit.

D

E

There are two types of shorts. SHORT

C

SHORT CIRCUIT

When a circuit contacts another circuit and causes the normal resistance to change.

SHORT TO GROUND

When a circuit contacts a ground source and grounds the circuit.

NOTE: Refer to “How to Check Terminal” to probe or check terminal.

F

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Testing for “Opens” in the Circuit Before you begin to diagnose and test the system, you should rough sketch a schematic of the system. This will help you to logically walk through the diagnosis process. Drawing the sketch will also reinforce your working knowledge of the system.

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SGI846-A

CONTINUITY CHECK METHOD The continuity check is used to find an open in the circuit. The digital multimeter (DMM) set on the resistance function will indicate an open circuit as over limit (no beep tone or no ohms symbol). Make sure to always start with the DMM at the highest resistance level. To help in understanding the diagnosis of open circuits, please refer to the previous schematic. ● Disconnect the battery negative cable. ● Start at one end of the circuit and work your way to the other end. (At the fuse block in this example) ● Connect one probe of the DMM to the fuse block terminal on the load side. ● Connect the other probe to the fuse block (power) side of SW1. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point A) ● Connect the probes between SW1 and the relay. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point B) ● Connect the probes between the relay and the solenoid. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point C) Any circuit can be diagnosed using the approach in the previous example.

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT VOLTAGE CHECK METHOD To help in understanding the diagnosis of open circuits please refer to the previous schematic. In any powered circuit, an open can be found by methodically checking the system for the presence of voltage. This is done by switching the DMM to the voltage function. ● Connect one probe of the DMM to a known good ground. ● Begin probing at one end of the circuit and work your way to the other end. ● With SW1 open, probe at SW1 to check for voltage. voltage; open is further down the circuit than SW1. no voltage; open is between fuse block and SW1 (point A). ● Close SW1 and probe at relay. voltage; open is further down the circuit than the relay. no voltage; open is between SW1 and relay (point B). ● Close the relay and probe at the solenoid. voltage; open is further down the circuit than the solenoid. no voltage; open is between relay and solenoid (point C). Any powered circuit can be diagnosed using the approach in the previous example.

Testing for “Shorts” in the Circuit To simplify the discussion of shorts in the system, please refer to the following schematic.

SGI847-A

RESISTANCE CHECK METHOD ● Disconnect the battery negative cable and remove the blown fuse. ● Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the fuse. ● Connect one probe of the DMM to the load side of the fuse terminal. Connect the other probe to a known good ground. ● With SW1 open, check for continuity. continuity; short is between fuse terminal and SW1 (point A). no continuity; short is further down the circuit than SW1. ● Close SW1 and disconnect the relay. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. continuity; short is between SW1 and the relay (point B). no continuity; short is further down the circuit than the relay. ● Close SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. continuity; short is between relay and solenoid (point C). no continuity; check solenoid, retrace steps. VOLTAGE CHECK METHOD ● Remove the blown fuse and disconnect all loads (i.e. SW1 open, relay disconnected and solenoid disconnected) powered through the fuse. ● Turn the ignition key to the ON or START position. Verify battery voltage at the battery + side of the fuse terminal (one lead on the battery + terminal side of the fuse block and one lead on a known good ground). ● With SW1 open and the DMM leads across both fuse terminals, check for voltage. voltage; short is between fuse block and SW1 (point A). Revision: 2005 November

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT

no voltage; short is further down the circuit than SW1. With SW1 closed, relay and solenoid disconnected and the DMM leads across both fuse terminals, check GI for voltage. voltage; short is between SW1 and the relay (point B). no voltage; short is further down the circuit than the relay. B With SW1 closed, relay contacts jumped with fused jumper wire check for voltage. voltage; short is down the circuit of the relay or between the relay and the disconnected solenoid (point C). no voltage; retrace steps and check power to fuse block. C

Ground Inspection Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit works. Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface. When inspecting a ground connection follow these rules: ● Remove the ground bolt or screw. ● Inspect all mating surfaces for tarnish, dirt, rust, etc. ● Clean as required to assure good contact. ● Reinstall bolt or screw securely. ● Inspect for “add-on” accessories which may be interfering with the ground circuit. ● If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one eyelet make sure no ground wires have excess wire insulation. For detailed ground distribution information, refer to “Ground Distribution” in PG section.

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SGI853

Voltage Drop Tests Voltage drop tests are often used to find components or circuits which have excessive resistance. A voltage drop in a circuit is caused by a resistance when the circuit is in operation. Check the wire in the illustration. When measuring resistance with DMM, contact by a single strand of wire will give reading of 0 ohms. This would indicate a good circuit. When the circuit operates, this single strand of wire is not able to carry the current. The single strand will have a high resistance to the current. This will be picked up as a slight voltage drop. Unwanted resistance can be caused by many situations as follows: ● Undersized wiring (single strand example) ● Corrosion on switch contacts ● Loose wire connections or splices. Revision: 2005 November

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT If repairs are needed always use wire that is of the same or larger gauge. MEASURING VOLTAGE DROP — ACCUMULATED METHOD ● Connect the DMM across the connector or part of the circuit you want to check. The positive lead of the DMM should be closer to power and the negative lead closer to ground. ● Operate the circuit. ● The DMM will indicate how many volts are being used to “push” current through that part of the circuit. Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb.

SGI974

MEASURING VOLTAGE DROP — STEP-BY-STEP The step-by-step method is most useful for isolating excessive drops in low voltage systems (such as those in “Computer Controlled Systems”). Circuits in the “Computer Controlled System” operate on very low amperage. The (Computer Controlled) system operations can be adversely affected by any variation in resistance in the system. Such resistance variation may be caused by poor connection, improper installation, improper wire gauge or corrosion. The step by step voltage drop test can identify a component or wire with too much resistance.

SAIA0258E

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT Control Unit Circuit Test GI

System Description:When the switch is ON, the control unit lights up the lamp.

B

C

D MGI034A

E

INPUT-OUTPUT VOLTAGE CHART Pin No.

Item

1

Switch

2

Lamp

Voltage value [V]

Condition

In case of high resistance such as single strand [V] *

Switch ON

Battery voltage

Lower than battery voltage Approx. 8 (Example)

Switch OFF

Approx. 0

Approx. 0

Switch ON

Battery voltage

Approx. 0 (Inoperative lamp)

Switch OFF

Approx. 0

Approx. 0

F

G

The voltage value is based on the body ground. *:If high resistance exists in the switch side circuit (caused by a single strand), terminal 1 does not detect battery voltage. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not supply power to light up the lamp.

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MGI035A

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INPUT-OUTPUT VOLTAGE CHART Pin No. 1

2

Item Lamp

Switch

Condition

Voltage value [V]

In case of high resistance such as single strand [V] *

Switch ON

Approx. 0

Battery voltage (Inoperative lamp)

Switch OFF

Battery voltage

Battery voltage

Switch ON

Approx. 0

Higher than 0 Approx. 4 (Example)

Switch OFF

Approx. 5

Approx. 5

The voltage value is based on the body ground. *:If high resistance exists in the switch side circuit (caused by a single strand), terminal 2 does not detect approx. 0V. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not control ground to light up the lamp.

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT Control Units and Electrical Parts

NAS00071

PRECAUTIONS ● ● ● ● ●

● ● ●

Never reverse polarity of battery terminals. Install only parts specified for a vehicle. Before replacing the control unit, check the input and output and functions of the component parts. Do not apply excessive force when disconnecting a connector. Do not apply excessive shock to the control unit by dropping or hitting it. Be careful to prevent condensation in the control unit due to rapid temperature changes and do not let water or rain get on it. If water is found in the control unit, dry it fully and then install it in the vehicle. Be careful not to let oil to get on the control unit connector. Avoid cleaning the control unit with volatile oil. Do not disassemble the control unit, and do not remove the upper and lower covers. SAIA0255E When using a DMM, be careful not to let test probes get close to each other to prevent the power transistor in the control unit from damaging battery voltage because of short circuiting. When checking input and output signals of the control unit, use the specified check adapter.

SEF348N

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CONSULT-II CHECKING SYSTEM CONSULT-II CHECKING SYSTEM Description

GI NAS00042

CONSULT-II is a hand-held type tester. When it is connected with a diagnostic connector equipped on the vehicle side, it will communicate with the control unit equipped in the vehicle and then enable various kinds of diagnostic tests. Refer to “CONSULT-II Software Operation Manual” for more information.

Function and System Application

-

RAS/HICAS

IVIS(NATS)*1

x

HEAD LAMP LEVELIZER

AIR PRESSURE MONITOR

ICC

VDC

ACT D/SUS

IVMS

MULTI AV

AIR BAG

Function

A/T

ENGINE

Diagnostic test mode

NAS00043

x

-

PRECRASH SEAT BELT

PFP:00000

This mode enables a technician to adjust some devices faster and more accurately by following the indications on CONSULT-II.

x

Self-diagnostic results

Self-diagnostic results can be read and erased quickly.

x

x

x

x

x

x

x

x

x

x

x

x

x

Trouble diagnostic record

Current self-diagnostic results and all trouble diagnostic records previously stored can be read.

-

-

x

-

-

-

-

-

-

-

-

-

-

Data monitor

Input/Output data in the ECU can be read.

x

x

-

x

x

x

x

x

x

-

-

x

x

CAN diagnosis support monitor

The condition of CAN communication line can be read.

x

x

-

-

-

-

x

x

-

-

-

x

x

Active test

Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the ECUs and also shifts some parameters in a specified range.

x

-

-

-

x

x

x

x

-

-

x

x

-

DTC confirmation

The results of SRT (System Readiness Test) and the self-diagnosis status/result can be confirmed.

x

-

-

-

-

-

-

-

-

-

x

-

-

DTC work support

The operating condition to confirm Diagnosis Trouble Codes can be selected.

x

x

-

-

-

-

-

-

-

-

-

-

-

ECU (ECM/TCM) part number

ECU (ECM/TCM) part number can be read.

x

x

-

-

x

x

x

x

x

-

x

x

x

ECU discriminated No.

Classification number of a replacement ECU can be read to prevent an incorrect ECU from being installed.

-

-

x

-

-

-

-

-

-

-

-

-

-

Function test

This mode can show results of self-diagnosis of ECU with either “OK” or “NG”. For engines, more practical tests regarding sensors/switches and/or actuators are available.

x

x

x

-

-

-

x

-

-

-

-

-

-

Control unit initialization

All registered ignition key IDs in NATS components can be initialized and new IDs can be registered.

-

-

-

-

-

-

-

-

-

x

-

-

-

Work support

-

-

-

x

-

x

x

GI-35

D

E

F

G

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NAS00044

CONSULT-II contains a nickel metal hydride battery. When replacing the battery obey the following: WARNING: Replace the nickel metal hydride battery with Genuine CONSULT-II battery only. Use of another battery may present a risk of fire or explosion. The battery may present a fire or chemical burn hazard if mistreated. Do not recharge, disassemble or dispose of in fire. Keep the battery out of reach of children and discard used battery conforming to the local regulations.

Revision: 2005 November

C

-

x: Applicable *1: IVIS (NATS) [INFINITI Vehicle Immobilizer system (NISSAN Anti-Theft System)]

Nickel Metal Hydride Battery Replacement

B

2006 Q45


CONSULT-II CHECKING SYSTEM Checking Equipment

NAS00045

When ordering the following equipment, contact your NISSAN/INFINITI distributor. Tool name

Description

NISSAN CONSULT-II 1. CONSULT-II unit (Tester internal soft: Resident version 3.3.0) and accessories 2. Program card UED05C and AEN04A-1 (For NATS) To confirm the best combination of these softwares, refer to CONSULT-II Operation Manual. 3. CONSULT-II CONVERTER 4. “CONSULT-II Pigtail” Cable SAIA0363E

CAUTION: ● Previous CONSULT-II “I” and “Y” DLC-I and DLC-II cables should NOT be used anymore because their DDL connector pins can be damaged during cable swapping. ● If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be detected in self- diagnosis depending on control unit which carry out CAN communication. ● If CONSULT-II CONVERTER is not connected with CONSULT-II, vehicle occur the “FAIL SAFE MODE” which is “LIGHT UP the HEAD LIGHT” and/or “COOLING FAN ROTATING” when CONSULT-II is started. NOTE: ● The CONSULT-II must be used in conjunction with a program card. CONSULT-II does not require loading (Initialization) procedure. ● Be sure the CONSULT-II is turned off before installing or removing a program card.

CONSULT-II Start Procedure

NAS00072

NOTE: Turning ignition switch off when performing CAN diagnosis could cause CAN memory to be erased. 1. Connect CONSULT-II and CONSULT-II CONVERTER to the data link connector.

PAIA0070E

2. 3.

If necessary, turn on the ignition switch. Touch “START(NISSAN BASED VHCL)” or System Shortcut key (eg: ENGINE) on the screen.

SAIA0450E

Revision: 2005 November

GI-36

2006 Q45


CONSULT-II CHECKING SYSTEM 4.

Touch necessary system on "SELECT SYSTEM" screen. If necessary system is not indicated, check power supply and ground of system control unit. If it is normal, refer to GI-37, "CONSULT-II Data Link Connector (DLC) Circuit" .

GI

B

C BCIA0030E

D

5.

Select the desired part to be diagnosed on the "SELECT DIAG MODE" screen. E

F

G BCIA0031E

CONSULT-II Data Link Connector (DLC) Circuit

NAS00047

INSPECTION PROCEDURE

H

If the CONSULT-II cannot diagnose the system properly, check the following items. Symptom

Check item CONSULT-II DLC power supply circuit (Terminal 8) and ground circuit (Terminal 4) (For detailed circuit, refer to “MIL & Data Link Connectors Wiring Diagram” in EC section.)

CONSULT-II DLC cable and CONSULT-II CONVERTER.

CONSULT-II program card (Check the appropriate CONSULT-II program card for the system. Refer to "Checking Equipment".)

Power supply and ground circuit for the control unit of the system (For detailed circuit, refer to wiring diagram for each system.)

Open or short circuit between the system and CONSULT-II DLC (For detailed circuit, refer to wiring diagram for each system.)

CONSULT-II cannot access any system.

CONSULT-II cannot access individual system. (Other systems can be accessed.)

I

J

NOTE: The DDL1 and DDL2 circuits from DLC pins 12, 13, 14 and 15 may be connected to more than one system. A short in a DDL circuit connected to a control unit in one system may affect CONSULT-II access to other systems.

Revision: 2005 November

GI-37

2006 Q45

K

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CONSULT-II CHECKING SYSTEM CIRCUIT DIAGRAM

TAWM0063E

Revision: 2005 November

GI-38

2006 Q45


LIFTING POINT LIFTING POINT Commercial Service Tools

PFP:00000

GI NAS00048

Tool name

Description

B

C

Board on attachment

D

S-NT001

E Safety stand attachment

F S-NT002

CAUTION: ● Every time the vehicle is lifted up, maintain the complete vehicle curb condition. ● Since the vehicle's center of gravity changes when removing main parts on the front side (engine, transmission, suspension etc.), support a jack up point on the rear side garage jack with a mission jack or equivalent. ● Since the vehicle's center of gravity changes when removing main parts on the rear side (rear axle, suspension, etc.), support a jack up point on the front side garage jack with a mission jack or equivalent. ● Be careful not to smash or do not do anything that would affect piping parts.

Garage Jack and Safety Stand

G

H

I

NAS00049

WARNING: ● Park the vehicle on a level surface when using the jack. Make sure to avoid damaging pipes, tubes, etc. under the vehicle. ● Never get under the vehicle while it is supported only by the jack. Always use safety stands when you have to get under the vehicle.

J

K

L

M

Revision: 2005 November

GI-39

2006 Q45


LIFTING POINT â—?

Place wheel chocks at both front and back of the wheels on the ground.

PIIB8440E

2-pole Lift

NAS0004A

WARNING: When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced. When setting the lift arm, do not allow the arm to contact the brake tubes, brake cable, fuel lines and sill spoiler.

SAIA0250E

Revision: 2005 November

GI-40

2006 Q45


LIFTING POINT Board-on Lift

NAS0004B

GI

CAUTION: Make sure vehicle is empty when lifting. ● The board-on lift attachment set at front end of vehicle should be set on the front of the sill under the front door opening. ● Position attachments at front and rear ends of board-on lift.

B

C

D

PIIB7445E

E

F

G

H

I

J

K

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Revision: 2005 November

GI-41

2006 Q45


TOW TRUCK TOWING TOW TRUCK TOWING Tow Truck Towing

PFP:00000 NAS0004C

CAUTION: ● All applicable state or Provincial (in Canada) laws and local laws regarding the towing operation must be obeyed. ● It is necessary to use proper towing equipment to avoid possible damage to the vehicle during towing operation. Towing is in accordance with Towing Procedure Manual at dealer. ● Always attach safety chains before towing. ● When towing, make sure that the transmission, steering system and power train are in good order. If any unit is damaged, dollies must be used. ● Never tow an automatic transmission model from the rear (that is backward) with four wheels on the ground. This may cause serious and expensive damage to the transmission. INFINITI recommends that the vehicle be towed with the driving (rear) wheels off the ground as illustrated. CAUTION: ● When towing models with the front wheels on the ground (If a towing dollies does not be used), turn the ignition key to the OFF position, and secure the steering wheel in the straight-ahead position with a rope or similar device. Never place the ignition key in the LOCK position. This will result in damage to the steering lock mechanism.

SGI065A

PAIA0285E

Revision: 2005 November

GI-42

2006 Q45


TOW TRUCK TOWING Vehicle Recovery (Freeing a Stuck Vehicle)

NAS0004D

GI

Front ● Tow chains or cables must be attached only to the main structural members of the vehicle. ● Pulling devices should be routed so they do not touch any part of the suspension, steering, brake or cooling systems. ● Always pull the cable straight out from the front or rear of the vehicle. Never pull on the vehicle at an angle. ● Pulling devices such as ropes or canvas straps are not recommended for use in vehicle towing or recovery. Rear ● Use the recovery hook only, not other parts of the vehicle. Otherwise, the vehicle body will be damaged. ● Use the recovery hook only to free a vehicle stuck in sand, snow, mud, etc. Never tow the vehicle for a long distance using only the towing hook. ● The recovery hook is under tremendous force when used to free a stuck vehicle. Always pull the cable straight out from the front or rear of the vehicle. Never pull on the hook at an angle. ● Stand clear of a stuck vehicle.

B

C

D

E

F

G

SAIA0267E

H

I

J

K

L

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Revision: 2005 November

GI-43

2006 Q45


TIGHTENING TORQUE OF STANDARD BOLTS TIGHTENING TORQUE OF STANDARD BOLTS Tightening Torque Table Grade

4T

7T

9T

Bolt size

Bolt diameter * mm

PFP:00000 NAS0004E

Tightening torque (Without lubricant) Pitch mm

Hexagon head bolt N·m

kg-m

Hexagon flange bolt

ft-lb

in-lb

N·m

kg-m

ft-lb

in-lb

M6

6.0

1.0

5.5

0.56

4

49

7

0.71

5

62

M8

8.0

1.25

13.5

1.4

10

17

1.7

13

1.0

13.5

1.4

10

17

1.7

13

M10

10.0

1.5

28

2.9

21

35

3.6

26

1.25

28

2.9

21

35

3.6

26

M12

12.0

1.75

45

4.6

33

55

5.6

41

1.25

45

4.6

33

65

6.6

48

M14

14.0

1.5

80

8.2

59

100

10

74

M6

6.0

1.0

9

0.92

7

80

11

1.1

8

97

1.25

22

2.2

16

28

2.9

21

M8

8.0

1.0

22

2.2

16

28

2.9

21

1.5

45

4.6

33

55

5.6

41

M10

10.0

1.25

45

4.6

33

55

5.6

41

1.75

80

8.2

59

100

10

74

M12

12.0

1.25

80

8.2

59

100

10

74

M14

14.0

1.5

130

13

96

170

17

125

M6

6.0

1.0

11

1.1

8

13.5

1.4

10

1.25

28

2.9

21

35

3.6

26

M8

8.0

1.0

28

2.9

21

35

3.6

26

1.5

55

5.6

41

80

8.2

59

M10

10.0

1.25

55

5.6

41

80

8.2

59

1.75

100

10

74

130

13

96

M12

12.0

1.25

100

10

74

130

13

96

M14

14.0

1.5

170

17

125

210

21

155

*: Nominal diameter 1. Special parts are excluded. 2. This standard is applicable to bolts having the following marks embossed on the bolt head.

MGI044A

Revision: 2005 November

GI-44

2006 Q45


RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS Recommended Chemical Products and Sealants

PFP:00000

GI NAS0004F

Refer to the following chart for help in selecting the appropriate chemical product or sealant. Product Description

1

2

3

Purpose

999MP-AM000P

99998-50505

Permatex 81844

Anaerobic Liquid Gasket

For metal-to-metal flange sealing. Can fill a 0.38 mm (0.015 inch) gap and provide instant sealing for most powertrain applications.

999MP-AM001P

99998-50503

Permatex 51813 and 51817

High Performance Thread Sealant

Provides instant sealing on any threaded straight or parallel threaded fitting. (Thread sealant only, no locking ability.)

999MP-AM002P

999MP-AM002P

Permatex 56521

Medium Strength Thread Locking Sealant (Blue)

Revision: 2005 November

C

D

99998-50506 (Ultra Grey)

Permatex Ultra Grey 82194; Three Bond 1207,1215, 1216, 1217F, 1217G and 1217H Nissan RTV Part No. 999MP-A7007

F

Do not use on plastic.

999MP-AM003P (Ultra Grey)

Silicone RTV

High Temperature, High Strength Thread Locking Sealant (Red)

B

E

Gasket Maker for Maxima/ Quest 5-speed automatic transmission (RE5F22A)

6

Aftermarket Crossreference Part Nos.

Used to permanently remount rear view mirrors to windows.

Gasket Maker

5

Nissan Canada Part No. (Canada)

Rear View Mirror Adhesive

4

Nissan North America Part No. (USA)

Threadlocker

Threadlocker (service tool removable)

999MP-AM004P

999MP-AM005P

GI-45

999MP-AM004P

999MP-AM005P

Three Bond 1281B or exact equivalent in its quality Permatex 27200; Three Bond 1360, 1360N, 1305 N&P, 1307N, 1335, 1335B, 1363B, 1377C, 1386B, D&E and 1388 Loctite 648 Permatex 24200, 24206, 24240, 24283 and 09178; Three Bond 1322, 1322N, 1324 D&N, 1333D, 1361C, 1364D, 1370C and 1374

2006 Q45

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IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION Model Variation Body

Sedan

Engine

VK45DE

PFP:00010 NAS0004G

Transmission

5 A/T

Axle

Model

2WD

BPHALGNF50EUA

2WD (with rear active steer (RAS))

BPHBLGNF50EUA

2WD

BPHALGNF50ENA

2WD (with rear active steer (RAS))

BPHBLGNF50ENA

Destination USA

Canada

Prefix and suffix designations:

SAIA1121E

IDENTIFICATION NUMBER

SAIA1127E

Revision: 2005 November

GI-46

2006 Q45


IDENTIFICATION INFORMATION VEHICLE Identification Number ARRANGEMENT GI

B

C

D

E

F SAIA1122E

G

IDENTIFICATION PLATE

H

I

J SGI315

ENGINE SERIAL NUMBER

K

L

M

SAIA0265E

AUTOMATIC TRANSMISSION NUMBER

SAIA0266E

Revision: 2005 November

GI-47

2006 Q45


IDENTIFICATION INFORMATION Dimensions

NAS0004H

Unit: mm (in) Overall length

5,100 (200.8)

Overall width

1,845 (72.6)

Overall height

1,490 (58.7)

Front tread

1,590 (62.6)*1, 1,580 (62.2)*2

Rear tread

1,570 (61.8)*1, 1,560 (61.4)*2

Wheelbase

2,870 (113.0)

*1: 17 inch wheel and 18 inch chrome wheel models *2: 18 inch without chrome wheel and 19 inch wheel models

Wheels & Tires

NAS0004I

Type

Size

Offset

17 X 7-1/2JJ 18 X 7-1/2JJ* 18 X 8JJ 19 X 8-1/2JJ

Road wheel Aluminum

1.38(35) 1.38(35) 1.57(40) 1.57(40)

Conventional

P 225/55R17 P 245/45R18 245/40R19

Spare

T145/90D16 Conventional

Tire

in(mm)

*: Model with chrome wheel

Revision: 2005 November

GI-48

2006 Q45


TERMINOLOGY TERMINOLOGY SAE J1930 Terminology List

PFP:00011

GI NAS0004J

All emission related terms used in this publication in accordance with SAE J1930 are listed. Accordingly, new terms, new acronyms/abbreviations and old terms are listed in the following chart. NEW ACRONYM / ABBREVIATION

NEW TERM Air cleaner

ACL

OLD TERM

C

Air cleaner

Barometric pressure

BARO

***

Barometric pressure sensor-BCDD

BAROS-BCDD

BCDD

Camshaft position

CMP

***

Camshaft position sensor

CMPS

Crank angle sensor

Canister

***

Canister

Carburetor

CARB

Carburetor

Charge air cooler

CAC

Intercooler

Closed loop

CL

Closed loop

Closed throttle position switch

CTP switch

Idle switch

Clutch pedal position switch

CPP switch

Clutch switch

Continuous fuel injection system

CFI system

***

Continuous trap oxidizer system

CTOX system

***

Crankshaft position

CKP

***

Crankshaft position sensor

CKPS

***

Data link connector

DLC

***

Data link connector for CONSULT-II

DLC for CONSULT-II

Diagnostic connector for CONSULT-II

Diagnostic test mode

DTM

Diagnostic mode

Diagnostic test mode selector

DTM selector

Diagnostic mode selector

Diagnostic test mode I

DTM I

Mode I

Diagnostic test mode II

DTM II

Mode II

Diagnostic trouble code

DTC

Malfunction code

Direct fuel injection system

DFI system

***

Distributor ignition system

DI system

Ignition timing control

Early fuel evaporation-mixture heater

EFE-mixture heater

Mixture heater

Early fuel evaporation system

EFE system

Mixture heater control

Electrically erasable programmable read only memory

EEPROM

***

Electronic ignition system

EI system

Ignition timing control

Engine control

EC

***

Engine control module

ECM

ECCS control unit

Engine coolant temperature

ECT

Engine temperature

Engine coolant temperature sensor

ECTS

Engine temperature sensor

Engine modification

EM

***

Engine speed

RPM

Engine speed

Erasable programmable read only memory

EPROM

***

Evaporative emission canister

EVAP canister

Canister

Evaporative emission system

EVAP system

Canister control solenoid valve

Exhaust gas recirculation valve

EGR valve

EGR valve

Revision: 2005 November

B

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E

F

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GI-49

2006 Q45


TERMINOLOGY NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Exhaust gas recirculation control-BPT valve

EGRC-BPT valve

BPT valve

Exhaust gas recirculation control-solenoid valve

EGRC-solenoid valve

EGR control solenoid valve

EGRT sensor

Exhaust gas temperature sensor

Flash electrically erasable programmable read only memory

FEEPROM

***

Flash erasable programmable read only memory

FEPROM

***

Flexible fuel sensor

FFS

***

Flexible fuel system

FF system

***

Fuel pressure regulator

***

Pressure regulator

Fuel pressure regulator control solenoid valve

***

PRVR control solenoid valve

Fuel trim

FT

***

Heated Oxygen sensor

HO2S

Exhaust gas sensor

Idle air control system

IAC system

Idle speed control

Idle air control valve-air regulator

IACV-air regulator

Air regulator

Idle air control valve-auxiliary air control valve

IACV-AAC valve

Auxiliary air control (AAC) valve

Idle air control valve-FICD solenoid valve

IACV-FICD solenoid valve

FICD solenoid valve

Idle air control valve-idle up control solenoid valve

IACV-idle up control solenoid valve

Idle up control solenoid valve

Exhaust gas recirculation temperature sensor EGR temperature sensor

Idle speed control-FI pot

ISC-FI pot

FI pot

Idle speed control system

ISC system

***

Ignition control

IC

***

Ignition control module

ICM

***

Indirect fuel injection system

IFI system

***

Intake air

IA

Air

Intake air temperature sensor

IAT sensor

Air temperature sensor

Knock

***

Detonation

Knock sensor

KS

Detonation sensor

Malfunction indicator lamp

MIL

Check engine light

Manifold absolute pressure

MAP

***

Manifold absolute pressure sensor

MAPS

***

Manifold differential pressure

MDP

***

Manifold differential pressure sensor

MDPS

***

Manifold surface temperature

MST

***

Manifold surface temperature sensor

MSTS

***

Manifold vacuum zone

MVZ

***

Manifold vacuum zone sensor

MVZS

***

Mass air flow sensor

MAFS

Air flow meter

Mixture control solenoid valve

MC solenoid valve

Air-fuel ratio control solenoid valve

Multiport fuel injection System

MFI system

Fuel injection control

Revision: 2005 November

GI-50

2006 Q45


TERMINOLOGY NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Nonvolatile random access memory

NVRAM

***

On board diagnostic system

OBD system

Self-diagnosis

Open loop

OL

Open loop

Oxidation catalyst

OC

Catalyst

Oxidation catalytic converter system

OC system

***

Oxygen sensor

O2S

Exhaust gas sensor

Park position switch

***

Park switch

Park/neutral position switch

PNP switch

Park/neutral switch Inhibitor switch Neutral position switch

Periodic trap oxidizer system

PTOX system

***

Positive crankcase ventilation

PCV

Positive crankcase ventilation

Positive crankcase ventilation valve

PCV valve

PCV valve

Powertrain control module

PCM

***

Programmable read only memory

PROM

***

Pulsed secondary air injection control solenoid valve

PAIRC solenoid valve

AIV control solenoid valve

Pulsed secondary air injection system

PAIR system

Air induction valve (AIV) control

Pulsed secondary air injection valve

PAIR valve

Air induction valve

Random access memory

RAM

***

Read only memory

ROM

***

Scan tool

ST

***

Secondary air injection pump

AIR pump

***

Secondary air injection system

AIR system

***

Sequential multiport fuel injection system

SFI system

Sequential fuel injection

Service reminder indicator

SRI

***

Simultaneous multiport fuel injection system

***

Simultaneous fuel injection

Smoke puff limiter system

SPL system

***

Supercharger

SC

***

Supercharger bypass

SCB

***

System readiness test

SRT

***

Thermal vacuum valve

TVV

Thermal vacuum valve

Three way catalyst

TWC

Catalyst

Three way catalytic converter system

TWC system

***

Three way + oxidation catalyst

TWC + OC

Catalyst

Three way + oxidation catalytic converter system

TWC + OC system

***

Throttle body

TB

Throttle chamber SPI body

Throttle body fuel injection system

TBI system

Fuel injection control

Throttle position

TP

Throttle position

Throttle position sensor

TPS

Throttle sensor

Throttle position switch

TP switch

Throttle switch

Torque converter clutch solenoid valve

TCC solenoid valve

Lock-up cancel solenoid Lock-up solenoid

Revision: 2005 November

GI-51

GI

B

C

D

E

F

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2006 Q45


TERMINOLOGY NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Transmission control module

TCM

A/T control unit

Turbocharger

TC

Turbocharger

Vehicle speed sensor

VSS

Vehicle speed sensor

Volume air flow sensor

VAFS

Air flow meter

Warm up oxidation catalyst

WU-OC

Catalyst

Warm up oxidation catalytic converter system

WU-OC system

***

Warm up three way catalyst

WU-TWC

Catalyst

Warm up three way catalytic converter system

WU-TWC system

***

Wide open throttle position switch

WOTP switch

Full switch

***: Not applicable

Revision: 2005 November

GI-52

2006 Q45


ENGINE MECHANICAL

B ENGINE

SECTION

EM

ENGINE MECHANICAL

A

EM

C

D

E

CONTENTS PRECAUTIONS .......................................................... 3 Precautions for Procedures without Cowl Top Cover..... 3 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 3 Precautions for Draining Engine Coolant ................. 3 Precautions for Disconnecting Fuel Piping .............. 3 Precautions for Removal and Disassembly ............. 3 Precautions for Inspection, Repair and Replacement ......................................................................... 3 Precautions for Assembly and Installation ............... 4 Parts Requiring Angle Tightening ............................. 4 Precautions for Liquid Gasket .................................. 4 REMOVAL OF LIQUID GASKET SEALING .......... 4 LIQUID GASKET APPLICATION PROCEDURE..... 5 PREPARATION ........................................................... 6 Special Service Tools ............................................... 6 Commercial Service Tools ........................................ 8 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ...............................................11 NVH Troubleshooting —Engine Noise ....................11 Use the Chart Below to Help You Find the Cause of the Symptom. ..................................................... 12 ENGINE ROOM COVER .......................................... 13 Removal and Installation ........................................ 13 REMOVAL ........................................................... 13 INSTALLATION ................................................... 13 DRIVE BELTS ........................................................... 14 Checking Drive Belts .............................................. 14 Tension Adjustment ................................................ 14 Removal and Installation ........................................ 14 REMOVAL ........................................................... 14 INSTALLATION ................................................... 15 Drive Belt Auto Tensioner and Idler Pulley ............. 15 REMOVAL ........................................................... 16 INSTALLATION ................................................... 16

Revision: 2005 November

AIR CLEANER AND AIR DUCT ............................... 17 Removal and Installation ........................................ 17 REMOVAL ........................................................... 17 INSTALLATION ................................................... 17 INSPECTION AFTER REMOVAL ....................... 18 CHANGING AIR CLEANER FILTER ................... 18 INTAKE MANIFOLD ................................................. 19 Removal and Installation ........................................ 19 REMOVAL ........................................................... 20 INSPECTION AFTER REMOVAL ....................... 21 INSTALLATION ................................................... 21 INSPECTION AFTER INSTALLATION ................ 22 EXHAUST MANIFOLD AND THREE WAY CATALYST .......................................................................... 23 Removal and Installation ........................................ 23 REMOVAL ........................................................... 23 INSPECTION AFTER REMOVAL ....................... 24 INSTALLATION ................................................... 24 OIL PAN AND OIL STRAINER ................................. 26 Removal and Installation ........................................ 26 REMOVAL ........................................................... 26 INSPECTION AFTER REMOVAL ....................... 27 INSTALLATION ................................................... 27 INSPECTION AFTER INSTALLATION ................ 28 IGNITION COIL ......................................................... 29 Removal and Installation ........................................ 29 REMOVAL ........................................................... 29 INSTALLATION ................................................... 29 SPARK PLUG (PLATINUM-TIPPED TYPE) ............. 30 Removal and Installation ........................................ 30 REMOVAL ........................................................... 30 INSPECTION AFTER REMOVAL ....................... 30 INSTALLATION ................................................... 31 FUEL INJECTOR AND FUEL TUBE ........................ 32 Removal and Installation ........................................ 32 REMOVAL ........................................................... 32 INSTALLATION ................................................... 34 INSPECTION AFTER INSTALLATION ................ 36

EM-1

2006 Q45

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ROCKER COVER ..................................................... 37 Removal and Installation ........................................ 37 REMOVAL ........................................................... 37 INSTALLATION .................................................... 38 TIMING CHAIN .......................................................... 39 Removal and Installation ........................................ 39 REMOVAL ........................................................... 40 INSPECTION AFTER REMOVAL ........................ 43 INSTALLATION .................................................... 44 INSPECTION AFTER INSTALLATION ................ 49 CAMSHAFT ............................................................... 50 Removal and Installation ........................................ 50 REMOVAL ........................................................... 50 INSPECTION AFTER REMOVAL ........................ 51 INSTALLATION .................................................... 54 INSPECTION AFTER INSTALLATION ................ 56 Valve Clearance ...................................................... 57 INSPECTION ....................................................... 57 ADJUSTMENT .................................................... 60 OIL SEAL .................................................................. 63 Removal and Installation of Valve Oil Seal ............. 63 REMOVAL ........................................................... 63 INSTALLATION .................................................... 63 Removal and Installation of Front Oil Seal ............. 64 REMOVAL ........................................................... 64 INSTALLATION .................................................... 64 Removal and Installation of Rear Oil Seal .............. 66 REMOVAL ........................................................... 66 INSTALLATION .................................................... 66 CYLINDER HEAD ..................................................... 67 On-Vehicle Service ................................................. 67 CHECKING COMPRESSION PRESSURE ......... 67 Removal and Installation ........................................ 68 REMOVAL ........................................................... 68 INSPECTION AFTER REMOVAL ........................ 69 INSTALLATION .................................................... 69 INSPECTION AFTER INSTALLATION ................ 70 Disassembly and Assembly .................................... 72 DISASSEMBLY ................................................... 72 ASSEMBLY ......................................................... 73 Inspection After Disassembly ................................. 74 VALVE DIMENSIONS .......................................... 74 VALVE GUIDE CLEARANCE .............................. 75 VALVE GUIDE REPLACEMENT ......................... 75 VALVE SEAT CONTACT ..................................... 76 VALVE SEAT REPLACEMENT ........................... 77 VALVE SPRING SQUARENESS ......................... 78 VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD ............................... 78 ENGINE ASSEMBLY ................................................ 79 Removal and Installation ........................................ 79 REMOVAL ........................................................... 79 INSTALLATION .................................................... 81 INSPECTION AFTER INSTALLATION ................ 82

Revision: 2005 November

CYLINDER BLOCK ...................................................83 Disassembly and Assembly ....................................83 DISASSEMBLY ....................................................84 ASSEMBLY ..........................................................88 How to Select Piston and Bearing ..........................94 DESCRIPTION ....................................................94 HOW TO SELECT PISTON .................................94 HOW TO SELECT CONNECTING ROD BEARING .......................................................................95 HOW TO SELECT MAIN BEARING ....................96 Inspection After Disassembly ................................ 100 CRANKSHAFT END PLAY ................................ 100 CONNECTING ROD SIDE CLEARANCE ......... 100 PISTON TO PISTON PIN CLEARANCE ........... 100 PISTON RING SIDE CLEARANCE ................... 101 PISTON RING END GAP .................................. 101 CONNECTING ROD BEND AND TORSION ..... 102 CONNECTING ROD BIG END DIAMETER ...... 102 CONNECTING ROD BUSHING OIL CLEARANCE ................................................................. 102 CYLINDER BLOCK DISTORTION .................... 103 MAIN BEARING HOUSING INNER DIAMETER.104 PISTON TO CYLINDER BORE CLEARANCE . 104 CRANKSHAFT MAIN JOURNAL DIAMETER ... 106 CRANKSHAFT PIN JOURNAL DIAMETER ...... 106 CRANKSHAFT OUT-OF-ROUND AND TAPER.106 CRANKSHAFT RUNOUT .................................. 106 CONNECTING ROD BEARING OIL CLEARANCE ................................................................. 107 MAIN BEARING OIL CLEARANCE ................... 107 CRUSH HEIGHT OF MAIN BEARING .............. 108 CRUSH HEIGHT OF CONNECTING ROD BEARING ........................................................... 108 DRIVE PLATE .................................................... 109 SERVICE DATA AND SPECIFICATIONS (SDS) .... 110 Standard and Limit ................................................ 110 GENERAL SPECIFICATIONS ........................... 110 DRIVE BELTS .................................................... 110 INTAKE MANIFOLD AND EXHAUST MANIFOLD ................................................................. 110 SPARK PLUG (PLATINUM-TIPPED TYPE) ...... 111 VALVE ................................................................ 111 CAMSHAFT AND CAMSHAFT BEARING ......... 115 CYLINDER HEAD .............................................. 115 CYLINDER BLOCK ............................................ 116 PISTON, PISTON RING AND PISTON PIN ...... 117 CONNECTING ROD .......................................... 118 CRANKSHAFT ................................................... 118 MAIN BEARING ................................................. 119 CONNECTING ROD BEARING ......................... 120

EM-2

2006 Q45


PRECAUTIONS PRECAUTIONS Precautions for Procedures without Cowl Top Cover

PFP:00001

A NBS004M2

When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc.

EM

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

E

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● 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 SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors.

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NBS004M3

Precautions for Draining Engine Coolant

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Drain engine coolant when engine is cooled.

Precautions for Disconnecting Fuel Piping ● ● ●

Before starting work, make sure no fire or spark producing items are in the work area. Release fuel pressure before disconnecting and disassembly. After disconnecting pipes, plug openings to stop fuel leakage.

Precautions for Removal and Disassembly ●

● ● ● ●

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NBS001O5

When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid forceful or uninstructed operations. Exercise maximum care to avoid damage to mating or sliding surfaces. Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials. Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly. When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used where noted in the step.

Precautions for Inspection, Repair and Replacement

NBS001O6

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and replace if necessary. Revision: 2005 November

EM-3

2006 Q45


PRECAUTIONS Precautions for Assembly and Installation ● ●

● ●

● ●

Use torque wrench to tighten bolts or nuts to specification. When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified. Replace with new liquid gasket, packing, oil seal or O-ring. Guide pins are used for several parts alignment. When replacing and reassembling parts with guide pins make sure that guide pins are installed in the original position. Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for any restriction and blockage. Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, engine oil sliding surfaces well. Release air within route when refilling after draining engine coolant. Before starting the engine, apply fuel pressure to fuel lines with turning ignition switch “ON” (with the engine stopped). Then make sure there are no leaks at fuel line connections. After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and exhaust gases for leakage.

Parts Requiring Angle Tightening ●

– – – –

● ● ●

NBS001O7

NBS001O8

Use the angle wrench [SST: KV10112100 (BT8653-A)] for the final tightening of the following engine parts: Cylinder head bolts Main bearing cap bolts Connecting rod cap nuts Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle tightening) 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.

Precautions for Liquid Gasket

NBS001O9

REMOVAL OF LIQUID GASKET SEALING ●

After removing the mounting bolts and nuts, separate the mating surface using the seal cutter (SST) and remove the old liquid gasket sealing. CAUTION: Be careful not to damage the mating surfaces. Tap seal cutter to insert it, and then slide it by tapping on the side as shown in the figure. In areas where seal cutter (SST) is difficult to use, use plastic hammer to lightly tap the parts, to remove it. CAUTION: If for some unavoidable reason tool such as screwdriver is used, be careful not to damage the mating surfaces.

Revision: 2005 November

EM-4

PBIC0002E

2006 Q45


PRECAUTIONS LIQUID GASKET APPLICATION PROCEDURE 1.

2.

A

Using a scraper, remove the old liquid gasket adhering to the liquid gasket application surface and the mating surface. ● Remove the liquid gasket completely from the groove of the liquid gasket application surface, mounting bolts, and bolt holes. Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove adhering moisture, grease and foreign materials.

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PBIC0003E

3.

Attach the liquid gasket tube to tube presser [SST: WS39930000 ( — )]. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-45, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".

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Apply the liquid gasket without breaks to the specified location with the specified dimensions. ● If there is a groove for the liquid gasket application, apply the liquid gasket to the groove. ● As for the bolt holes, normally apply the liquid gasket inside the holes. Occasionally, it should be applied outside the holes. Make sure to read the text of this manual. ● Within 5 minutes of liquid gasket application, install the mating component. ● If the liquid gasket protrudes, wipe it off immediately. ● Do not retighten mounting nuts or bolts after the installation. ● Wait 30 minutes or more after installing, refill the engine oil and engine coolant. CAUTION: If there are specific instructions in this manual, observe them.

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Revision: 2005 November

EM-5

2006 Q45


PREPARATION PREPARATION Special Service Tools

PFP:00002 NBS001OA

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

KV10111100 (J-37228) Seal cutter

Removing steel oil pan and front cover, etc.

S-NT046

KV10114400 (J-38365) Heated oxygen sensor wrench

Loosening or tightening heated oxygen sensors a: 22 mm (0.87 in)

S-NT636

EG15050500 (J-45402) Compression gauge adapter

Inspection of compression pressure on No. 7 and No. 8 cylinders

ZZA1225D

KV10116200 (J-26336-A) Valve spring compressor 1. KV10115900 (J-26336-20) Attachment 2. KV10109230 ( — ) Adapter KV101151S0 (J-38972) Lifter stopper set 1. KV10115110 (J-38972-1) Camshaft pliers 2. KV10115120 (J-38972-2) Lifter stopper

Disassembling and assembling valve mechanism Part (1) is a component of KV10116200 (J26336-A), but part (2) is not so.

PBIC1650E

Changing adjusting shims

S-NT041

KV10112100 (BT8653-A) Angle wrench

Tightening bolts for bearing cap, cylinder head, etc.

S-NT014

Revision: 2005 November

EM-6

2006 Q45


PREPARATION Tool number (Kent-Moore No.) Tool name

A

Description

KV10114700 (J-38139) Main bearing cap remover

Removing crankshaft main bearing cap

EM

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KV10107902 (J-38959) Valve oil seal puller

D

Removing valve oil seal

E

S-NT011

KV10115600 (J-38958) Valve oil seal drift

F Installing 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)

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S-NT603

EM03470000 (J-8037) Piston ring compressor

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Installing piston assembly into cylinder bore

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ST16610001 (J-23907) Pilot bushing puller

Removing crankshaft pilot converter

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WS39930000 ( — Tube presser

Pressing the tube of liquid gasket

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S-NT052

Revision: 2005 November

EM-7

2006 Q45


PREPARATION Tool number (Kent-Moore No.) Tool name

Description

— (J- 45476) Ring gear stopper

Removing and installing crankshaft pulley

PBIC1655E

— (J-45488) Quick connector release

Removing fuel tube quick connectors in engine room

PBIC0198E

Commercial Service Tools

NBS001OB

(Kent-Moore No.) Tool name ( — Power tool

Description )

Loosening bolts and nuts

PBIC0190E

( — ) Spark plug wrench

Removing and installing spark plug

S-NT047

(J-24239-01) Cylinder head bolt wrench

Loosening and tightening cylinder head bolt, and used with angle wrench [SST: KV10112100 (BT8653-A)] a: 13 (0.51) dia. b: 12 (0.47) c: 10 (0.39) Unit: mm (in) NT583

( — ) Valve seat cutter set

Finishing valve seat dimensions

S-NT048

Revision: 2005 November

EM-8

2006 Q45


PREPARATION (Kent-Moore No.) Tool name

Description

( — ) Piston ring expander

A

Removing and installing piston ring

EM

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( — ) 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.

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( — ) Valve guide reamer

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

S-NT016

( — ) Front oil seal drift

Installing front oil seal when front cover is removed

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( — ) Rear oil seal drift

Installing rear oil seal

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a: (J-43897-18) b: (J-43897-12) oxygen sensor thread cleaner

AEM488

Revision: 2005 November

EM-9

Reconditioning the exhaust system threads before installing a new heated oxygen sensor (Use with anti-seize lubricant shown below.) a: J-43897- 18 [18mm (0.71 in) dia.] for zirconia heated oxygen sensor and air fuel ratio sensor b: J-43897-12 [12mm (0.47 in) dia.] for titania heated oxygen sensor and air fuel ratio sensor

2006 Q45

M


PREPARATION (Kent-Moore No.) Tool name

Description

( — ) Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907)

Lubricating heated oxygen sensor thread cleaning tool when reconditioning exhaust system threads

AEM489

( — ) Manual lift table caddy

Removing and installing engine

ZZA1210D

Revision: 2005 November

EM-10

2006 Q45


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

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Revision: 2005 November

EM-11

2006 Q45


NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING Use the Chart Below to Help You Find the Cause of the Symptom.

NBS001OD

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

Front of engine Timing chain cover

Front of engine

Reference page

After warmup

When starting

When idling

When racing

While driving

Ticking or clicking

C

A

A

B

Tappet noise

Valve clearance

EM-57

Rattle

C

A

A

B

C

Camshaft bearing noise

Camshaft journal clearance Camshaft runout

EM-52 EM-51

Piston pin noise

Piston and piston pin clearance Connecting rod bushing oil clearance

EM-100 EM-102

A

Piston slap noise

Piston to cylinder bore clearance Piston ring side clearance Piston ring end gap Connecting rod bend and torsion

EM-104 EM-101 EM-101 EM-102

Connecting rod bushing oil clearance Connecting rod bearing clearance (Big end)

EM-102 EM-107

Slap or knock

Crankshaft pulley Cylinder block (Side of engine) Oil pan

Source of noise

Before warmup

Slap or rap

A

A

B

B

B

B

Check item

Knock

A

B

C

B

B

B

Connecting rod bearing noise

Knock

A

B

A

B

C

Main bearing noise

Main bearing oil clearance Crankshaft runout

EM-107 EM-106

Timing chain cracks and wear Chain tensioner operation

EM-43 EM-39

Tapping or ticking

A

A

B

B

B

Timing chain and chain tensioner noise

Squeaking or fizzing

A

B

B

C

Drive belts (Sticking or slipping)

Drive belts deflection Idler pulley bearing operation Water pump operation

Creaking

A

B

A

B

A

B

Drive belts (Slipping)

Squall Creak

A

B

B

A

B

Water pump noise

A: Closely related

B: Related

Revision: 2005 November

C: Sometimes related

EM-14

CO-20, "WATER PUMP"

—: Not related

EM-12

2006 Q45


ENGINE ROOM COVER ENGINE ROOM COVER Removal and Installation

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1.

Engine cover

2.

Relay box

3.

Battery cover

4.

Front air guide

5.

Air duct (inlet)

6.

Air cleaner cover

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REMOVAL ●

1. 2. 3. 4. 5. 6.

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Remove clips on back with clip driver for each cover. CAUTION: Do not damage or scratch cover when installing or removing. Major parts and inspection points under each cover are as follows; (numbered as in figure) Spark plug, intake manifold, fuel injector Relay Battery, relay box Power steering fluid cooling tube Engine assembly front side, drive belts, cooling fan Mass air flow sensor, air cleaner case

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INSTALLATION Install in the reverse order of removal.

Revision: 2005 November

EM-13

2006 Q45


DRIVE BELTS DRIVE BELTS Checking Drive Belts

PFP:02117 NBS001OF

PBIC2162E

WARNING: Be sure to perform when engine is stopped. ● Remove air duct (inlet) when inspecting drive belt for alternator, water pump and A/C compressor. ● Remove engine undercover (with power tool) when inspecting power steering oil pump belt. ● Make sure that indicator (single line notch) of each auto tensioner is within the allowable working range (between three line notches). NOTE: ● Check auto tensioner indication when engine is cold. ● When new drive belt is installed, the range should be A. ● The indicator notch is located on the moving side of auto tensioner for alternator, water pump and A/C compressor belt, while it is found on the fixed side for power steering oil pump belt. ● Visually check entire belt for wear, damage or cracks. ● If the indicator is out of allowable working range or belt is damaged, replace drive belt.

Tension Adjustment

NBS001OG

Belt tensioning is not necessary, as it is automatically adjusted by auto tensioner.

Removal and Installation

NBS001OH

REMOVAL Alternator, Water Pump and A/C Compressor Belt 1. 2.

3.

Remove air duct (inlet). Refer to EM-17, "AIR CLEANER AND AIR DUCT" . With box wrench, and while securely holding the hexagonal part in pulley center of auto tensioner, move the wrench handle in the direction of arrow (loosening direction of tensioner). CAUTION: ● Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off. ● Do not loosen the hexagonal part in center of drive belt auto–tensioner pulley (Do not turn it clockwise). If turned clockwise, the complete drive belt auto–tensioner must be replaced as a unit, including the pulley. Under the above condition, insert a metallic bar of approximately 6 mm (0.24 in) in diameter (hexagonal bar wrench shown as example in the figure) through the holding boss to lock auto tensioner pulley arm.

Revision: 2005 November

EM-14

PBIC2787E

2006 Q45


DRIVE BELTS Leave auto tensioner pulley arm locked until belt is installed again. Remove alternator, water pump and A/C compressor belt.

4.

A

Power Steering Oil Pump Belt 1. 2. 3.

4.

5.

Remove air duct (inlet) and engine undercover (with power tool). Refer to EM-17, "AIR CLEANER AND EM AIR DUCT" . Remove alternator, water pump and A/C compressor belt. Refer to EM-14, "Alternator, Water Pump and A/C Compressor Belt" . C While securely holding the hexagonal protrusion part of auto tensioner pulley with box wrench, move the wrench handle in the direction of arrow (loosening direction of tensioner). D CAUTION: Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off. E Under the above condition, insert a metallic bar of approximately 6 mm (0.24 in) in diameter (hexagonal bar wrench shown as example in the figure) through the holding boss to lock auto tensioner pulley arm. F PBIC1543E ● Leave auto tensioner pulley arm locked until belt is installed again. Remove power steering oil pump belt. G

INSTALLATION Note the following, and install in the reverse order of removal. CAUTION: Make sure belt is securely installed around all pulleys. ● Unlock auto tensioner pulley arm to give tension to belt. ● Rotate crankshaft pulley several turns clockwise to equalize belt tension between pulleys. ● Make sure that belt tension is within the allowable working range, using indicator notch on auto tensioner. Refer to EM-14, "Checking Drive Belts" .

Drive Belt Auto Tensioner and Idler Pulley

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PBIC2788E

1.

Auto tensioner (Used for alternator, water pump and A/C compressor belt)

2.

Idler pulley

3.

Auto tensioner (Used for power steering oil pump belt)

CAUTION: The complete drive belt auto–tensioner must be replaced as a unit, including the pulley. Revision: 2005 November

EM-15

2006 Q45


DRIVE BELTS REMOVAL 1. 2. 3. 4.

Remove air duct (inlet). Refer to EM-17, "AIR CLEANER AND AIR DUCT" . Remove engine undercover (with power tool). Remove drive belts. Refer to EM-14, "Removal and Installation" . ● Keep auto tensioner pulley arm locked after belt is removed. Remove auto tensioner and idler pulley with power tool. ● Keep auto tensioner pulley arm locked to install or remove auto tensioner. CAUTION: Do not loosen the hexagonal part in center of drive belt auto–tensioner pulley (Do not turn it clockwise). If turned clockwise, the complete drive belt auto–tensioner must be replaced as a unit, including the pulley.

INSTALLATION Install in the reverse order of removal. CAUTION: Do not swap the pulley between new and old drive belt auto–tensioner.

Revision: 2005 November

EM-16

2006 Q45


AIR CLEANER AND AIR DUCT AIR CLEANER AND AIR DUCT Removal and Installation

PFP:16500

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PBIC2772E

1.

Air cleaner filter

2.

Holder

3.

4.

Air duct

5.

Mass air flow sensor

6.

O-ring

7.

Air duct (inlet)

8.

Bracket

9.

Air cleaner case

10.

Bracket

K

Vacuum hose

L

REMOVAL 1. 2. 3. 4. 5.

M

Remove engine cover with power tool. Refer to EM-13, "ENGINE ROOM COVER" . Remove air cleaner cover. Refer to EM-13, "ENGINE ROOM COVER" . Disconnect harness connector from mass air flow sensor. Remove air duct (inlet), air duct and air cleaner case assembly disconnecting their joints. ● Add marks as necessary for easier installation. Remove mass air flow sensor from air cleaner case, as necessary. CAUTION: Handle mass air flow sensor with the following cares. ● Do not shock it. ● Do not disassemble it. ● Do not touch its sensor.

INSTALLATION Note the following, and install in the reverse order of removal. ● Align marks. Attach each joint. Screw clamps firmly.

Revision: 2005 November

EM-17

2006 Q45


AIR CLEANER AND AIR DUCT INSPECTION AFTER REMOVAL Inspect air duct and resonator assembly for check or tear â—? If anything found, replace air duct and resonator assembly.

CHANGING AIR CLEANER FILTER Removal 1. 2. 3.

Remove air cleaner cover. Refer to EM-13, "ENGINE ROOM COVER" . Unhook clips and lift up holder with air cleaner filter. Remove air cleaner filter.

Installation Install in the reverse order of removal.

Revision: 2005 November

EM-18

2006 Q45


INTAKE MANIFOLD INTAKE MANIFOLD Removal and Installation

PFP:14003

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C

D

E

F

G

H

I

J

K

L

M

PBIC4180E

1.

PCV tube

2.

PCV hose

3.

EVAP canister purge volume control solenoid valve bracket

4.

EVAP canister purge volume control solenoid valve

5.

EVAP hose

6.

EVAP tube

7.

Vacuum gallery

8.

Engine cover front bracket

9.

EVAP hose

Revision: 2005 November

EM-19

2006 Q45


INTAKE MANIFOLD 10. EVAP service port

11. Engine cover rear bracket

12. VIAS control solenoid valve

13. Water gallery

14. Gasket

15. Intake manifold (lower)

16. Water hose

17. Electric throttle control actuator

18. Intake manifold adapter

19. Engine cover rear bracket

20. Intake manifold (upper)

21. Vacuum tank

REMOVAL WARNING: To avoid the danger of being scalded, do not drain engine coolant when engine is hot. 1. Remove engine cover (with power tool), air duct (inlet), air cleaner cover and battery cover. Refer to EM13, "Removal and Installation" . 2. Release fuel pressure. Refer to EC-80, "FUEL PRESSURE RELEASE" . 3. Remove air duct and air cleaner case assembly. Refer to EM-17, "Removal and Installation" . 4. Drain engine coolant when engine is cooled. Refer to CO-8, "Changing Engine Coolant" . 5. Disconnect fuel feed hose quick connector on engine side. Refer to EM-32, "FUEL INJECTOR AND FUEL TUBE" .

SBIA0353E

6.

Remove or disconnect intake manifold (upper), harnesses, brackets, vacuum hose, water gallery, vacuum gallery and PCV hose and tube. ● Add mating marks as necessary for easier installation. 7. Remove electric throttle control actuator as follows: a. Disconnect harness connector. b. Loosen mounting bolts diagonally. CAUTION: ● Handle carefully to avoid any shock to electric throttle control actuator. ● Do not disassemble. 8. Disconnect water hoses from water gallery. 9. Remove intake manifold adapter. 10. Remove fuel injectors and fuel tube assembly. Refer to EM-32, "Removal and Installation" . 11. Loosen bolts in the reverse order of figure to remove intake manifold (upper) with power tool.

PBIC0014E

Revision: 2005 November

EM-20

2006 Q45


INTAKE MANIFOLD 12. Loosen bolts in the reverse order of figure to remove intake manifold (lower) with power tool. CAUTION: Cover engine openings to avoid entry of foreign materials.

A

EM

C PBIC0015E

D

13. Remove intake manifold gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials. 14. Remove EVAP canister purge volume control solenoid from intake manifold (upper), if necessary. 15. Remove VIAS control solenoid valve from water gallery, if necessary. 16. Remove vacuum tank from intake manifold (lower), if necessary.

E

F

INSPECTION AFTER REMOVAL Surface Distortion â—?

Limit â—?

G

Using a straightedge and a feeler gauge, inspect surface distortion of intake manifold (upper and lower). : 0.1 mm (0.004 in)

H

If it exceeds the limit, replace intake manifold (lower) and/or intake manifold (upper). I

J PBIC0016E

INSTALLATION K

Note the following, and install in the reverse order of removal.

Intake Manifold (Lower) Tighten in numerical order as shown in the figure. NOTE: No. 7 and 8 have longer bolt length than others.

L

M

PBIC0015E

Revision: 2005 November

EM-21

2006 Q45


INTAKE MANIFOLD Intake Manifold (Upper ) Tighten in numerical order as shown in the figure. NOTE: No. 4 to 7 have longer bolt length than others.

PBIC0014E

Electric Throttle Control Actuator ●

● ●

Install intake manifold adapter gasket and electric throttle control actuator gasket so that three protrusions for installation identification do not face downward. Tighten mounting bolts of electric throttle control actuator equally and diagonally in several steps. After installation perform procedure in EM-22, "INSPECTION AFTER INSTALLATION" .

Water Hose Install 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).

Vacuum Hose Refer to EC-102, "Vacuum Hose Drawing" .

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 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-78, "Throttle Valve Closed Position Learning" . If electric throttle control actuator is replaced, perform procedures for “Idle Air Volume Learning” after finishing repairs. Refer to EC-78, "Idle Air Volume Learning" .

Revision: 2005 November

EM-22

2006 Q45


EXHAUST MANIFOLD AND THREE WAY CATALYST EXHAUST MANIFOLD AND THREE WAY CATALYST Removal and Installation

PFP:14004

A NBS001OL

EM

C

D

E

F

G

H

I PBIC3108E

1.

Air fuel ratio sensor 1 (bank 2)

2.

Exhaust manifold cover (right bank)

3.

4.

Gasket

5.

Exhaust manifold and three way cat6. alyst (left bank)

7.

Air fuel ratio sensor 1 (bank 1)

Exhaust manifold and three way catalyst (right bank)

J

Exhaust manifold cover (left bank)

K

REMOVAL 1. a. b. c. d.

Remove Air fuel ratio sensors. ● Put marks to identify installation positions of each air fuel ratio sensor 1. Remove engine cover, air duct (inlet), battery cover and air cleaner cover. Refer to EM-13, "ENGINE ROOM COVER" . Remove engine undercover (with power tool). Disconnect harness connector of each air fuel ratio sensor 1, and harness from bracket and middle clamp. Using the heated oxygen sensor wrench (SST), remove air fuel ratio sensor 1 (bank1 and bank2). CAUTION: ● Be careful not to damage air fuel ratio sensor. ● Discard any heated oxygen sensor which has been dropped onto a hard surface such as a concrete floor; use a new one.

PBIC1000E

2.

Remove exhaust manifold and three way catalyst (left bank) using the steps below.

Revision: 2005 November

EM-23

2006 Q45

L

M


EXHAUST MANIFOLD AND THREE WAY CATALYST a. b. c. d. e. f.

3. a. b. c. d. e. f. g. h.

Remove A/C compressor with power tool and put aside with piping connected. Refer to ATC-149, "Removal and Installation of Compressor" . Remove exhaust front tube with power tool. Refer to EX-3, "Removal and Installation" . Remove steering lower joint to enable steering shaft to move freely. Refer to PS-15, "POWER STEERING GEAR" . Support and lift up bottom of engine with transmission jack. Remove left engine mounting insulator along with left engine mounting brackets. Remove exhaust manifold cover (left bank). Loosen nuts in the reverse order of figure to remove exhaust manifold and three way catalyst (left bank) with power tool. NOTE: Disregard No. 9 to No. 12 when loosening. Remove exhaust manifold and three way catalyst (right bank) using the steps below. Remove drive belt. Refer to EM-14, "DRIVE BELTS" . Remove alternator. Refer to SC-25, "Removal and Installation" . Remove exhaust front tube with power tool. Refer to EX-3, "Removal and Installation" . PBIC0022E Remove nuts on bottom of right engine mounting insulator, and lift up right side of engine approximately 3 cm (1.18 in) with transmission jack. Remove starter motor. Refer to SC-14, "Removal and Installation" . Support and lift up bottom of engine with transmission jack. Remove right engine mounting insulator along with right engine mounting brackets. Remove exhaust manifold cover (right bank). Loosen nuts in the reverse order of figure to remove exhaust manifold and three way catalyst (right bank) with power tool. NOTE: Disregard No. 9 to No. 12 when loosening.

INSPECTION AFTER REMOVAL Surface Distortion â—?

Use a straightedge and a feeler gauge to check the surface distortion of each exhaust manifold and three way catalyst flange surface. Limit

â—?

: 0.3mm (0.012in)

If it exceeds the limit, replace exhaust manifold and three way catalyst.

PBIC0023E

INSTALLATION Note the following, and install in the reverse order of removal.

Exhaust Manifold Gasket Install exhaust manifold gasket with its directional protrusion set upward. Refer to EM-23, "Removal and Installation" .

Revision: 2005 November

EM-24

2006 Q45


EXHAUST MANIFOLD AND THREE WAY CATALYST Exhaust Manifold ●

A

Install exhaust manifold and three way catalyst in numerical order shown in the figure. Tighten nuts No. 1 to No. 4 in two steps. Order No. 9 to 12 shows second step.

EM

C

PBIC0022E

D

Air Fuel Ratio sensor 1 and Heated Oxygen Sensor 2 ● ●

Install air fuel ratio sensor and heated oxygen sensors in the original position. Install referring the following if the installation positions cannot be identified.

E

Glass tube color

F 1

: Black

Air fuel ratio sensor 1 (bank 2)*1

: Black

2

: White

Heated oxygen sensor 2 (bank 2)*2

: White

Air fuel ratio sensor 1 (bank 1)*

Heated oxygen sensor 2 (bank 1)*

1

G

H

* : Length of bank1 for air fuel ratio sensor is different from bank2. *2 : Refer to EX-3, "EXHAUST SYSTEM" about heated oxygen sensor 2. CAUTION: ● Before installing a new air fuel ratio sensor 1 and a new heated oxygen sensor 2, clean exhaust system threads using the heated oxygen sensor thread cleaner (commercial service tool: J-4389718 or J-43897-12), and apply anti-seize lubricant (commercial service tool). ● Do not over torque the air fuel ratio sensor 1 and heated oxygen sensor 2. Doing so may cause damage to the air fuel ratio sensor 1 and heated oxygen sensor 2, resulting in the MIL coming on. PBIC2652E

I

J

K

L

M

Revision: 2005 November

EM-25

2006 Q45


OIL PAN AND OIL STRAINER OIL PAN AND OIL STRAINER Removal and Installation

PFP:11110 NBS001OM

PBIC2806E

1.

Oil pan

2.

O-ring

3.

Crankshaft position sensor (POS)

4.

O-ring

5.

Oil pressure switch

6.

Gasket

7.

Oil strainer

8.

Oil pan drain plug

9.

Washer

10.

Oil filter

11.

Rear plate cover

REMOVAL WARNING: To avoid the danger of being scalded, do not drain engine oil when engine is hot. 1. Remove front tires. 2. Remove hood assembly. Refer to BL-13, "HOOD" . 3. Remove engine undercover (with power tool). 4. Remove engine cover, battery cover, air duct (inlet) and air cleaner cover. Refer to EM-13, "ENGINE ROOM COVER" . 5. Drain engine oil. Refer to LU-7, "Changing Engine Oil" . 6. Remove drive belts. Refer to EM-14, "Removal and Installation" . 7. Remove auto tensioner of power steering oil pump belt. Refer to EM-15, "Drive Belt Auto Tensioner and Idler Pulley" . 8. Move power steering oil pump and remove power steering oil pump bracket. 9. Remove oil filter. Refer to LU-9, "Removal and Installation" . 10. Remove A/C compressor fitting bolts, and put A/C compressor temporarily on vehicle side with ropes or equivalent. Refer to ATC-149, "Removal and Installation of Compressor" . 11. Disconnect harness and wires of lower side of oil pan from oil pan. 12. Remove crankshaft position sensor (POS) from transmission. CAUTION: â—? Do not drop or shock it. Revision: 2005 November

EM-26

2006 Q45


OIL PAN AND OIL STRAINER Do not disassemble it. A Do not let steel powders contact magnetic parts of sensor tips. ● Do not leave where magnetically effected. 13. Install engine slinger and hang engine assembly to secure position. Refer to EM-79, "Removal and InstalEM lation" . 14. Remove front suspension member with power tool. Refer to FSU-16, "FRONT SUSPENSION MEMBER" . 15. Remove oil pan as follows: C a. Remove rear plate cover. b. Remove transmission joint bolts (M12: 4 bolts) which pierce oil pan. Refer to AT-249, "TRANSMISSION ASSEMBLY" . D c. Loosen oil pan bolts with power tool in the reverse order of figure to remove. NOTE: E Disregard No. 11 and No. 17 when loosening. ● ●

F

G PBIC0194E

d.

Insert the seal cutter (SST) between oil pan and cylinder block. Slide the seal cutter by tapping on side of the seal cutter with a hammer. Remove oil pan. CAUTION: ● Be careful not to damage mating surface. ● Do not insert a screwdriver, this will damage the mating surface.

H

I

J

SEM365E

K

e. Remove O-rings from bottom of oil pump and front cover. 16. Remove oil strainer. L

INSPECTION AFTER REMOVAL Clean oil strainer if any object attached.

INSTALLATION 1. 2. a.

M

Install oil strainer. Install oil pan as follows: Use scraper to remove old liquid gasket from mating surfaces. ● Also remove the old liquid gasket from mating surface of cylinder block. ● Remove old liquid gasket from the bolt holes and threads. CAUTION: Do not scratch or damage the mating surfaces when cleaning off old liquid gasket.

Revision: 2005 November

EM-27

2006 Q45


OIL PAN AND OIL STRAINER b.

Apply liquid gasket thoroughly as shown in figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-45, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . CAUTION: Attaching should be done within 5 minutes after coating.

PBIC0195E

c. d.

Install new O-ring to oil pump and front cover side. Install oil pan. CAUTION: Install avoiding misalignment of O-rings. ● Tighten mounting bolts in numerical order as shown in the figure. NOTE: Tighten mounting bolts No. 1 and 2 in two steps. The numerical order No. 11 and 17 shown second steps. ● There are three types of mounting bolts. Refer to the following for locating bolts. M6 × 30 mm (1.18 in) M8 × 100 mm (3.94 in) M8 × 45 mm (1.77 in)

: 18, 19 : 5, 9 : Except the above

PBIC0194E

e. f. 3.

Tighten transmission joint bolts. Refer to AT-249, "TRANSMISSION ASSEMBLY" . Install rear plate cover. Install oil pan drain plug. ● Refer to EM-26, "Removal and Installation" for installation direction of washer. 4. Install in the reverse order of removal. NOTE: Pour engine oil at least 30 minutes after oil pan is installed.

INSPECTION AFTER INSTALLATION 1. 2. 3. 4.

Check engine oil level and adjust the level. Refer to LU-6, "ENGINE OIL" . Start engine, and make sure there is no leak of engine oil. Stop engine and wait for 15 minutes. Check and adjust engine oil level again. Refer to LU-6, "ENGINE OIL" .

Revision: 2005 November

EM-28

2006 Q45


IGNITION COIL IGNITION COIL Removal and Installation

PFP:22448

A NBS001ON

EM

C

D

E

F

G PBIC1589E

1.

Ignition coil

2.

Spark plug

H

REMOVAL 1. 2. 3. 4. 5.

Remove engine cover (with power tool), air duct (inlet), air cleaner cover and battery cover. Refer to EM13, "Removal and Installation" . Remove air duct and air cleaner case assembly. Refer to EM-17, "AIR CLEANER AND AIR DUCT" . Move heater hose and its peripheral parts aside. (No. 7 cylinder) Disconnect harness connector from ignition coil. Remove ignition coil. CAUTION: Do not shock it.

INSTALLATION

I

J

K

Install in the reverse order of removal. L

M

Revision: 2005 November

EM-29

2006 Q45


SPARK PLUG (PLATINUM-TIPPED TYPE) SPARK PLUG (PLATINUM-TIPPED TYPE) Removal and Installation

PFP:22401 NBS001OO

REMOVAL 1. 2.

Remove ignition coil. Refer to EM-29, "IGNITION COIL" . Remove spark plug with the spark plug wrench (commercial service tool). CAUTION: Do not drop or shock it.

SEM294A

INSPECTION AFTER REMOVAL Use standard type spark plug for normal condition. The hot type spark plug is suitable when fouling occurs with the standard type spark plug under conditions such as: ● Frequent engine starts ● Low ambient temperatures The cold type spark plug is suitable when spark knock occurs with the standard type spark plug under conditions such as: ● Extended highway driving ● Frequent high engine revolution ●

Spark plug (Platinum-tipped type): Make

NGK

Standard type

PLFR5A-11

Hot type

PLFR4A-11

Cold type

PLFR6A-11

Plug gap (Nominal)

: 1.1 mm (0.043 in)

CAUTION: ● Do not drop or shock spark plug. ● 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 SMA773C

Revision: 2005 November

EM-30

2006 Q45


SPARK PLUG (PLATINUM-TIPPED TYPE) ●

Checking and adjusting plug gap is not required between change intervals.

A

EM

C SMA806CA

D

INSTALLATION Install in the reverse order of removal. Spark plug:

E

: 24.6 N·m (2.5 kg-m, 18 ft-lb) F

G

H

I

J

K

L

M

Revision: 2005 November

EM-31

2006 Q45


FUEL INJECTOR AND FUEL TUBE FUEL INJECTOR AND FUEL TUBE Removal and Installation

PFP:16600 NBS001OP

PBIC4065E

1.

Fuel injector sub harness (right)

2.

4.

Quick connector cap

5.

O-ring

6.

Fuel damper (right)

7.

Fuel tube (right)

8.

Spacer

9.

Fuel feed damper

Clip

12. O-ring (Green)

10. Fuel damper and fuel hose assembly 11. 13. Fuel injector

Centralized under-floor piping

14. O-ring (Black)

3.

Fuel feed hose

15. Fuel tube (left)

16. Fuel injector sub harness (left)

CAUTION: Do not remove or disassemble parts unless instructed as shown in the figure.

REMOVAL WARNING: ● Put a “CAUTION: INFLAMMABLE” sign in the workshop. ● Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher. ● Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area. 1. Remove engine cover with power tool. Refer to EM-13, "ENGINE ROOM COVER" . 2. Release fuel pressure. Refer to EC-80, "FUEL PRESSURE RELEASE" .

Revision: 2005 November

EM-32

2006 Q45


FUEL INJECTOR AND FUEL TUBE 3.

Disconnect fuel feed hose on engine side with the following: (Excepting to confirm whether or not there is quick connector cap, perform same procedure for the side of centralized underfloor piping as well.)

A

EM

C SBIA0353E

D

a.

Remove quick connector cap from quick connector connection. (engine side only) E

F

G SBIA0354E

b.

Disconnect quick connector from fuel tube (fuel feed damper) with the following: CAUTION: Disconnect quick connector by using the quick connector release (SST: J-45488), not by picking out retainer tabs (centralized under-floor piping side). i. With the sleeve side of the quick connector release facing quick connector, install the quick connector release onto fuel tube. ii. Insert the quick connector release into quick connector until sleeve contacts and goes no further. Hold the quick connector release on that position. CAUTION: Inserting the quick connector release hard will not disconnect quick connector. Hold the quick connector release where it contacts and goes no further. iii. Draw and pull out quick connector straight from fuel tube. CAUTION: ● Pull quick connector holding “A” position as shown in KBIA0702E the figure. ● 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. ● Keep parts away from heat source. Especially, be careful when welding is performed around them. ● Do not expose parts to battery electrolyte or other acids. ● Do not bend or twist connection between quick connector and fuel feed hose during installation/removal.

Revision: 2005 November

EM-33

2006 Q45

H

I

J

K

L

M


FUEL INJECTOR AND FUEL TUBE ●

To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar.

PBIC1899E

4.

5. 6. 7.

Disconnect fuel damper and fuel hose assembly from fuel tubes (right and left). CAUTION: ● While hoses are disconnected, plug them to prevent fuel from draining. ● Do not separate fuel damper and fuel hose assembly. Remove intake manifold (upper) with power tool. Refer to EM-19, "Removal and Installation" . Disconnect fuel injector sub harness connector from fuel injector. Loosen mounting bolts “2” to “1” as shown in the figure, and remove fuel tube and fuel injector assembly. CAUTION: ● When removing, be careful to avoid any interference with fuel injector. ● Use a shop cloth to absorb any fuel leaks from fuel tube.

PBIC2338E

8. 9. a. b.

Remove spacers on intake manifold (lower). Remove fuel injector from fuel tube with the following: Open and remove clip. Remove fuel injector from fuel tube by pulling straight. CAUTION: ● Be careful with remaining fuel that may go out from fuel tube. ● Be careful not to damage injector nozzles during removal. ● Do not bump or drop fuel injectors. ● Do not disassemble fuel injectors.

PBIC1264E

10. Remove fuel damper (right) and fuel feed damper.

INSTALLATION 1.

Install fuel damper (right) and fuel feed damper.

Revision: 2005 November

EM-34

2006 Q45


FUEL INJECTOR AND FUEL TUBE When handling O-rings, be careful of the following: A CAUTION: ● Handle O-ring with bare hands. Do not wear gloves. ● Lubricate O-ring with new engine oil. EM ● Do not clean O-ring with solvent. ● Make sure that O-ring and its mating part are free of foreign material. ● When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it C quickly into fuel tube. ● Insert O-ring straight into fuel tube. Do not decenter or twist it. D ● Insert fuel damper (right) and fuel feed damper straight into fuel tube (right). ● Tighten mounting bolts evenly in turn. ● After tightening mounting bolts, make sure that there is no gap between flange and fuel tube (right). E Install O-rings to fuel injector paying attention to the items below. CAUTION: ● Upper and lower O-ring are different. Be careful not to confuse them. F Fuel tube side : Black Nozzle side : Green G ● Handle O-ring with bare hands. Do not wear gloves. ● Lubricate O-ring with new engine oil. ● Do not clean O-ring with solvent. H ● Make sure that O-ring and its mating part are free of foreign material. ● When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it I quickly into fuel tube. ● Insert O-ring straight into fuel tube. Do not decenter or twist it. Install fuel injector to fuel tube with the following: J Insert clip into clip mounting groove on fuel injector. ● Insert clip so that lug “A” of fuel injector matches notch “A” of the clip. K CAUTION: ● Do not reuse clip. Replace it with a new one. L ● Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring. Insert fuel injector into fuel tube with clip attached. M ● Insert it while matching it to the axial center. ● Insert fuel injector so that lug “B” of fuel tube matches notch “B” of the clip. ● Make sure that fuel tube flange is securely fixed in flange fixing groove on clip. Make sure that installation is complete by making sure that fuel injector does not rotate or come off. ● Make sure that protrusions of fuel injectors are aligned with notch of clips after installation. ●

2.

3. a.

b.

c.

PBIC2337E

4. 5.

Install spacers on intake manifold (lower). Install fuel tube and fuel injector assembly to intake manifold. CAUTION: Be careful not to let tip of injector nozzle come in contact with other parts.

Revision: 2005 November

EM-35

2006 Q45


FUEL INJECTOR AND FUEL TUBE ●

Tighten mounting bolts “1” to “2” as shown in the figure and in two steps. 1st step

: 10.1 N·m (1.0 kg-m, 7 ft-lb)

2nd step

: 23.5 N·m (2.4 kg-m, 17 ft-lb)

PBIC2338E

6. a. b. c.

d. e. f.

Connect fuel feed hose on engine side with the following: (Excepting to confirm whether or not there is quick connector cap, perform same procedure for the side of centralized under-floor piping as well.) Make sure no foreign substances are deposited in and around fuel tube (fuel feed damper) and quick connector, and no damage on them. Thinly apply new engine oil around fuel tube from tip end to spool end. Align center to insert quick connector straightly into fuel tube. ● Insert fuel tube into quick connector until top spool is completely inside quick connector, and 2nd level spool exposes right below quick connector. CAUTION: ● Hold “A” position as shown in the figure when inserting fuel tube into quick connector. ● Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick connector. ● Insert until you hear a “click” sound and actually feel the engagement. KBIA0272E ● To avoid misidentification of engagement with a similar sound, be sure to perform the next step. 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. Install quick connector cap on quick connector connection. (on engine side only). Install fuel feed hose to hose clamps.

SBIA0354E

7.

Install in the reverse order of removal.

INSPECTION AFTER INSTALLATION Check on Fuel Leakage 1.

2.

Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. NOTE: Use mirrors for checking at points out of clear sight. Start engine. With engine speed increased, check again for fuel leakage at connection points. CAUTION: Do not touch engine immediately after stopped, as engine becomes extremely hot.

Revision: 2005 November

EM-36

2006 Q45


ROCKER COVER ROCKER COVER Removal and Installation

PFP:13264

A NBS001OQ

EM

C

D

E

F

G

H

I PBIC2353E

1.

Rocker cover (left bank)

2.

PCV valve

3.

O-ring

4.

Rocker cover gasket (left bank)

5.

Rocker cover (right bank)

6.

PCV valve

7.

O-ring

8.

Oil filler cap

9.

Oil catcher

J

K

10. Rocker cover gasket (right bank)

REMOVAL 1. a. b. c. d. e. f. 2. a. b. c. d. 3. 4.

Refer to the following for removal works related to left-bank. Remove engine cover (with power tool) and air cleaner cover. Refer to EM-13, "Removal and Installation" . Remove air duct (inlet), air duct and air cleaner case assembly. Refer to EM-17, "Removal and Installation" . Remove bracket (installation parts for No.6 camshaft bracket). Refer to EM-50, "CAMSHAFT" . Move harness on upper rocker cover and its peripheral aside. Remove ignition coil. Refer to EM-29, "Removal and Installation" . Remove PCV valve hose from PCV valve. Refer to the following for removal works related to right-bank. Remove engine cover (with power tool) and battery cover. Refer to EM-13, "Removal and Installation" . Move harness on upper rocker cover and its peripheral aside. Remove ignition coil EM-29, "Removal and Installation" . Remove PCV valve hose from PCV valve. Remove PCV valves and O-rings from rocker covers (right and left bank), if necessary. Remove oil filler cap and oil catcher from rocker cover (right bank), if necessary.

Revision: 2005 November

EM-37

2006 Q45

L

M


ROCKER COVER 5.

Loosen bolts in the reverse order shown in the figure (with power tool). CAUTION: Do not hold oil filler neck (right bank) not to damage it.

PBIC0027E

6. 7.

Remove rocker cover gaskets from rocker covers (right and left bank). Use scraper to remove all traces of liquid gasket from cylinder head and camshaft bracket (No. 1 and 6). CAUTION: Do not scratch or damage the mating surface when cleaning off oil liquid gasket.

INSTALLATION 1.

a. b.

Apply liquid gasket to joint part of cylinder head and camshaft bracket as follows: NOTE: Figure shows an example of left-bank side (zoomed in shows No.1 camshaft bracket). Apply only to No.1 camshaft bracket for right-bank side. Refer to figure “a” to apply liquid gasket to joint part of No.1 and No.6 camshaft bracket and cylinder head. Refer to figure “b” to apply liquid gasket in 90 degrees to figure “a”. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-45, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .

PBIC2444E

2.

Install rocker cover. ● Check if rocker cover gasket is not dropped from installation groove of rocker cover.

3.

Tighten bolts in two steps separately in numerical order as shown in the figure. CAUTION: Do not hold oil filler neck (right bank) not to damage it. 1st step : 2.0 N·m (0.2 kg-m, 18 in-lb) 2nd step : 8.3 N·m (0.85 kg-m, 73 in-lb) PBIC0027E

4.

Install in the reverse order of removal.

Revision: 2005 November

EM-38

2006 Q45


TIMING CHAIN TIMING CHAIN Removal and Installation

PFP:13028

A NBS001OR

EM

C

D

E

F

G

H

I

J

K

L

M

PBIC4128E

Revision: 2005 November

EM-39

2006 Q45


TIMING CHAIN 1.

Camshaft sprocket (EXH)

2.

Camshaft sprocket (INT)

3.

Camshaft sprocket (INT)

4.

Camshaft sprocket (EXH)

5.

Front cover

6.

Intake valve timing control solenoid valve (right bank)

7.

O-ring

8.

Seal ring

9.

Intake valve timing control position sensor (right bank)

10. O-ring

11.

Intake valve timing control cover (right bank)

12.

Intake valve timing control position sensor (left bank)

13. O-ring

14.

Intake valve timing control cover (left 15. Seal ring bank)

16.

Intake valve timing control solenoid valve (left bank)

17. O-ring

18. Oil level gauge

19. Oil level gauge guide

20. O-ring

21. Crankshaft pulley bolt

22. Crankshaft pulley

23. Front oil seal

24. Chain tensioner cover

25. Camshaft position sensor (PHASE)

26. O-ring

27. Oil pump drive spacer

28. Oil pump assembly

29. Crankshaft sprocket

30. O-ring

31. O-ring

Chain tension guide 32. (right bank)

33.

34. Timing chain (right bank)

35. Timing chain (left bank)

36. Chain tensioner (left bank)

37. Chain tensioner (right bank)

38.

Chain slack guide (left bank)

39.

Chain slack guide (right bank) Chain tension guide (left bank)

40. O-ring

REMOVAL 1. 2.

3.

4.

5. a. b.

Remove engine assembly from vehicle. Refer to EM-79, "Removal and Installation" . Remove the following components and related parts: ● Drive belt auto tensioner and idler pulley; Refer to EM-15, "Drive Belt Auto Tensioner and Idler Pulley" . ● Thermostat housing and hoses; Refer to CO-22, "Removal and Installation" . ● Ignition coil; Refer to EM-29, "Removal and Installation" . ● Rocker cover; Refer to EM-37, "Removal and Installation" . If necessary, remove intake valve timing control position sensor (right and left bank) and camshaft position sensor (PHASE) from intake valve timing control cover and front cover. CAUTION: ● Handle components and parts carefully to avoid dropping and shocks. ● Do not disassemble. If necessary, remove intake valve timing control solenoid valve from intake valve timing control cover. CAUTION: PBIC0050E ● Handle components and parts carefully to avoid dropping and shocks. ● Do not disassemble. Remove intake valve timing control cover as follows: Loosen and remove fixing bolts in reverse order of that shown in figure. Use the seal cutter [SST: KV10111100 (J-37228)] or the equivalent to cut liquid gasket for removal. CAUTION: ● Be careful not to damage mating surfaces. ● Pull out cover keeping levelness without an angle, as inner part of cover is engaged with the center of camshaft sprocket (INT). PBIC0051E

Revision: 2005 November

EM-40

2006 Q45


TIMING CHAIN 6.

Remove O-ring from front cover. A

EM

C SBIA0374E

D

7. a.

Obtain compression TDC of No. 1 cylinder as follows: Turn crankshaft pulley clockwise to align the TDC identification notch (without paint mark) with timing indicator on front cover.

E

F

G PBIC2341E

b.

H

At this time, make sure the both intake and exhaust cam noses of No.1 cylinder (top front on left bank) face outside. ● If they do not face outside, turn crankshaft pulley by 360 degrees once more.

I

J

K KBIA0400J

8. a. b. c. d.

Remove crankshaft pulley as follows: Remove rear plate cover. Refer to EM-26, "OIL PAN AND OIL STRAINER" . Set the ring gear stopper (SST). Loosen crankshaft pulley bolt. Pull crankshaft pulley with both hands to remove it. CAUTION: ● Do not remove crankshaft pulley bolt. Keep loosened crankshaft pulley bolt in place to protect removed crankshaft pulley from dropping. ● Do not remove balance weight (inner hexagon bolt) at the front of crankshaft pulley.

L

M

PBIC1656E

9.

Remove oil pan and oil strainer. Refer to EM-26, "OIL PAN AND OIL STRAINER" .

Revision: 2005 November

EM-41

2006 Q45


TIMING CHAIN 10. Remove front cover as follows: a. Loosen and remove fixing bolts in the reverse order of that shown in figure. b. Use the seal cutter [SST: KV10111100 (J-37228)] or the equivalent to cut liquid gasket for removal. CAUTION: Be careful not to damage mating surfaces.

KBIA0354J

11. Remove front oil seal from front cover using suitable tool. CAUTION: Be careful not to damage front cover. 12. Remove O-rings from cylinder heads (right and left bank) and cylinder block.

SBIA0373E

13. Remove chain tensioner cover from front cover. ● Use seal cutter (SST: KV10111100) or equivalent to cut liquid gasket for remove. 14. Remove oil pump drive spacer. ● Install bolts into two bolt holes [M6 x pitch 1.0 mm (0.04 in)] on front surface. Using a small puller, pull spacer off from crankshaft. NOTE: The center to center dimension between the two bolt holes is 33 mm (1.30 in).

PBIC0054E

15. Remove oil pump. Refer to LU-10, "OIL PUMP" . 16. Remove chain tensioner (left bank) as follows: NOTE: To remove timing chain and associated parts, start with those on left bank. The procedure for removing parts on right bank is omitted because it is the same as that for left bank. a. Press tab in the direction of arrow (or turn lever in the direction of arrow) to unlock the locking with the groove that stops tensioner plunger from returning. ● Lightly press tensioner plunger to release the tension of spring for this operation. b. Push in tensioner plunger to align the hole on lever and that on pump main body. ● Pushing in tensioner plunger too far does not allow the holes to align. Therefore, push in the plunger to the degree at which the start of stopper groove and tab engages. PBIC2343E

Revision: 2005 November

EM-42

2006 Q45


TIMING CHAIN c.

Insert a stopper pin [hard wire with approx. 0.5 mm (0.020 in) diameter or a similar tool] to fix plunger. With the plunger fixed, remove chain tensioner. A 17. Remove chain tension guide and chain slack guide. 18. Remove timing chain and crankshaft sprocket. EM 19. With hexagonal part of camshaft locked with wrench, loosen bolts securing camshaft sprocket to remove camshaft sprocket. CAUTION: C To avoid interference between valves and pistons, do not turn crankshaft or camshaft with timing chain is disconnected. D

PBIC0030E

20. Using the same procedure as for left bank, remove timing chain and associated parts on right side. 21. Use scraper to remove all traces of old liquid gasket from front cover and opposite mating surfaces. â—? Remove old liquid gasket from bolt hole and thread.

E

F

G

H

I PBIC2084E

INSPECTION AFTER REMOVAL

J

Check for cracks and any excessive wear at roller links and link plates. Replace timing chain if necessary. K

L

M PBIC0282E

Revision: 2005 November

EM-43

2006 Q45


TIMING CHAIN INSTALLATION

PBIC2344E

NOTE: ● The above figure shows the relationship between the mating mark on each timing chain and that on the corresponding sprocket, with the components installed. ● Parts with an identification mark (R or L) should be installed on the corresponding bank according to the mark. Parts with an identification mark: ● Camshaft sprocket (INT) ● Dowel pin groove of camshaft sprocket (EXH) (camshaft sprocket is same part both banks) ● Chain tension guide ● Chain slack guide To install timing chain and associated parts, start with those on right bank. The procedure for installing parts on left bank is omitted because it is the same as that for installation on right bank. 1. Make sure that crankshaft key and dowel pin of each camshaft are facing in the direction indicated.(No.1 cylinder at compression TDC.) NOTE: Camshaft does not stop at the position as shown in the figure, for the placement of cam nose. However it is generally accepted camshaft is placed for the same direction of the figure. Camshaft dowel pin : At cylinder head upper face side in each bank. Crankshaft Key : At cylinder head side of left bank.

Revision: 2005 November

EM-44

SBIA0356E

2006 Q45


TIMING CHAIN 2.

Install camshaft sprockets. ● Install onto correct side by checking with identification mark on surface. ● Install camshaft sprocket (EXH) by selectively using the groove of dowel pin according to the bank. (Common part used for both banks.) ● Lock the hexagonal part of camshaft in the same way as for removal, and tighten fixing bolts.

A

EM

C PBIC2345E

D

3.

Install crankshaft sprockets for both banks. ● Install each crankshaft sprocket so that its flange side (the larger diameter side without teeth) faces in the direction shown in figure. NOTE: The same parts are used but facing directions are different.

E

F

G PBIC0057E

4.

Install timing chains and associated parts.

H

I

J

K

L

M

PBIC2344E

Align the mating mark on each sprocket and the timing chain for installation. NOTE: Before installing chain tensioner, it is possible to change the position of mating mark on timing chain for that on each sprocket for alignment.

Revision: 2005 November

EM-45

2006 Q45


TIMING CHAIN

5. 6. 7. a.

b.

CAUTION: For the above reason, after the mating marks are aligned, keep them aligned by holding them with a hand. ● Install chain slack guides and chain tension guides onto correct side by checking with identification mark on surface. ● Install chain tensioner with plunger fixed as described in its removal. CAUTION: ● Before and after the installation of chain tensioner, make sure that the mating mark on timing chain is not out of alignment. ● After installing chain tensioner, remove the stopper pin to release tensioner. Make sure that tensioner is released. ● To avoid chain-link skipping of timing chain, do not move crankshaft or camshafts until front cover is installed. In the same way as for right bank, install timing chain and associated parts on left side. Install oil pump assembly. Refer to LU-10, "OIL PUMP" . Install oil pump drive spacer as follows: Insert oil pump drive spacer according to the directions of crankshaft key and the two flat surfaces of oil pump inner rotor. ● If the positional relationship does not allow the insertion, rotate oil pump inner rotor with a finger to allow the spacer. After confirming that the position of each part is in correct condition to allow for the spacer, force fit the spacer by lightly tapping with a plastic hammer until it contacts and does not go further. PBIC0058E

8.

Install front oil seal onto front cover. ● Install new oil seal in the direction shown in the figure.

SEM715A

Using the front oil seal drift (commercial service tool) or drift with 54 mm (2.13 in) diameter, force fit the seal until it levels with the front end surface of front cover. CAUTION: Be careful not to scratch or make burrs on circumference of oil seal.

PBIC0059E

Revision: 2005 November

EM-46

2006 Q45


TIMING CHAIN 9.

Install chain tensioner cover onto front cover. ● Apply liquid gasket as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-45, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .

A

EM

C SBIA0372E

D

10. Install front cover as follows: a. Install new O-rings onto cylinder head (right and left bank) and cylinder block.

E

F

G SBIA0373E

b.

c.

Apply liquid gasket as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-45, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . Make sure again that the timing mating mark on timing chain and that on each sprocket are aligned. Then, install front cover. CAUTION: Be careful to avoid interference with the front end of oil pump drive spacer. Such interference may damage front oil seal.

H

I

J

PBIC0062E

d.

K

Tighten mounting bolts in the numerical order shown in the figure. L

M

KBIA0354J

There are four type of mounting bolts.

PBIC0063E

Revision: 2005 November

EM-47

2006 Q45


TIMING CHAIN e.

After tightening, re-tighten to the specified torque. CAUTION: Be sure to wipe off any excessive liquid gasket leaking onto surface mating with oil pan.

11. Install intake valve timing control cover as follows: a. At the back of intake valve timing control cover, install new seal rings (three for each) to the area to be inserted into camshaft sprocket (INT). CAUTION: Do not spread seal ring excessively to avoid breaks and deformation. b. On the side of front cover, install new O-ring (one for each bank).

SBIA0374E

c.

Apply liquid gasket as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-45, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .

SBIA0375E

d.

Tighten mounting bolts in the numerical order shown in the figure.

PBIC0051E

12. Install intake valve timing control position sensor, intake valve timing control solenoid valve and camshaft position sensor (PHASE) to intake valve timing control cover and front cover. ● Be sure to tighten bolts with flanges completely seated. 13. Install crankshaft pulley. ● Install according to the dowel pin of oil pump drive spacer. ● Lightly tapping its center with plastic hammer, insert pulley. CAUTION: Do not tap pulley on the side surface where belt is installed (outer circumference). 14. Tighten fixing bolt of crankshaft pulley as follows: a. Fix crankshaft with ring gear stopper (SST: J-45476). b. Apply engine oil onto threaded parts of bolts and seating areas. Revision: 2005 November

EM-48

2006 Q45


TIMING CHAIN c.

Tighten bolt crankshaft pulley bolt. A

: 93.1 N·m (9.5 kg-m, 69 ft-lb). d.

e.

Select one most visible notch of the four on bolt flange. Corresponding to the selected notch, put a mating mark (such as paint) on crankshaft pulley. Tighten further by 90 degrees. (Angle tightening) ● Check the tightening angle by referencing to the notches. The angle between two notches is 90 degrees.

EM

C

D

PBIC2346E

E

15. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to check for interference among parts. 16. Install in the reverse order of removal. NOTE: If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in guide may generate a pounding noise during and just after engine start. However, this does not indicate an unusualness. Noise will stop after hydraulic pressure rises.

INSPECTION AFTER INSTALLATION Inspection for Leaks

Summary of the inspection items: Engine running

After engine stopped

Engine coolant

Level

Leakage

Level

Engine oil

Level

Leakage

Level

Other oils and fluids *

Level

Leakage

Level

Leakage

Leakage

Leakage

Leakage

Exhaust gas

* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.

Revision: 2005 November

I

J

K

L

M

Before starting engine

Fuel

G

H

The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak. ● Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to MA-10, "RECOMMENDED FLUIDS AND LUBRICANTS" . ● Use procedure below to check for fuel leakage. – Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. – Start engine. With engine speed increased, check again for fuel leakage at connection points. ● Run engine to check for unusual noise and vibration. ● Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including engine oil and engine coolant. ● Bleed air from passages in lines and hoses, such as in cooling system. ● After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to specified level, if necessary.

Item

F

EM-49

2006 Q45


CAMSHAFT CAMSHAFT Removal and Installation

PFP:13001 NBS001OS

PBIC4127E

1.

Cylinder head (right bank)

4.

Valve lifter

5.

Camshaft bracket (No. 1)

6.

Washer

7.

Camshaft (EXH)

8.

Camshaft sprocket (EXH)

9.

Camshaft sprocket (INT)

11.

Cylinder head (left bank)

12. Adjusting shim

10. Camshaft (INT)

2.

Camshaft bracket (No. 2, 3, 4, 5)

3.

Adjusting shim

13. Valve lifter

14. Camshaft (INT)

15. Camshaft sprocket (INT)

16. Camshaft sprocket (EXH)

17. Camshaft (EXH)

18. Camshaft bracket (No.1)

19. Washer

20. Camshaft bracket (No. 2, 3, 4, 5)

21. Camshaft bracket (INT, No. 6)

22. Bracket

REMOVAL 1. 2.

Remove timing chain. Refer to EM-39, "Removal and Installation" . With hexagonal part of camshaft locked with wrench, loosen bolts securing camshaft sprocket to remove camshaft sprocket. CAUTION: To avoid interference between valves and pistons, do not turn crankshaft or camshaft with timing chain disconnected.

PBIC0030E

Revision: 2005 November

EM-50

2006 Q45


CAMSHAFT 3.

Loosen fixing bolts in the reverse order of that shown in the figure to remove camshaft brackets. ● Lightly tapping with plastic hammer, remove No. 1 camshaft bracket and No. 6 camshaft bracket. NOTE: The bottom surface of each bracket will be stuck to cylinder head because of liquid gasket.

A

EM

C

D

E

F

G PBIC0031E

4. 5.

Remove camshaft. Remove adjusting shims and valve lifters if necessary. ● Correctly identify location where each part is installed. Keep parts in an organized way to avoid mixing them up.

INSPECTION AFTER REMOVAL Camshaft Runout 1.

2. 3.

Put V block on precise flat bed, and support No. 2 and No. 5 journal of camshaft. CAUTION: Do not support journal No.1 (on the side of camshaft sprocket) because it has a different diameter from the other four locations. Set a dial indicator vertically to No.3 journal. Turn camshaft to one direction with hands, and measure camshaft runout on a dial indicator. (Total indicator reading) Limit ●

: 0.02 mm (0.0008 in)

K

L

PBIC2499E

If it exceeds the limit, replace camshaft.

Measure camshaft cam height. Standard: Intake Exhaust

: 44.865 - 45.055 mm (1.7663 - 1.7738 in) : 43.925 - 44.115 mm (1.7293 - 1.7368 in)

Cam wear limit

: 0.2 mm (0.008 in)

If it exceeds the limit, replace camshaft. PBIC0039E

Revision: 2005 November

EM-51

I

J

Camshaft Cam Height ●

H

2006 Q45

M


CAMSHAFT Camshaft Journal Oil Clearance CAMSHAFT JOURNAL OUTER DIAMETER ● Measure outer diameter of camshaft journal with a micrometer. Standard: No. 1 : 25.938 - 25.955 mm (1.0212 - 1.0218 in) No. 2, 3, 4, 5 : 25.953 - 25.970 mm (1.0218 - 1.0224 in)

PBIC0040E

CAMSHAFT BRACKET INNER DIAMETER ● Tighten camshaft bracket bolt with specified torque. Refer to EM-54, "INSTALLATION" for the tightening procedure. ● Measure the inner diameter “A” of camshaft bracket with an inside micrometer. Standard: 26.000 - 26.021 mm (1.0236 - 1.0244 in)

PBIC1645E

CAMSHAFT JOURNAL OIL CLEARANCE ● (Journal oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal outer diameter) Standard: No. 1 No. 2, 3, 4, 5

: 0.045 - 0.083 mm (0.0018 - 0.0033 in) : 0.030 - 0.068 mm (0.0012 - 0.0027 in)

● If out of the standard, replace either or both camshaft and cylinder head. NOTE: It is impossible to replace only camshaft bracket as camshaft bracket is manufactured with cylinder head. Replace the whole cylinder head assembly.

Camshaft End Play 1. 2.

Install camshaft in cylinder head. Refer to EM-54, "INSTALLATION" for tightening procedure. Install a dial indicator in thrust direction on front end of camshaft. Measure the camshaft end play when camshaft is moved forward/backward (in direction to axis). Standard: 0.115 - 0.188 mm (0.0045 - 0.0074 in)

PBIC2446E

Revision: 2005 November

EM-52

2006 Q45


CAMSHAFT ●

Measure the following parts if out of the standard. Dimension “A” for camshaft No. 1 journal Standard

: 30.500 - 30.548 mm (1.2008 - 1.2027 in)

Dimension “B” for cylinder head No. 1 journal Standard

A

EM

: 30.360 - 30.385 mm (1.1953 - 1.1963 in)

Refer to the standards above, and then replace camshaft and/ or cylinder head.

C KBIA2426J

D

Camshaft Sprocket Runout 1.

2.

Put V-block on precise flat table, and support No. 2 and No. 5 journal of camshaft. CAUTION: Do not support journal No. 1 (on the side of camshaft sprocket) because it has a different diameter from the other four locations. Measure camshaft sprocket runout with a dial indicator (total indicator reading). Limit ●

E

F

: 0.15 mm (0.0059 in)

G

If it exceeds the limit, replace camshaft sprocket.

H PBIC0930E

Valve Lifter and Adjusting Shim Check if surface of valve lifter and adjusting shim has any wear or cracks. ● If anything above is found, replace valve lifter or adjusting shim. ● When replacing adjusting shim. Refer to EM-57, "Valve Clearance" .

I

J

K

PBIC0231E

L

Valve Lifter Clearance VALVE LIFTER OUTER DIAMETER ● Measure outer diameter of valve lifter with a micrometer.

M

Standard: 33.965 - 33.975 mm (1.3372 - 1.3376 in)

SEM961E

Revision: 2005 November

EM-53

2006 Q45


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2006 INFINITI Q45 Service Repair Manual  
2006 INFINITI Q45 Service Repair Manual  
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