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QUICK REFERENCE INDEX Edition: December 2002 A GENERAL INFORMATION Revision: April 2004 Publication No. SM3E-1S50U3 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

TF PR FFD RFD FAX RAX FSU RSU WT BR PB BRC PS

Transfer Propeller Shaft Front Final Drive Rear Final Drive Front Axle Rear Axle Front Suspension Rear Suspension Road Wheels & Tires Brake System Parking Brake System Brake Control System Power Steering System

SB SRS

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 BCS LAN AV

MA

Starting & Charging System Lighting System Driver Information System Wiper, Washer & Horn Body Control System 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 2003 INFINITI FX35/FX45. 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.


INCH TO METRIC CONVERSION TABLE

METRIC TO INCH CONVERSION TABLE

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

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

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

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

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


QUICK REFERENCE CHART FX35/FX45 QUICK REFERENCE CHART FX35/FX45 ENGINE TUNE-UP DATA (VQ35DE) Engine model

2003 PFP:00000 ELS0003W

VQ35DE

Firing order

1-2-3-4-5-6

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

rpm

650±50

Ignition timing (BTDC at idle speed) A/T (In “P” or “N” position)

15°± 5°

CO% at idle

0.7 - 9.9 % and engine runs smoothly Deflection adjustment

Drive Belt

Used belt Limit

After adjustment

Alternator and air conditioner compressor belt

7 (0.28)

4-5 (0.16 - 0.20)

Power steering oil pump belt

12 (0.47)

9 - 10 (0.35 - 0.39)

Applied pushing force

Unit: mm (in)

Tension adjustment Used belt

New belt

New belt

Limit

After adjustment

3.5 - 4.5 (0.138 - 0.177)

294 (30, 66)

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

838 - 926 (85.5 - 94.5, 188 - 208)

8-9 (0.31 - 0.35)

196 (20, 44)

348 - 436 (35.5 - 44.5, 78 - 98)

470 - 559 (48 - 57, 106 - 126)

98N (10kg, 22lb)

Radiater cap relief pressure

Unit: N (kg, lb)

kPa (kg/cm2 , psi) 78 - 98 (0.8 - 1.0, 11 - 14)

Standard Limit

59 (0.6, 9)

Cooling system leakage testing pressure

kPa (kg/cm2 , psi)

Compression pressure

kPa (kg/cm2 , psi)/rpm

157(1.6, 23)

1,275 (13.0, 185) /300

Standard Minimum Spark plug

981 (10.0, 142)/300

Standard type

PLFR5A - 11

Hot type

PLFR4A - 11

Cold type

PLFR6A - 11


QUICK REFERENCE CHART FX35/FX45

2003

ENGINE TUNE-UP DATA (VK45DE) Engine model

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°

CO% at idle

0.7 - 9.9 % and engine runs smoothly

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)

ELS0003X

Minimum

– 1° 29′ ( – 1.48° )

Nominal

– 0° 44′ ( – 0.73° )

Maximum Left and right difference Caster

Degree minute (Decimal degree)

Total toe-in

Degree minute (Decimal degree)

Distance (A – B)

Angle (left plus right) Degree minute (Degree) Wheel turning angle (Full turn)

45′ ( 0.75° ) or less

Minimum

3° 02′ ( 3.03° )

Nominal

3° 47′ ( 3.78° )

Maximum

4° 32′ ( 4.53° )

Left and right difference Kingpin inclination

0° 01′ ( 0.02° )

45′ ( 0.75° ) or less

Minimum

12° 20′ ( 12.33° )

Nominal

13° 05′ ( 13.08° )

Maximum

13° 50′ ( 13.83° )

Minimum

0.6 mm ( 0.024 in )

Nominal

1.6 mm ( 0.063 in )

Maximum

2.6 mm ( 0.102 in )

Minimum

Nominal

6′ ( 0.1° )

Maximum

Inside

MInimum

32° 00′ ( 32.0° )

Degree minute (Decimal degree)

Nominal

35° 00′ ( 35.0° )

Maximum

36° 00′ ( 36.0° )

Nominal

30° 00′ ( 30.0° )

Outside Degree minute (Decimal degree)

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


QUICK REFERENCE CHART FX35/FX45

2003

REAR WHEEL ALIGNMENT (Unladen*) Camber Degree minute (Decimal degree) Distance ( A – B )

Total toe-in Angle (left plus right ) Degree minute (Degree)

ELS0003Y

Minimum

– 1° 18′ ( – 1.30° )

Nominal

– 0° 48′ ( – 0.80° )

Maximum

– 0° 18′ ( – 0.30° )

Minimum

2.4 mm ( 0.094 in )

Nominal

4.7 mm ( 0.185 in )

Maximum

7.0 mm ( 0.276 in )

Minimum

0° 05′ ( 0.08° )

Nominal

0° 10′ ( 0.17° )

Maximum

0° 15′ ( 0.25° )

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

BRAKE

ELS0003Z

Front brake

Pad wear limit

2.0 ( 0.079 )

Rotor repair limit

26.0 mm ( 1.024 in )

Rear brake

Pad wear limit

2.0 mm ( 0.079 in )

Rotor repair limit

14.0 mm ( 0.551 in )

Pedal free height

161.5 - 171.5 mm ( 6.358 - 6.752 in )

Pedal depressed height*

90 mm ( 3.54 in )

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

REFILL CAPACITIES

ELS00040

UNIT

Liter

US measure

90

23 - 3/4 gal

VQ35DE

8.6

9 - 1/8 qt

VK45DE

10.0

10 - 5/8 qt

With oil filter change

4.7

5 qt

Without oil filter change

4.4

4 - 5/8 qt

5.4

5 - 3/4 qt

With oil filter change

6.6

7qt

Without oil filter change

6.0

6 - 3/8 qt

Dry engine (Overhaul)

7.7

8 - 1/8 qt

A/T

10.3

10 - 7/8 qt

1.25

2 - 5/8 pt

Front

0.65

1 - 3/8 pt

Rear

1.4

3 pt

1.0

1 - 1/8 qt

0.18

6.0 fl oz

0.55 kg

1.21 lb

Fuel tank Coolant ( With reservoir tank )

Drain and refill Engine(VQ35DE)

Dry engine (Overhaul) Drain and refill Engine(VK45DE)

Transmission Transfer Differential carrier Power steering system Air conditioning system

Compressor oil Refrigerant


Attachment No.35

TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II) The following is the information specified in Mode 6 of SAE J1979. The test value is a parameter used to determine whether a system/circuit diagnostic test is “OK” or “NG” while being monitored by the ECM during self-diagnosis. The test limit is a reference value which is specified as the maximum or minimum value and is compared with the test value being monitored. These data (test value and test limit) are specified by Test ID (TID) and Component ID (CID) and can be displayed on the GST screen.

SRT item

Self-diagnostic test item

Three way catalyst function (Bank 1) CATALYST Three way catalyst function (Bank 2)

EVAP SYSTEM

EVAP control system (Small leak) EVAP control system purge flow monitoring EVAP control system (Very small leak)

Heated oxygen sensor 1 (Bank 1)

Heated oxygen sensor 1 (Bank 2) HO2S

Heated oxygen sensor 2 (Bank 1)

Heated oxygen sensor 2 (Bank 2)

Heated oxygen sensor 1 heater (Bank 1) Heated oxygen sensor 1 heater (Bank 2) HO2S HTR Heated oxygen sensor 2 heater (Bank 1) Heated oxygen sensor 2 heater (Bank 2)

DTC P0420 P0420 P0430 P0430 P0442 P0441 P0456 P0133 P1143 P1144 P0132 P0134 P0153 P1163 P1164 P0152 P0154 P0139 P1147 P1146 P0138 P0159 P1167 P1166 P0158 P0032 P0031 P0052 P0051 P0038 P0037 P0058 P0057

Test value (GST display) TID 01H 02H 03H 04H 05H 06H 07H 09H 0AH 0BH 0CH 0DH 11H 12H 13H 14H 15H 19H 1AH 1BH 1CH 21H 22H 23H 24H 29H 2AH 2BH 2CH 2DH 2EH 2FH 30H

CID 01H 81H 02H 82H 03H 83H 03H 04H 84H 04H 04H 04H 05H 85H 05H 05H 05H 86H 86H 06H 06H 87H 87H 07H 07H 08H 88H 09H 89H 0AH 8AH 0BH 8BH

Test limit

Conversion

Max. Min. Max. Min. Max. Min. Max. Max. Min. Max. Max. Max. Max. Min. Max. Max. Max. Min. Min. Max. Max. Min. Min. Max. Max. Max. Min. Max. Min. Max. Min. Max. Min.

1/128 1 1/128 1 1/128mm2 20mV 1/128mm2 16ms 10mV 10mV 10mV 1s 16ms 10mV 10mV 10mV 1s 10mV/500ms 10mV 10mV 10mV 10mV/500ms 10mV 10mV 10mV 20mV 20mV 20mV 20mV 20mV 20mV 20mV 20mV


GENERAL INFORMATION

A GENERAL INFORMATION

SECTION

GI

GENERAL INFORMATION

GI

B

C

D

E

CONTENTS PRECAUTIONS .......................................................... 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 Precautions Necessary for Steering Wheel Rotation After Battery Disconnect .......................................... 4 OPERATION PROCEDURE ................................. 4 General Precautions ................................................ 4 Precautions for Three Way Catalyst ......................... 6 Precautions for Fuel (Unleaded Premium Gasoline Recommended) ........................................................ 6 Precautions for Fuel (Unleaded Premium Gasoline Required) ................................................................. 7 Precautions for Multiport Fuel Injection System or Engine Control System ............................................ 7 Precautions for Hoses .............................................. 7 HOSE REMOVAL AND INSTALLATION ............... 7 HOSE CLAMPING ................................................ 8 Precautions for Engine Oils ...................................... 8 HEALTH PROTECTION PRECAUTIONS ............. 8 ENVIRONMENTAL PROTECTION PRECAUTIONS ................................................................... 8 Precautions for Air Conditioning ............................... 8 HOW TO USE THIS MANUAL ................................... 9 Description ............................................................... 9 Terms ....................................................................... 9 Units ......................................................................... 9 Contents ................................................................... 9 Components ........................................................... 10 SYMBOLS ........................................................... 10 How to Follow Trouble Diagnoses ...........................11 DESCRIPTION .....................................................11 HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES ................................................11 HARNESS WIRE COLOR AND CONNECTOR NUMBER INDICATION ....................................... 12 KEY TO SYMBOLS SIGNIFYING MEASURE-

Revision; 2004 April

MENTS OR PROCEDURES ............................... 13 How to Read Wiring Diagrams ............................... 15 CONNECTOR SYMBOLS ................................... 15 SAMPLE/WIRING DIAGRAM - EXAMPL - .......... 16 DESCRIPTION .................................................... 17 Abbreviations .......................................................... 23 SERVICE INFORMATION FOR ELECTRICAL INCIDENT ......................................................................... 24 How to Check Terminal ........................................... 24 CONNECTOR AND TERMINAL PIN KIT ............ 24 HOW TO PROBE CONNECTORS ...................... 24 How to Perform Efficient Diagnosis for an Electrical Incident ................................................................... 27 WORK FLOW ...................................................... 27 INCIDENT SIMULATION TESTS ........................ 27 CIRCUIT INSPECTION ....................................... 30 Control Units and Electrical Parts ........................... 35 PRECAUTIONS .................................................. 35 CONSULT-II CHECKING SYSTEM .......................... 37 Description .............................................................. 37 Function and System Application ........................... 37 Nickel Metal Hydride Battery Replacement ............ 38 Checking Equipment .............................................. 38 CONSULT-II Start Procedure .................................. 39 CONSULT-II Data Link Connector (DLC) Circuit ... 40 INSPECTION PROCEDURE .............................. 41 LIFTING POINT ......................................................... 42 Special Service Tools ............................................. 42 Garage Jack and Safety Stand ............................... 42 2-Pole Lift ............................................................... 43 Board-On Lift .......................................................... 44 TOW TRUCK TOWING ............................................. 45 Tow Truck Towing ................................................... 45 2WD MODELS .................................................... 45 AWD MODELS .................................................... 46 Vehicle Recovery (Freeing a Stuck Vehicle) ........... 46 TIGHTENING TORQUE OF STANDARD BOLTS ... 47 Tightening Torque Table ......................................... 47 RECOMMENDED CHEMICAL PRODUCTS AND

GI-1

2003 FX

F

G

H

I

J

K

L

M


SEALANTS ............................................................... 48 Recommended Chemical Products and Sealants... 48 IDENTIFICATION INFORMATION ............................ 49 Model Variation ....................................................... 49 IDENTIFICATION NUMBER ................................ 50 IDENTIFICATION PLATE .................................... 51

Revision; 2004 April

ENGINE SERIAL NUMBER .................................51 AUTOMATIC TRANSMISSION NUMBER ...........51 Dimensions .............................................................52 Wheels & Tires ........................................................52 TERMINOLOGY ........................................................53 SAE J1930 Terminology List ...................................53

GI-2

2003 FX


PRECAUTIONS PRECAUTIONS PFP:00001 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

GI

AAS000OF

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.

B

C

D

E

F

G

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

AAS000EX

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.

Revision; 2004 April

GI-3

2003 FX

H

I

J

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M


PRECAUTIONS Precautions Necessary for Steering Wheel Rotation After Battery Disconnect AAS000OG

NOTE: ● This Procedure is applied only to models with Intelligent Key system and NVIS/IVIS (NISSAN/INFINITI VEHICLE IMMOBILIZER SYSTEM - NATS). ● Remove and install all control units after disconnecting both battery cables with the ignition knob in the ″LOCK″ position. ● Always use CONSULT-II to perform self-diagnosis as a part of each function inspection after finishing work. If DTC is detected, perform trouble diagnosis according to self-diagnostic results. For models equipped with the Intelligent Key system and NVIS/IVIS, an electrically controlled steering lock mechanism is adopted on the key cylinder. For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and steering wheel rotation will become impossible. If steering wheel rotation is required when battery power is interrupted, follow the procedure below before starting the repair operation.

OPERATION PROCEDURE 1.

2. 3. 4. 5. 6.

Connect both battery cables. NOTE: Supply power using jumper cables if battery is discharged. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the steering lock will be released. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be rotated. Perform the necessary repair operation. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting the battery cables. (At this time, the steering lock mechanism will engage.) Perform a self-diagnosis check of all control units using CONSULT-II.

General Precautions ●

AAS000EY

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

Revision; 2004 April

GI-4

2003 FX


PRECAUTIONS ●

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.

GI

B

C SEF289H

D ●

● ● ●

● ● ● ●

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. 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.

E

F

G

H

I

J

K

L

M

PBIC0190E

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

SGI234

Revision; 2004 April

GI-5

2003 FX


PRECAUTIONS 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.

Precautions for Three Way Catalyst

AAS000EZ

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 Recommended)

AAS000F0

Use unleaded regular gasoline with an octane rating of at least 87 AKI (Anti-Knock Index) number (Research octane number 91). For improved vehicle performance, NISSAN/INFINITI recommend the use of unleaded premium gasoline with an octane rating of at least 91 AKI number (Research octane number 96). CAUTION: Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Using a fuel other than that specified could adversely affect the emission control devices and systems, and could also affect the warranty coverage validity.

Revision; 2004 April

GI-6

2003 FX


PRECAUTIONS Precautions for Fuel (Unleaded Premium Gasoline Required)

AAS000GS

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.

GI

B

C

D

CAUTION: Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. 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 ●

E

AAS000F1

F

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.

G

H

I SGI787

Precautions for Hoses

AAS000F2

HOSE REMOVAL AND INSTALLATION ●

J

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

L

M 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

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PRECAUTIONS 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

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

SMA022D

Precautions for Engine Oils

AAS000F3

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.

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.

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

AAS000F4

Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to ATC/MTC section “HFC-134a (R-134a) Service Procedure”, “REFRIGERANT LINES” for specific instructions. Revision; 2004 April

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HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL Description

PFP:00008

GI AAS000DW

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

Terms ●

AAS000DX

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 ●

B

C

D

E

AAS000GX

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.

F

G

“Example” Range Outer Socket Lock Nut

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

H

Standard Drive Shaft Installation Bolt

I

: 44.3 N·m (4.5 kg-m, 33 ft-lb)

Contents

AAS000DZ

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—?

AAS000K2

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 .

SBR364AC

SYMBOLS SYMBOL

DESCRIPTION Tightening torque

Should be lubricated with grease. Unless otherwise indicated, use recommended multi-purpose grease. Should be lubricated with oil. Sealing point Checking point Always replace after every disassembly. Apply petroleum jelly. P Apply ATF. Select with proper thickness. Adjustment is required.

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HOW TO USE THIS MANUAL How to Follow Trouble Diagnoses

AAS000E1

GI

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.

B

C

D

E

F

HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES G

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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.

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

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

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.

AGI070

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

B

C

D

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F

G

H

SGI144A

I

KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES Symbol

Symbol explanation

Symbol

Symbol explanation

Check after disconnecting the connector to be measured.

Procedure with Generic Scan Tool (GST, OBD-II scan tool)

Check after connecting the connector to be measured.

Procedure without CONSULT, CONSULT-II or GST

Insert key into ignition switch.

A/C switch is “OFF”.

Remove key from ignition switch.

A/C switch is “ON”.

J

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L

M

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Turn ignition switch to “OFF” position.

REC switch is “ON”.

Turn ignition switch to “ON” position.

REC switch is “OFF”.

Turn ignition switch to “START” position.

Fan switch is “ON”. (At any position except for “OFF” position)

Turn ignition switch from “OFF” to “ACC” position.

Fan switch is “OFF”.

Turn ignition switch from “ACC” to “OFF” position.

Apply positive voltage from battery with fuse directly to components.

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HOW TO USE THIS MANUAL Symbol

Symbol explanation

Symbol

Symbol explanation

Turn ignition switch from “OFF” to “ON” position.

Drive vehicle.

Turn ignition switch from “ON” to “OFF” position.

Disconnect battery negative cable.

Do not start engine, or check with engine stopped.

Depress brake pedal.

Start engine, or check with engine running.

Release brake pedal.

Apply parking brake.

Depress accelerator pedal.

Release parking brake.

Release accelerator pedal.

Check after engine is warmed up sufficiently.

Pin terminal check for SMJ type ECM and TCM connectors. For details regarding the terminal arrangement, refer to the “ELECTRICAL UNITS” electrical reference page at the end of the manual.

Voltage should be measured with a voltmeter. Circuit resistance should be measured with an ohmmeter.

Current should be measured with an ammeter. Pulse signal should be checked with an oscilloscope. Procedure with CONSULT-II Procedure without CONSULT-II

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HOW TO USE THIS MANUAL How to Read Wiring Diagrams

AAS000E2

GI

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”.

B

C

D

E

F

G

H SAIA0257E

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

I

J

K

L

M

SGI363

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

For detail, refer to following “DESCRIPTION”.

SGI091A

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HOW TO USE THIS MANUAL Optional Splice GI

B

C

D

E

F

G

H

SGI942

I

DESCRIPTION Number 1 2

Item Power condition

Fusible link/fuse location

4

Fuse

5

6

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).

Fusible link

3

Current rating

Connectors

J

Description

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.

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

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

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

Cell code

19

20

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.

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.

Current flow arrow

System branch

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

21

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.

25

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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HOW TO USE THIS MANUAL Harness Indication ●

GI

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

B

C

D

E

F

G AGI070

H

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

Switch Positions

I

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.

J

K

L

M

SGI860

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

SGI862-B

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HOW TO USE THIS MANUAL Multiple Switch GI

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.

B

C

D

E

F

G

H

I

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K SGI875

L

M

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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 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.

SGI092A

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HOW TO USE THIS MANUAL Abbreviations

AAS000E3

GI

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

B

C

D

E

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

F

G

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

PFP:00000 AAS000E4

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. 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

Description

WAIA0004E

WAIA0005E

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.

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.

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.

GI

B

C SEL266V

D

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

E

F

G SEL267V

How to Check Enlarged Contact Spring of Terminal

H

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.

I

J

K

L 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.

M

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.

SEL272V

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

SEL273V

Waterproof Connector Inspection 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. 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.

SEL275V

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

AAS000E5

GI

WORK FLOW

B

C

D

E

F

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

G

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.

H

I

J

Operate the system, road test if necessary. Verify the parameter of the incident. If the problem cannot be duplicated, refer to “Incident Simulation Tests”.

K

Get the proper diagnosis materials together including: ●

Power Supply Routing

System Operation Descriptions

Applicable Service Manual Sections

Check for any Service Bulletins

STEP 3

L

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; 2004 April

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M


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

Vehicle Vibration 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.

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) GI during vehicle vibration. If the wiring runs under seating areas, inspect wire routing for possible damage or pinching.

Heat Sensitive

B

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.

C

D

E 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.

F

G

H

I SGI843

Water Intrusion

J

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.

K

L

M 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 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.

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. There are two types of shorts.

SHORT

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.

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.

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. Revision; 2004 April

GI-30

2003 FX


SERVICE INFORMATION FOR ELECTRICAL INCIDENT VOLTAGE CHECK METHOD To help in understanding the diagnosis of open circuits please refer to the previous schematic. GI 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. B ● 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. C 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. D 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. E 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

F

To simplify the discussion of shorts in the system, please refer to the following schematic. G

H

I SGI847-A

J

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; 2004 April

GI-31

2003 FX

K

L

M


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 for voltage. voltage; short is between SW1 and the relay (point B). no voltage; short is further down the circuit than the relay. 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.

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.

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; 2004 April

GI-32

2003 FX


SERVICE INFORMATION FOR ELECTRICAL INCIDENT If repairs are needed always use wire that is of the same or larger gauge. GI

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.

B

C

D

E

F

G

H

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.

I

J

K

L

M

SAIA0258E

Revision; 2004 April

GI-33

2003 FX


SERVICE INFORMATION FOR ELECTRICAL INCIDENT Control Unit Circuit Test System Description:When the switch is ON, the control unit lights up the lamp.

MGI034A

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

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.

MGI035A

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.

Revision; 2004 April

GI-34

2003 FX


SERVICE INFORMATION FOR ELECTRICAL INCIDENT Control Units and Electrical Parts

AAS000E6

GI

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. If a connector is installed by tightening bolts, loosen bolt mounting it, then take it out by hand.

B

C

D SAIA0251E

E

Before installing a connector, make sure the terminal is not bent or damaged, and then correctly connect it. When installing a connector by tightening bolts, fix it by tightening the mounting bolt until the painted projection of the connector becomes even with the surface.

F

G

H SAIA0252E

For removal of the lever type connector, pull the lever up to the direction pointed to by the arrow A in the figure, and then remove the connector.

I

J

K

SAIA0253E

For installation of the lever type connector, pull down the lever to the direction pointed by the arrow B in the figure, and then push the connector until a clicking noise is heard.

M

SAIA0254E

Revision; 2004 April

GI-35

L

2003 FX


SERVICE INFORMATION FOR ELECTRICAL INCIDENT ●

● ● ●

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

Revision; 2004 April

GI-36

2003 FX


CONSULT-II CHECKING SYSTEM CONSULT-II CHECKING SYSTEM Description

PFP:00000

GI AAS000E7

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

-

ICC

IVIS (NATS)

x

IPDM E/R

AIR PRESSURE MONITOR

AUTO DRIVE POS.

ABS (Including VDC)

BCM

METER A/C AMP

REARVIEW CAMERA

A/T

Function

AIR BAG

ENGINE

Diagnostic test mode

AAS000E8

INTELLIGENT KEY

ALL MODE AWD/4WD

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 ECM can be read.

x

x

-

x

x

x

x

x

x

-

x

x

x

x

CAN diagnosis suppport monitor

Indicates the communication condition of CAN communication line.

x

x

-

-

x

x

x

x

x

-

x

x

x

x

Active test

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

x

-

-

-

-

x

x

x

-

-

x

x

x

x

DTC confirmation

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

x

-

-

-

-

-

-

-

-

-

-

-

-

-

DTC work support

Select the operating condition to confirm Diagnosis Trouble Codes.

x

x

-

-

-

-

-

-

-

-

-

-

-

-

ECM (ECU) part number

ECM (ECU) 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

Conducted by CONSULT-II instead of a technician to determine whether each system is “OK” or “NG”.

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

-

-

-

-

-

-

-

-

-

x

-

-

-

-

-

-

-

-

Individual control unit number can be read. For future information, refer to “CONSULT-II operation manual NATS-IVIS/NVIS”

-

-

-

-

-

-

-

-

-

x

-

-

-

-

Configuration Note

Pin read

-

-

x

-

x

x

x

-

x

-

E

G

H

I

J

K

L

M

NOTE: This item is indicated, but it is what it does not use.

GI-37

D

x

x: Applicable

Revision; 2004 April

C

F

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

Work support

B

2003 FX


CONSULT-II CHECKING SYSTEM Nickel Metal Hydride Battery Replacement

AAS000E9

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.

Checking Equipment

AAS000EA

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 AED03E and AEN02C (For NATS) 3. CONSULT-II CONVERTER 4. “CONSULT-II Pigtail” Cable

SAIA0363E

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. CAUTION: ● 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 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. ● 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.

Revision; 2004 April

GI-38

2003 FX


CONSULT-II CHECKING SYSTEM CONSULT-II Start Procedure 1. 2.

AAS000EB

GI

Turn ignition switch OFF. Connect CONSULT-II and CONSULT-II CONVERTER to the data link connector.

B

C

D PAIA0070E

3. 4.

Turn ignition switch ON. Touch “START (NISSAN BASED VHCL)” or “System Shortcut” (eg: ENGINE) on the screen.

E

F

G SAIA0450E

H

I

J

K

L

M

Revision; 2004 April

GI-39

2003 FX


CONSULT-II CHECKING SYSTEM CONSULT-II Data Link Connector (DLC) Circuit

AAS000EC

TAWM0002E

Revision; 2004 April

GI-40

2003 FX


CONSULT-II CHECKING SYSTEM INSPECTION PROCEDURE GI

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.)

Open or short circuit CAN communication line. Refer to LAN-4, "Precautions When Using CONSULT-II" .

CONSULT-II cannot access any system.

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

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.

B

C

D

E

F

G

H

I

J

K

L

M

Revision; 2004 April

GI-41

2003 FX


LIFTING POINT LIFTING POINT Special Service Tools

PFP:00000 AAS000ED

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

LM4086-0200 ( - ) Board on attachment S-NT001

LM4519-0000 ( - ) Safety stand attachment 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

AAS000EE

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.

Revision; 2004 April

GI-42

2003 FX


LIFTING POINT â—?

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

B

C

D

E

F

G

H

PAIA0095E

I

CAUTION: There is canister just behind Garage jack point rear. Jack up be carefully. J

2-Pole Lift

AAS000EF

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.

K

L

M

PAIA0096E

Revision; 2004 April

GI-43

2003 FX


LIFTING POINT Board-On Lift

AAS000EG

CAUTION: Make sure vehicle is empty when lifting. ● The board-on lift attachment (LM4086-0200) 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.

AGI016

Revision; 2004 April

GI-44

2003 FX


TOW TRUCK TOWING TOW TRUCK TOWING Tow Truck Towing

PFP:00000

GI AAS000EH

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.

C

2WD MODELS

E

B

D

F

G

H

I

J

PAIA0097E

INFINITI recommends that your vehicle be towed with the driving (rear) wheels off the ground or that a dolly be used as illustrated. CAUTION: ● Never tow automatic transmission models with the rear wheels on the ground or four wheels on the ground (forward or backward) as this may cause serious and expensive damage to the transmission. If it is necessary to tow the vehicle with the front wheels raised, always use towing dollies under the rear wheels. ● When towing rear wheel drive models with the front wheels on the ground or on towing dollies: – Turn the ignition key to the OFF position, and secure the steering wheel in a straight ahead position with a rope or similar device.Never secure the steering wheel by turning the ignition key to the LOCK position. This may damage the steering lock mechanism. – Move the selector lever to the N (Neutral) position. ● When the battery of vehicle equipped with the Intelligent Key system is discharged, your vehicle should be towed with the front wheels on towing dollies or place the vehicle on a flat bed truck.

Revision; 2004 April

GI-45

2003 FX

K

L

M


TOW TRUCK TOWING AWD MODELS

PAIA0098E

INFINITI recommends that a dolly be used as illustrated when towing AWD models. CAUTION: Never tow AWD models with any of the wheels on the ground as this may cause serious and expensive damage to the power train.

Vehicle Recovery (Freeing a Stuck Vehicle) ●

AAS000EI

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 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. Use the towing hook only, not other parts of the vehicle. Otherwise, the vehicle body will be damaged. Use the towing 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 towing hook is under tremendous force when used to free a stuck vehicle. Stand clear of a stuck vehicle.

PAIA0099E

Revision; 2004 April

GI-46

2003 FX


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

Bolt size

M6

4T

9T

6.0

GI AAS000EJ

Tightening torque (Without lubricant) Pitch mm

Hexagon head bolt N·m

kg-m

B

Hexagon flange bolt

ft-lb

in-lb

N·m

kg-m

ft-lb

in-lb

1.0

5.5

0.56

4

49

7

0.71

5

62

1.25

13.5

1.4

10

17

1.7

13

1.0

13.5

1.4

10

17

1.7

13

1.5

28

2.9

21

35

3.6

26

1.25

28

2.9

21

35

3.6

26

1.75

45

4.6

33

55

5.6

41

1.25

45

4.6

33

65

6.6

48

M8

8.0

M10

10.0

M12

12.0

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

1.0

22

2.2

16

28

2.9

21

1.5

45

4.6

33

55

5.6

41

1.25

45

4.6

33

55

5.6

41

1.75

80

8.2

59

100

10

74

M8

7T

Bolt diameter * mm

PFP:00000

8.0

M10

10.0

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

1.25

55

5.6

41

80

8.2

59

1.75

100

10

74

130

13

96

1.25

100

10

74

130

13

96

1.5

170

17

125

210

21

155

M10

10.0

M12

12.0

M14

14.0

C

D

E

F

G

H

I

J

K

L

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

M

MGI044A

Revision; 2004 April

GI-47

2003 FX


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

PFP:00000 AAS000EK

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

999MP-AM002P

999MP-AM002P

Permatex 56521

99998-50506 (Ultra Grey)

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

High Performance Thread Sealant

Provides instant sealing on any threaded straight or parallel threaded fitting. (Thread sealant only, no locking ability.) Do not use on plastic.

999MP-AM003P (Ultra Grey)

Silicone RTV 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)

High Temperature, High Strength Thread Locking Sealant (Red)

Medium Strength Thread Locking Sealant (Blue)

Revision; 2004 April

Threadlocker

Threadlocker (service tool removable)

999MP-AM004P

999MP-AM005P

GI-48

Three Bond 1281B or exact equivalent in its quality

999MP-AM004P

Permatex 27200; Three Bond 1360, 1360N, 1305 N&P, 1307N, 1335, 1335B, 1363B, 1377C, 1386B, D&E and 1388

999MP-AM005P

Permatex 24200, 24206, 24240, 24283 and 09178; Three Bond 1322, 1322N, 1324 D&N, 1333D, 1361C, 1364D, 1370C and 1374

2003 FX


IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION Model Variation

PFP:00010

GI AAS000EL

Destination Body

Wagon

Grade

Transmission

Base

RE5R05A (5A/T)

Engine

VQ35DE VK45DE

Axle

USA

CANADA

Two-wheel drive

TLJALTN-EUA

—

All-wheel drive

TLJNLTN-EUA

TLJNLTN--ENA

All-wheel drive

TPHNLTN-EUA

TPHNLTN-ENA

Prefix and suffix designations:

B

C

D

E

F

G

H

I PAIA0100E

J

K

L

M

Revision; 2004 April

GI-49

2003 FX


IDENTIFICATION INFORMATION IDENTIFICATION NUMBER

PAIA0101E

VEHICLE Identification Number ARRANGEMENT

PAIA0102E

Revision; 2004 April

GI-50

2003 FX


IDENTIFICATION INFORMATION IDENTIFICATION PLATE GI

B

C

D

E

SGI315

F

ENGINE SERIAL NUMBER G

H

I PAIA0110E

J

K

L PAIA0111E

M

AUTOMATIC TRANSMISSION NUMBER

PAIA0054E

Revision; 2004 April

GI-51

2003 FX


IDENTIFICATION INFORMATION Dimensions

AAS000EM

Unit: mm (in) Overall length

4,803 (189.1)

Overall width

1,925 (75.8)

Overall height

without roof rack rail

1,652 (65.0)

with roof rack rail

1,672.6 (65.9)

Front tread

1,592 (62.7)

Rear tread

1,642 (64.6)

Wheelbase

2,850 (112.2)

Wheels & Tires

AAS000EN

Conventional Road wheel/offset mm (in)

18 X 8JJ Aluminum/40 (1.57) 20 X 8JJ Aluminum/40 (1.57)

Tire size

P265/60R18 P265/50R20

Spare T175/90D18 Conventional*

*: Option for Canada

Revision; 2004 April

GI-52

2003 FX


TERMINOLOGY TERMINOLOGY SAE J1930 Terminology List

PFP:00011

GI AAS000EO

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; 2004 April

B

D

E

F

G

H

I

J

K

L

M

GI-53

2003 FX


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; 2004 April

GI-54

2003 FX


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; 2004 April

GI-55

GI

B

C

D

E

F

G

H

I

J

K

L

M

2003 FX


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; 2004 April

GI-56

2003 FX


ENGINE MECHANICAL

B ENGINE

SECTION

EM

ENGINE MECHANICAL

A

EM

C

D

E

CONTENTS VQ35DE PRECAUTIONS .......................................................... 5 Precautions Necessary for Steering Wheel Rotation After Battery Disconnect .......................................... 5 OPERATION PROCEDURE ................................. 5 Precautions for Drain Engine Coolant ...................... 5 Precautions for Disconnecting Fuel Piping .............. 5 Precautions for Removal and Disassembly ............. 5 Precautions for Inspection, Repair and Replacement ......................................................................... 5 Precautions for Assembly and Installation ............... 5 Parts Requiring Angle Tightening ............................. 6 Precautions for Liquid Gasket .................................. 6 REMOVAL OF LIQUID GASKET SEALING .......... 6 LIQUID GASKET APPLICATION PROCEDURE..... 6 PREPARATION ........................................................... 8 Special Service Tools ............................................... 8 Commercial Service Tools ...................................... 10 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .............................................. 13 NVH Troubleshooting —Engine Noise ................... 13 Use the Chart Below to Help You Find the Cause of the Symptom. ..................................................... 14 DRIVE BELTS ........................................................... 15 Checking Drive Belts .............................................. 15 Tension Adjustment ................................................ 15 ALTERNATOR AND POWER STEERING OIL PUMP BELT ........................................................ 16 AIR CONDITIONER COMPRESSOR BELT ....... 16 Removal and Installation ........................................ 16 REMOVAL ........................................................... 16 INSTALLATION ................................................... 16 AIR CLEANER AND AIR DUCT ............................... 17 Removal and Installation ........................................ 17 REMOVAL ........................................................... 17 INSTALLATION ................................................... 17 Changing Air Cleaner Filter .................................... 18 INSPECTION ...................................................... 18 REMOVAL ........................................................... 18 INSTALLATION ................................................... 18 Revision; 2004 April

INTAKE MANIFOLD COLLECTOR .......................... 19 Removal and Installation ........................................ 19 REMOVAL ........................................................... 19 INSPECTION AFTER REMOVAL ....................... 21 INSTALLATION ................................................... 21 INTAKE MANIFOLD ................................................. 23 Removal and Installation ........................................ 23 REMOVAL ........................................................... 23 INSPECTION AFTER REMOVAL ....................... 23 INSTALLATION ................................................... 24 EXHAUST MANIFOLD AND THREE WAY CATALYST .......................................................................... 25 Removal and Installation ........................................ 25 REMOVAL ........................................................... 25 INSPECTION AFTER REMOVAL ....................... 26 INSTALLATION ................................................... 26 OIL PAN AND OIL STRAINER ................................. 28 Removal and Installation ........................................ 28 2WD MODEL ....................................................... 28 REMOVAL ........................................................... 28 INSPECTION AFTER REMOVAL ....................... 30 INSTALLATION ................................................... 30 INSPECTION AFTER INSTALLATION ................ 32 AWD MODEL ...................................................... 33 REMOVAL ........................................................... 34 INSPECTION AFTER REMOVAL ....................... 36 INSTALLATION ................................................... 36 INSPECTION AFTER INSTALLATION ................ 38 IGNITION COIL ......................................................... 40 Removal and Installation ........................................ 40 REMOVAL ........................................................... 40 INSTALLATION ................................................... 40 SPARK PLUG (PLATINUM-TIPPED TYPE) ............. 41 Removal and Installation ........................................ 41 REMOVAL ........................................................... 41 INSPECTION AFTER REMOVAL ....................... 41 INSTALLATION ................................................... 42

EM-1

2003 FX

F

G

H

I

J

K

L

M


FUEL INJECTOR AND FUEL TUBE ........................ 43 Removal and Installation ........................................ 43 REMOVAL ........................................................... 44 INSTALLATION .................................................... 45 INSPECTION AFTER INSTALLATION ................ 47 ROCKER COVER ..................................................... 49 Removal and Installation ........................................ 49 REMOVAL ........................................................... 49 INSTALLATION .................................................... 50 FRONT TIMING CHAIN CASE ................................. 52 Removal and Installation ........................................ 52 REMOVAL ........................................................... 52 INSTALLATION .................................................... 56 INSPECTION AFTER INSTALLATION ................ 60 TIMING CHAIN .......................................................... 61 Removal and Installation ........................................ 61 REMOVAL ........................................................... 62 INSPECTION AFTER REMOVAL ........................ 69 INSTALLATION .................................................... 69 INSPECTION AFTER INSTALLATION ................ 78 CAMSHAFT ............................................................... 80 Removal and Installation ........................................ 80 REMOVAL ........................................................... 80 INSPECTION AFTER REMOVAL ........................ 82 INSTALLATION .................................................... 85 Valve Clearance ...................................................... 87 INSPECTION ....................................................... 87 ADJUSTMENT .................................................... 90 OIL SEAL .................................................................. 92 Removal and Installation of Valve Oil Seal ............. 92 REMOVAL ........................................................... 92 INSTALLATION .................................................... 92 Removal and Installation of Front Oil Seal ............. 93 REMOVAL ........................................................... 93 INSTALLATION .................................................... 94 Removal and Installation of Rear Oil Seal .............. 94 REMOVAL ........................................................... 94 INSTALLATION .................................................... 94 CYLINDER HEAD ..................................................... 96 On-Vehicle Service ................................................. 96 CHECKING COMPRESSION PRESSURE ......... 96 Removal and Installation ........................................ 97 REMOVAL ........................................................... 97 INSPECTION AFTER REMOVAL ........................ 98 INSTALLATION .................................................... 99 Disassembly and Assembly .................................. 100 DISASSEMBLY ................................................. 101 Inspection After Disassembly ............................... 101 CYLINDER HEAD DISTORTION ...................... 101 VALVE DIMENSIONS ........................................ 102 VALVE GUIDE CLEARANCE ............................ 103 VALVE GUIDE REPLACEMENT ....................... 103 VALVE SEAT CONTACT ................................... 104 VALVE SEAT REPLACEMENT ......................... 105 VALVE SPRING SQUARENESS ....................... 106 VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD ............................. 106 ASSEMBLY ....................................................... 106 Revision; 2004 April

ENGINE ASSEMBLY ............................................... 108 Removal and Installation ....................................... 108 2WD MODEL ..................................................... 108 REMOVAL .......................................................... 109 INSTALLATION .................................................. 111 INSPECTION AFTER INSTALLATION .............. 112 AWD MODEL ..................................................... 113 REMOVAL .......................................................... 113 INSTALLATION .................................................. 116 INSPECTION AFTER INSTALLATION .............. 116 CYLINDER BLOCK ................................................. 118 Disassembly and Assembly .................................. 118 DISASSEMBLY .................................................. 119 ASSEMBLY ........................................................ 124 How to Select Piston and Bearing ........................ 129 DESCRIPTION .................................................. 129 HOW TO SELECT PISTON ............................... 129 HOW TO SELECT CONNECTING ROD BEARING ..................................................................... 130 HOW TO SELECT MAIN BEARING .................. 131 Inspection After Disassembly ................................ 134 CRANKSHAFT END PLAY ................................ 134 CONNECTING ROD SIDE CLEARANCE ......... 134 PISTON AND PISTON PIN OIL CLEARANCE . 134 PISTON RING SIDE CLEARANCE ................... 135 PISTON RING END GAP .................................. 135 CONNECTING ROD BEND AND TORSION ..... 135 CONNECTING ROD BEARING HOUSING DIAMETER (BIG END) ...................................... 136 CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END) ......................................... 136 CYLINDER BLOCK DISTORTION .................... 137 INNER DIAMETER OF MAIN BEARING HOUSING ..................................................................... 137 PISTON TO CYLINDER BORE CLEARANCE . 138 OUTER DIAMETER OF CRANKSHAFT JOURNAL .................................................................... 139 OUTER DIAMETER OF CRANKSHAFT PIN .... 139 OUT-OF-ROUND AND TAPER OF CRANKSHAFT ............................................................... 139 CRANKSHAFT RUNOUT .................................. 140 CONNECTING ROD BEARING OIL CLEARANCE ................................................................. 140 MAIN BEARING OIL CLEARANCE ................... 141 CRUSH HEIGHT OF MAIN BEARING .............. 141 CRUSH HEIGHT OF CONNECTING ROD BEARING ........................................................... 141 OUTER DIAMETER OF MAIN BEARING CAP BOLT .................................................................. 142 OUTER DIAMETER OF CONNECTING ROD BOLT .................................................................. 142 DRIVE PLATE .................................................... 142 OIL JET .............................................................. 142 OIL JET RELIEF VALVE ....................................142 SERVICE DATA AND SPECIFICATIONS (SDS) .... 143 Standard and Limit ................................................ 143 GENERAL SPECIFICATIONS ........................... 143 DRIVE BELT ...................................................... 144 INTAKE MANIFOLD COLLECTOR, INTAKE

EM-2

2003 FX


MANIFOLD AND EXHAUST MANIFOLD ......... 144 SPARK PLUG ................................................... 144 CYLINDER HEAD ............................................. 145 VALVE ............................................................... 145 CAMSHAFT AND CAMSHAFT BEARING ........ 150 CYLINDER BLOCK ........................................... 151 PISTON, PISTON RING AND PISTON PIN ...... 152 CONNECTING ROD ......................................... 153 CRANKSHAFT .................................................. 154 AVAILABLE MAIN BEARING ............................ 155 CONNECTING ROD BEARING ........................ 156 BEARING OIL CLEARANCE ............................ 156

VK45DE PRECAUTIONS ...................................................... 157 Precautions for Drain Engine Coolant .................. 157 Precautions for Disconnecting Fuel Piping .......... 157 Precautions for Removal and Disassembly ......... 157 Precautions for Inspection, Repair and Replacement ..................................................................... 157 Precautions for Assembly and Installation ........... 157 Parts Requiring Angular Tightening ..................... 157 Precautions for Liquid Gasket .............................. 158 REMOVAL OF LIQUID GASKET SEALING ...... 158 LIQUID GASKET APPLICATION PROCEDURE. 158 PREPARATION ....................................................... 159 Special Service Tools ........................................... 159 Commercial Service Tools .................................... 161 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ............................................ 164 NVH Troubleshooting —Engine Noise ................. 164 Use the Chart Below to Help You Find the Cause of the Symptom. ................................................... 165 ENGINE ROOM COVER ........................................ 166 Removal and Installation ...................................... 166 REMOVAL ......................................................... 166 INSTALLATION ................................................. 166 DRIVE BELTS ......................................................... 167 Checking Drive Belts ............................................ 167 Tension Adjustment .............................................. 167 Removal and Installation ...................................... 167 REMOVAL ......................................................... 167 INSTALLATION ................................................. 168 Drive Belt Auto Tensioner and Idler Pulley ........... 169 REMOVAL ......................................................... 169 INSTALLATION ................................................. 169 AIR CLEANER AND AIR DUCT ............................. 170 Removal and Installation ...................................... 170 REMOVAL ......................................................... 170 INSTALLATION ................................................. 170 CHANGING AIR CLEANER FILTER ................. 171 INTAKE MANIFOLD ............................................... 172 Removal and Installation ...................................... 172 REMOVAL ......................................................... 173 INSPECTION AFTER REMOVAL ..................... 174 INSTALLATION ................................................. 174 INSPECTION AFTER INSTALLATION ............. 176 EXHAUST MANIFOLD AND THREE WAY CATARevision; 2004 April

LYST ........................................................................ 177 Removal and Installation ...................................... 177 REMOVAL ......................................................... 177 INSPECTION AFTER REMOVAL ..................... 178 INSTALLATION ................................................. 179 OIL PAN AND OIL STRAINER ............................... 180 Removal and Installation ...................................... 180 REMOVAL ......................................................... 180 INSPECTION AFTER REMOVAL ..................... 181 INSTALLATION ................................................. 181 INSPECTION AFTER INSTALLATION .............. 182 IGNITION COIL ....................................................... 183 Removal and Installation ...................................... 183 REMOVAL ......................................................... 183 INSTALLATION ................................................. 183 SPARK PLUG (PLATINUM-TIPPED TYPE) ........... 184 Removal and Installation ...................................... 184 REMOVAL ......................................................... 184 INSPECTION AFTER REMOVAL ..................... 184 INSTALLATION ................................................. 185 FUEL INJECTOR AND FUEL TUBE ...................... 186 Removal and Installation ...................................... 186 REMOVAL ......................................................... 186 INSTALLATION ................................................. 187 INSPECTION AFTER INSTALLATION .............. 188 ROCKER COVER ................................................... 189 Removal and Installation ...................................... 189 REMOVAL ......................................................... 189 INSTALLATION ................................................. 190 TIMING CHAIN ........................................................ 192 Removal and Installation ...................................... 192 REMOVAL ......................................................... 193 INSPECTION AFTER REMOVAL ..................... 195 INSTALLATION ................................................. 196 CAMSHAFT ............................................................ 202 Removal and Installation ...................................... 202 REMOVAL ......................................................... 202 INSTALLATION ................................................. 203 INSPECTION AFTER REMOVAL ..................... 205 Valve Clearance ................................................... 208 INSPECTION .................................................... 208 ADJUSTMENT .................................................. 209 OIL SEAL ................................................................ 213 Removal and Installation of Valve Oil Seal ........... 213 REMOVAL ......................................................... 213 INSTALLATION ................................................. 213 Removal and Installation of Front Oil Seal ........... 214 REMOVAL ......................................................... 214 INSTALLATION ................................................. 214 Removal and Installation of Rear Oil Seal ............ 215 REMOVAL ......................................................... 215 INSTALLATION ................................................. 215 CYLINDER HEAD ................................................... 217 On-Vehicle Service ............................................... 217 CHECKING COMPRESSION PRESSURE ....... 217 Removal and Installation ...................................... 218 REMOVAL ......................................................... 218 INSPECTION AFTER REMOVAL ..................... 219 INSTALLATION ................................................. 219

EM-3

2003 FX

A

EM

C

D

E

F

G

H

I

J

K

L

M


Disassembly and Assembly .................................. 220 DISASSEMBLY ................................................. 220 ASSEMBLY ....................................................... 221 Inspection After Disassembly ............................... 222 CYLINDER HEAD DISTORTION ...................... 222 VALVE DIMENSIONS ........................................ 222 VALVE GUIDE CLEARANCE ............................ 222 VALVE GUIDE REPLACEMENT ....................... 223 VALVE SEAT CONTACT ................................... 224 VALVE SEAT REPLACEMENT ......................... 225 VALVE SPRING SQUARENESS ....................... 226 VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD ............................. 226 ENGINE ASSEMBLY .............................................. 227 Removal and Installation ...................................... 227 REMOVAL ......................................................... 227 INSTALLATION .................................................. 229 INSPECTION AFTER INSTALLATION .............. 229 CYLINDER BLOCK ................................................. 231 Disassembly and Assembly .................................. 231 DISASSEMBLY ................................................. 232 ASSEMBLY ....................................................... 235 How to Select Piston and Bearing ........................ 240 DESCRIPTION .................................................. 240 HOW TO SELECT PISTON ............................... 240 HOW TO SELECT CONNECTING ROD BEARING .................................................................... 241 HOW TO SELECT MAIN BEARING .................. 242 Inspection After Disassembly ............................... 245 CRANKSHAFT END PLAY ................................ 245 CONNECTING ROD SIDE CLEARANCE ......... 246 PISTON AND PISTON PIN CLEARANCE ........ 246 PISTON RING SIDE CLEARANCE ................... 247 PISTON RING END GAP .................................. 247 CONNECTING ROD BEND AND TORSION ..... 248 CONNECTING ROD BEARING (BIG END) ...... 248 CONNECTING ROD BUSHING OIL CLEAR-

Revision; 2004 April

ANCE (SMALL END) ......................................... 248 CYLINDER BLOCK DISTORTION .................... 249 INNER DIAMETER OF MAIN BEARING HOUSING ..................................................................... 250 PISTON TO CYLINDER BORE CLEARANCE . 250 OUTER DIAMETER OF CRANKSHAFT JOURNAL .................................................................... 252 OUTER DIAMETER OF CRANKSHAFT PIN .... 252 OUT-OF-ROUND AND TAPER OF CRANKSHAFT ............................................................... 252 CRANKSHAFT RUNOUT .................................. 252 CONNECTING ROD BEARING OIL CLEARANCE ................................................................. 253 MAIN BEARING OIL CLEARANCE ................... 253 CRUSH HEIGHT OF MAIN BEARING .............. 254 CRUSH HEIGHT OF CONNECTING ROD BEARING ........................................................... 254 SERVICE DATA AND SPECIFICATIONS (SDS) .... 255 Standard and Limit ................................................ 255 GENERAL SPECIFICATIONS ........................... 255 INTAKE MANIFOLD AND EXHAUST MANIFOLD ................................................................. 255 DRIVE BELTS .................................................... 255 CYLINDER HEAD .............................................. 256 VALVE ................................................................ 256 CAMSHAFT AND CAMSHAFT BEARING ......... 260 CYLINDER BLOCK ............................................ 261 PISTON, PISTON RING AND PISTON PIN ...... 262 CONNECTING ROD .......................................... 263 CRANKSHAFT ................................................... 263 MAIN BEARING ................................................. 264 CONNECTING ROD BEARING ......................... 265

EM-4

2003 FX


PRECAUTIONS [VQ35DE]

PRECAUTIONS PFP:00001 Precautions Necessary for Steering Wheel Rotation After Battery Disconnect [VQ35DE]

A

ABS00B3H

NOTE: ● This Procedure is applied only to models with Intelligent Key system and NVIS/IVIS (NISSAN/INFINITI EM VEHICLE IMMOBILIZER SYSTEM - NATS). ● Remove and install all control units after disconnecting both battery cables with the ignition knob in the C ″LOCK″ position. ● Always use CONSULT-II to perform self-diagnosis as a part of each function inspection after finishing work. If DTC is detected, perform trouble diagnosis according to self-diagnostic results. For models equipped with the Intelligent Key system and NVIS/IVIS, an electrically controlled steering lock D mechanism is adopted on the key cylinder. For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and steering wheel rotation will become impossible. E If steering wheel rotation is required when battery power is interrupted, follow the procedure below before starting the repair operation.

OPERATION PROCEDURE 1.

2. 3. 4. 5. 6.

F

Connect both battery cables. NOTE: Supply power using jumper cables if battery is discharged. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the steering lock will be released. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be rotated. Perform the necessary repair operation. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting the battery cables. (At this time, the steering lock mechanism will engage.) Perform a self-diagnosis check of all control units using CONSULT-II.

Precautions for Drain Engine Coolant

ABS005ZK

G

H

I

J

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 ●

● ● ● ●

ABS005ZL

L ABS005ZM

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

ABS005ZN

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

Precautions for Assembly and Installation ●

ABS005ZO

Use torque wrench to tighten bolts or nuts to specification.

Revision; 2004 April

EM-5

K

2003 FX

M


PRECAUTIONS [VQ35DE] ●

● ●

● ●

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. 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, oil sliding surfaces well. Release air within route when refilling after draining engine coolant. Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then make sure that 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 systems for leakage.

Parts Requiring Angle Tightening ●

– – – –

● ● ●

ABS005ZP

Use an 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

ABS005ZQ

REMOVAL OF LIQUID GASKET SEALING ●

After removing the mounting bolts and nuts, separate the mating surface using a 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 is difficult to use, use plastic hammer to lightly tap the areas where the liquid gasket is applied. CAUTION: If for some unavoidable reason tool such as screwdriver is used, be careful not to damage the mating surfaces.

PBIC0002E

LIQUID GASKET APPLICATION PROCEDURE 1.

2.

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.

PBIC0003E

Revision; 2004 April

EM-6

2003 FX


PRECAUTIONS [VQ35DE] 3.

4.

Attach the liquid gasket tube to the tube presser [SST: WS39930000 ( – )]. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . 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.

A

EM

C EMA0622D

D

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 service manual. ● Within five minutes of liquid gasket application, install the mating component. ● If the liquid gasket protrudes, wipe it off immediately. ● Do not retighten mounting bolts and nuts after the installation. ● After 30 minutes or more have passed from the installation, fill engine oil and engine coolant. CAUTION: If there are specific instructions in this manual, observe them. ●

E

F

G SEM159F

H

I

J

K

L

M

Revision; 2004 April

EM-7

2003 FX


PREPARATION [VQ35DE]

PREPARATION Special Service Tools

PFP:00002 ABS004TT

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number (Kent-Moore No.) Tool name ST0501S000 ( — ) Engine stand assembly 1. ST05011000 ( — ) Engine stand 2. ST05012000 ( — ) Base

Description Disassembling and assembling

NT042

KV10106500 ( — ) Engine stand shaft

NT028

KV10117000 (J-41262) Engine sub-attachment

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

NT373

KV10117001 ( — ) Engine sub-attachment

Installing on the cylinder block

NT372

KV10116200 (J-26336-A) Valve spring compressor 1. KV10115900 (J-26336-20) Attachment 2. KV10109220 ( — ) Adapter

Disassembling valve mechanism Part (1) is a component of KV10116200 (J-26336-A), but Part (2) is not so.

PBIC1650E

KV10107902 (J-38959) Valve oil seal puller 1. KV10116100 ( — ) Valve oil seal puller adapter

Replacing valve oil seal

S-NT605

Revision; 2004 April

EM-8

2003 FX


PREPARATION [VQ35DE] Tool number (Kent-Moore No.) Tool name

A

Description

(J-39386) Valve oil seal drift

Installing valve oil seal

EM

C NT024

EM03470000 (J-8037) Piston ring compressor

Installing piston assembly into cylinder bore

D

E

NT044

ST16610001 (J-23907) Pilot bushing puller

F Removing crankshaft pilot bushing

G

H

NT045

KV10111100 (J-37228) Seal cutter

Removing steel oil pan (lower and upper) and front and rear timing chain case

I

J NT046

WS39930000 ( — Tube presser

Pressing the tube of liquid gasket )

K

L NT052

KV10112100 (BT8653-A) Angle wrench

Tightening bolts for bearing cap, cylinder head, etc. in angle

NT014

KV10117100 (J-3647-A) Heated oxygen sensor wrench

Loosening or tightening heated oxygen sensor 2 For 22 mm (0.87 in) width hexagon nut

NT379

Revision; 2004 April

EM-9

2003 FX

M


PREPARATION [VQ35DE] Tool number (Kent-Moore No.) Tool name

Description

KV10114400 (J-38365) Heated oxygen sensor wrench

Loosening or tightening rear heated oxygen sensor 1 a: 22 mm (0.87 in)

NT636

KV10117700 (J-44716) Ring gear stopper

Removing and installing crankshaft pulley

NT822

10006 31U00 ( — ) Engine rear slinger

Removing and installing oil pan (upper) for on vehicle service

SBIA0530E

— (J-45488) Quick connector release

Removing fuel tube quick connectors in engine room (Right member side) (Available in SEC. 164 of PARTS CATALOG: Part No. 16441 6N210)

PBIC0198E

Commercial Service Tools

ABS004TU

(Kent-Moore No.) Tool name

Description

Power tool

Loosening bolts and nuts

PBIC0190E

Manual lift table caddy

Removing and installing engine

ZZA1210D

Revision; 2004 April

EM-10

2003 FX


PREPARATION [VQ35DE] (Kent-Moore No.) Tool name

Description

(BT3373-F) Belt tension gauge

A

Checking drive belt tension

EM

C AMA126

(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)

D

E

NT583

Spark plug wrench

Removing and installing spark plug

F

G

NT047

Valve seat cutter set

H

Finishing valve seat dimensions

I

J

NT048

Piston ring expander

Removing and installing piston ring

K

L NT030

Valve guide drift

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

M

NT015

Valve guide reamer

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

NT016

Revision; 2004 April

EM-11

2003 FX


PREPARATION [VQ35DE] (Kent-Moore No.) Tool name

Description

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

Reconditioning the exhaust system threads before installing a new heated oxygen sensor (Use with anti-seize lubricant shown below.) a: J-43897-18 [18 mm (0.71 in) dia.] for zirconia heated oxygen sensor b: J-43897-12 [12 mm (0.47 in) dia.] for titania heated oxygen sensor AEM488

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

Revision; 2004 April

EM-12

2003 FX


NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING [VQ35DE]

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

PFP:00003

A ABS004TV

EM

C

D

E

F

G

H

I

J

K

L

M

PBIC2039E

Revision; 2004 April

EM-13

2003 FX


NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING [VQ35DE]

Use the Chart Below to Help You Find the Cause of the Symptom.

ABS004TW

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 case

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-87

Rattle

C

A

A

B

C

Camshaft bearing noise

Camshaft runout Camshaft journal clearance

EM-82 EM-82

Piston pin noise

Piston and piston pin oil clearance Connecting rod bushing oil clearance (Small end)

EM-134 EM-136

A

Piston slap noise

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

EM-138 EM-135 EM-135 EM-135

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

EM-136 EM-140

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-141 EM-140

B

Timing chain and chain tensioner noise

Timing chain cracks and wear Timing chain tensioner operation

EM-61

C

Drive belts (Sticking or slipping)

Drive belts deflection

Tapping or ticking

A

A

B

B

Squeaking or fizzing

A

Creaking

A

B

A

B

A

B

Drive belts (Slipping)

Idler pulley bearing operation

Squall Creak

A

B

B

A

B

Water pump noise

Water pump operation

A: Closely related

B: Related

Revision; 2004 April

B

C: Sometimes related

B

EM-15

CO-21, "WATER PUMP"

—: Not related

EM-14

2003 FX


DRIVE BELTS [VQ35DE]

DRIVE BELTS Checking Drive Belts

PFP:02117

A ABS004TX

WARNING: Be sure to perform when engine is stopped. 1. Inspect belts for cracks, fraying, wear and oil. If necessary, replace. 2. Inspect drive belt deflection or tension at a point on the belt midway between pulleys. ● Inspection should be done only when engine is cold, or over 30 minutes after engine is stopped. ● Measure belt tension with belt tension gauge (Commercial Service Tool: BT3373-F or equivalent) at points marked shown in the figure. ●

EM

C

D

E

When measuring deflection, apply 98 N (10 kg, 22 lb) at the KBIA1731J marked point. Adjust if belt deflection exceeds the limit or if belt tension is not within specifications. CAUTION: ● When checking belt deflection or tension immediately after installation, first adjust it to the specified value. Then, after turning the crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflection between pulleys. ● Tighten idler pulley lock nut by hand and measure deflection or tension without looseness.

Belt Deflection and Tension Used belt Limit

After adjustment

Alternator and power steering oil pump belt

7 (0.28)

4-5 (0.16 - 0.20)

Air conditioner compressor belt

12 (0.47)

9 - 10 (0.35 - 0.39)

Applied pushing force

Unit: mm (in)

Tension adjustment*

Unit: N (kg, lb)

Used belt

New belt

New belt

Limit

After adjustment

3.5 - 4.5 (0.138 - 0.177)

294 (30, 66)

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

838 - 926 (85.5 - 94.5, 188 - 208)

8-9 (0.31 - 0.35)

196 (20, 44)

348 - 436 (35.5 - 44.5, 78 - 98)

470 - 559 (48 - 57, 106 - 126)

98 N (10 kg, 22 lb)

I

J

K

L

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

Tension Adjustment

ABS004TY

Portion

M

Belt tightening method for adjustment

Alternator and power steering oil pump belt

Adjusting bolt on idler pulley

Air conditioner compressor belt

Adjusting bolt on idler pulley

CAUTION: ● When belt is replaced with a new one, adjust it to value for “New belt” to accommodate for insufficient adaptability with pulley grooves. ● When deflection or tension of belt being used exceeds “Limit”, adjust it to value for “After adjustment of used belt”. ● When checking belt deflection or tension immediately after installation, first adjust it to the specified value. Then, after turning the crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflection between pulleys. ● When installing belt, make sure that it is correctly engaged with pulley grooves. ● Keep engine oil, working fluid and engine coolant away from belt and pulley grooves. ● Do not twist or bend belt excessively.

Revision; 2004 April

G

H

Deflection adjustment Items

F

EM-15

2003 FX


DRIVE BELTS [VQ35DE] ALTERNATOR AND POWER STEERING OIL PUMP BELT 1. 2.

3.

Remove front engine undercover with power tool. Loosen idler pulley lock nut (A) and adjust tension by turning adjusting bolt (B). ● For specified belt tension, refer to EM-15, "Checking Drive Belts" . Tighten nut (A). : 34.8 N·m (3.5 kg-m, 26 ft-lb)

SBIA0532E

AIR CONDITIONER COMPRESSOR BELT 1. 2. 3.

Remove front engine undercover with power tool. Loosen idler pulley lock nut (C) and adjust tension by turning adjusting bolt (D). ● For specified belt tension, refer to EM-15, "Checking Drive Belts" . Tighten nut (C). : 34.8 N·m (3.5 kg-m, 26 ft-lb)

Removal and Installation

ABS004TZ

REMOVAL 1. 2. 3.

Remove front engine undercover with power tool. Remove alternator and power steering oil pump belt. Refer to EM-16, "ALTERNATOR AND POWER STEERING OIL PUMP BELT" . Remove air conditioner compressor belt. Refer to EM-16, "AIR CONDITIONER COMPRESSOR BELT" . CAUTION: Grease is applied to idler pulley adjusting bolt. Be careful to keep grease away from belt.

INSTALLATION 1.

2. 3. 4.

Install belts to pulley in reverse order of removal. CAUTION: ● Make sure belt is correctly engaged with the pulley groove. ● Check for engine oil and engine coolant are not adhered to belt and each pulley grooves. Adjust belt tension. Refer to EM-15, "Tension Adjustment" . Tighten each adjusting bolt and nut to the specified torque. Make sure that tension of each belt is within the standard. Refer to EM-15, "Checking Drive Belts" .

Revision; 2004 April

EM-16

2003 FX


AIR CLEANER AND AIR DUCT [VQ35DE]

AIR CLEANER AND AIR DUCT Removal and Installation

PFP:16500

A ABS004U0

EM

C

D

E

F

G

H

I SBIA0462E

1.

Air hose

2.

PCV hose

3.

Air duct

4.

Air hose

5.

Power duct

6.

Clip

7.

Air duct (Inlet)

8.

Resonator

9.

Grommet

10. Air cleaner case

11. Air cleaner filter

13. O-ring

14. Mass air flow sensor

J

K

12. Air cleaner case

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

7.

Remove engine cover with power tool. Refer to EM-19, "INTAKE MANIFOLD COLLECTOR" . ● This work is unnecessary when parts located forward of mass air flow sensor are removed/installed. Remove air duct (inlet). Disconnect the mass air flow sensor harness connector. Disconnect PCV hose. Remove air cleaner case/mass air flow sensor and air duct disconnecting their joints. ● Add marks as necessary for easier installation. Remove mass air flow sensor from air cleaner case. CAUTION: Handle mass air flow sensor with care. ● Do not shock it. ● Do not disassemble it. ● Do not touch its sensor. Remove resonator in the fender, lifting left fender protector.

INSTALLATION Install in the reverse order of removal paying attention to the following. ● Align marks. Attach each joint. Screw clamps firmly. Revision; 2004 April

EM-17

2003 FX

L

M


AIR CLEANER AND AIR DUCT [VQ35DE] ●

To position air cleaner case, refer to EM-18, "Changing Air Cleaner Filter" .

Changing Air Cleaner Filter

ABS004U1

INSPECTION Check status (fouling, damage, etc.) of air cleaner filter at power duct hole.

SBIA0463E

REMOVAL Removal in the order below. 1. Remove air duct (inlet) from air cleaner case. 2. Disconnect harness connector from mass air flow sensor. 3. Loosen clamp bolts of air hose. 4. Remove mounting bolts for air cleaner case. Remove air cleaner case/mass air flow sensor/air hose assembly. 5. Unclip and open air cleaner case, and remove air cleaner filter.

SBIA0464E

INSTALLATION Install in the reverse order of removal paying attention to the following. ● If grommet at bottom of air cleaner case comes off together with air cleaner case, fix it to vehicle before installation. ● Look at internal bottom face through power duct hole, and position air cleaner case with resonator upper end circle and air cleaner case round hole aligned. Then push air cleaner case straight down. ● At this time, check by hand if protrusion at bottom of air cleaner case has been inserted into grommet on vehicle side. ● Clip power duct with bulge on reverse side of lower end engaged with air cleaner case.

Revision; 2004 April

EM-18

KBIA0954E

2003 FX


INTAKE MANIFOLD COLLECTOR [VQ35DE]

INTAKE MANIFOLD COLLECTOR Removal and Installation

PFP:14003

A ABS004U2

EM

C

D

E

F

G

H

I

J

SBIA0585E

1.

Electric throttle control actuator

2.

Gasket

3.

Vacuum hose

4.

EVAP canister purge volume control solenoid valve

5.

Bracket

6.

Intake manifold collector (upper)

7.

Intake manifold collector cover

8.

Gasket

9.

Water hose

10. Bracket

11. Water hose

L

12. PCV hose

13. Intake manifold collector (lower)

M

REMOVAL WARNING: â—? To avoid the danger of being scalded, never drain engine coolant when engine is hot. â—? Gasket for intake manifold collector (upper) is secured together with mounting bolt for intake manifold collector (lower). Thus, even when only gasket for upper side is replaced, gasket for lower side must be also replaced.

Revision; 2004 April

K

EM-19

2003 FX


INTAKE MANIFOLD COLLECTOR [VQ35DE] 1.

Remove engine cover with power tool.

SBIA0486E

2.

3. 4.

Disconnect water hoses from intake manifold collector (upper), attach blind plug to prevent engine coolant leakage. CAUTION: Perform when engine is cold. Remove air cleaner case and air duct. Refer to EM-17, "AIR CLEANER AND AIR DUCT" . Remove electric throttle control actuator. Loosen bolts in the reverse order of that shown in the figure. CAUTION: ● Handle carefully to avoid any shock to electric throttle control actuator. ● Do not disassemble.

KBIA0957E

5. 6. 7. 8.

Remove fuel sub-tube mounting bolt to disconnect from rear of intake manifold collector (lower). Refer to EM-43, "FUEL INJECTOR AND FUEL TUBE" . Disconnect vacuum hose and water hose from intake manifold collector (upper). Remove EVAP canister purge volume control solenoid valve bracket mounting bolt from intake manifold collector (upper). Loosen bolts in reverse order as shown in the figure to remove intake manifold collector (upper) with power tool.

PBIC0773E

Revision; 2004 April

EM-20

2003 FX


INTAKE MANIFOLD COLLECTOR [VQ35DE] 9. Remove PCV hose [between intake manifold collector and rocker cover (right bank)]. 10. Loosen bolts in reverse order as shown in the figure, and remove intake manifold collector cover, gasket, intake manifold collector (lower) and gasket with power tool. CAUTION: Cover engine openings to avoid entry of foreign materials.

A

EM

C

PBIC0774E

INSPECTION AFTER REMOVAL Surface Distortion â—?

E

Using straightedge and feeler gauge, inspect the surface distortion of both intake manifold collector (upper and lower). Limit

â—?

D

F

: 0.1 mm (0.004 in)

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

H PBIC0775E

INSTALLATION I

Install in the reverse order of removal paying attention to the following.

Part Installation Direction Referring to front marks, install parts shown in figure.

J

K

L

M

PBIC0776E

Revision; 2004 April

EM-21

2003 FX


INTAKE MANIFOLD COLLECTOR [VQ35DE] Intake Manifold Collector (Lower) Tighten in numerical order as shown in the figure. NOTE: Tighten mounting bolts to secure gasket (lower), intake manifold collector (lower), gasket (upper), and intake manifold collector cover.

PBIC0774E

Intake Manifold Collector (Upper) ●

If stud bolts were removed, install them and tighten to the specified torque below. : 5.9 N·m (0.6 kg-m, 52 in-lb)

Shank length under bolt head varies with bolt location. Install bolts while referring to numbers shown below and in figure. (Bolt length does not include pilot portion.) Bolt M6 × 25 mm (0.98 in) M6 × 45 mm (1.77 in) M6 × 60 mm (2.36 in) M6 Nut

: 7, 8, 10, 11, 13, 14, 15, 16, 18 : 2, 4, 5 : 1, 3, 6, 9 : 12, 17

PBIC0773E

Tighten in numerical order as shown in the figure.

Water Hose ● ●

Insert hose by 27 to 32 mm (1.06 to 1.26 in) from connector end. Clamp hose at location of 3 to 7 mm (0.12 to 0.28 in) from hose end.

Electric Throttle Control Actuator ● ● ●

Install gasket with three protrusions for installation check facing any direction other than upward. Tighten in numerical order as shown in the figure. Perform the “Throttle Valve Closed Position Learning” when harness connector of electric throttle control actuator is disconnected. Refer to EC-63, "Throttle Valve Closed Position Learning" . Perform the “Idle Air Volume Learning” and “Throttle Valve Closed Position Learning” when electric throttle control actuator is replaced. Refer to EC-63, "Idle Air Volume Learning" .

KBIA0957E

Revision; 2004 April

EM-22

2003 FX


INTAKE MANIFOLD [VQ35DE]

INTAKE MANIFOLD Removal and Installation

PFP:14003

A ABS004U3

EM

C

D

E

F

G SBIA0487E

1.

Harness bracket

2.

Intake manifold

3.

Gasket

H

REMOVAL 1. 2. 3. 4.

Release fuel pressure. Refer to EC-65, "FUEL PRESSURE RELEASE" . Remove intake manifold collector (upper and lower). Refer to EM-19, "INTAKE MANIFOLD COLLECTOR" . Remove fuel tube and fuel injector assembly. Refer to EM-43, "FUEL INJECTOR AND FUEL TUBE" . Loosen bolts and nuts in reverse order of illustration to remove intake manifold assembly with power tool.

I

J

K

L

PBIC0778E

5.

Remove intake manifold gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

INSPECTION AFTER REMOVAL Surface Distortion ●

Using straightedge and feeler gauge, inspect the surface distortion of each surface on intake manifold. Limit

: 0.1 mm (0.04 in)

If it exceeds the limit, replace intake manifold.

PBIC0870E

Revision; 2004 April

EM-23

2003 FX

M


INTAKE MANIFOLD [VQ35DE] INSTALLATION Install in the reverse order of removal paying attention to the following.

Intake Manifold ●

If stud bolts were removed, install them and tighten to the specified torque below. : 10.8 N·m (1.1 kg-m, 8 ft-lb)

Tighten all mounting bolts and nuts to specified torque in two or more steps in numerical order shown in figure. 1st step: : 7.4 N·m (0.75 kg-m, 5 ft-lb) 2nd step: : 29.0 N·m (3.0 kg-m, 21 ft-lb)

Revision; 2004 April

PBIC0778E

EM-24

2003 FX


EXHAUST MANIFOLD AND THREE WAY CATALYST [VQ35DE]

EXHAUST MANIFOLD AND THREE WAY CATALYST Removal and Installation

PFP:14004

A ABS004U4

EM

C

D

E

F

G

H

I

J

SBIA0583E

1.

Heated oxygen sensor 2 (bank 1)

4.

heated oxygen sensor 1 (bank 1)

5.

Exhaust manifold cover (right bank)

6.

Exhaust manifold (right bank)

7.

Exhaust manifold (left bank)

8.

Exhaust manifold cover (left bank)

9.

Three way catalyst (left bank)

10. heated oxygen sensor 1 (bank 2)

2.

Three way catalyst (right bank)

3.

K

Gasket

L

11. Heated oxygen sensor 2 (bank 2)

REMOVAL M

WARNING: Perform the work when the exhaust and cooling system have completely cooled down. 1. Remove engine cover with power tool. Refer to EM-19, "INTAKE MANIFOLD COLLECTOR" . 2. Remove air cleaner case and air duct. Refer to EM-17, "AIR CLEANER AND AIR DUCT" . 3. Remove front and rear engine undercover and front cross bar with power tool. 4. Disconnect heated oxygen sensors 2 (bank 1 and bank 2) harness connectors. 5. Using heated oxygen sensor wrench (SST), remove heated oxygen sensors 2 (bank 1 and bank 2). CAUTION: ● Be careful not to damage heated oxygen sensor. ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; replace with a new sensor. 6. Remove bracket between right/left catalytic converter and transmission. Refer to EX-3, "EXHAUST SYSTEM" . KBIA1740E

Revision; 2004 April

EM-25

2003 FX


EXHAUST MANIFOLD AND THREE WAY CATALYST [VQ35DE] 7. 8. 9.

Remove three way catalyst (RH and LH bank). Remove heated oxygen sensors 1 (bank 1 and bank 2) harness connectors and harness clip. Using heated oxygen sensor wrench (SST), remove heated oxygen sensors 1 (bank 1 and bank 2). CAUTION: ● Be careful not to damage heated oxygen sensor. ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; replace with a new sensor. 10. Remove water pipes on both RH and LH side. Refer to CO-27, "WATER OUTLET AND WATER PIPING" . SBIA0575E

11. Remove exhaust manifold cover (RH and LH bank). 12. Loosen nuts in the reverse order as shown in the figure to remove exhaust manifold with power tool. NOTE: Disregard the numerical order No. 7 and No. 8 in removal.

KBIA0968E

KBIA0969E

13. Remove exhaust manifold gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

INSPECTION AFTER REMOVAL Surface Distortion ●

Use a reliable straightedge and feeler gauge to check the flatness of exhaust manifold fitting surface. Limit

: 0.3 mm (0.012 in)

If it exceeds the limit, replace exhaust manifold.

PBIC1096E

INSTALLATION Install in the reverse order of removal paying attention to the following. Revision; 2004 April

EM-26

2003 FX


EXHAUST MANIFOLD AND THREE WAY CATALYST [VQ35DE] Exhaust Manifold Gasket ●

A

Install in direction shown below. (Follow same procedure for both banks.) Locate thick side of port connecting part on right side from technician’s view. Locate round press in thick side of port connecting part above center level line of port.

EM

C

KBIA1051E

D

Exhaust Manifold ●

If stud bolts were removed, install them and tighten to the specified torque below.

E

: 14.7 N·m (1.5 kg-m, 11 ft-lb) ●

F

Install exhaust manifold in the numerical order as shown in the figure. Tighten nuts No. 1 and No. 2 in two steps. The numerical order No. 7 and No. 8 shows second step.

G

KBIA0968E

H

I

J

K KBIA0969E

L

Heated Oxygen Sensor CAUTION: ● Before installing a new heated oxygen sensor, clean exhaust system threads using heated oxygen sensor thread cleaner tool (Commercial Service Tool: J-43897-18 or J-43897-12) and apply antiseize lubricant. ● Do not over torque heated oxygen sensor. Doing so may cause damage to heated oxygen sensor, resulting in the “MIL” coming on.

Revision; 2004 April

EM-27

2003 FX

M


OIL PAN AND OIL STRAINER [VQ35DE]

OIL PAN AND OIL STRAINER Removal and Installation

PFP:11110 ABS004U5

2WD MODEL

SBIA0587E

1.

Oil pan gasket (rear)

2.

Oil pan (upper)

3.

O-ring

4.

Oil pan gasket (front)

5.

Oil filter

6.

Connector bolt

7.

Oil cooler

8.

O-ring

9.

Relief valve

10. Oil pressure switch

11. Bracket

12. Oil strainer

13. Drain plug

14. Drain plug washer

15. Oil pan (lower)

16. Rear plate

17. Crankshaft position sensor (POS)

18. Seal rubber

19. Rear cover plate

REMOVAL CAUTION: To avoid the danger of being scalded, never drain engine oil when engine is hot. NOTE: To remove oil pan (lower) only, take step 5, then step 20. Removal of step 1, hood assembly (step 2) and step 4 are unnecessary. 1. Remove front tire. 2. Remove hood assembly. Refer to BL-14, "HOOD" . 3. Remove front and rear engine undercover with power tool. 4. Remove front cross bar with power tool. Refer to FSU-6, "FRONT SUSPENSION ASSEMBLY" . 5. Drain engine oil. Refer to LU-9, "Changing Engine Oil" . 6. Drain engine coolant. Refer to CO-11, "Changing Engine Coolant" .

Revision; 2004 April

EM-28

2003 FX


OIL PAN AND OIL STRAINER [VQ35DE]

7. 8. 9.

CAUTION: Perform when engine is cold. A Remove engine cover with power tool. Refer to EM-19, "INTAKE MANIFOLD COLLECTOR" . Remove air hose from air duct to mass air flow sensor side and electric throttle control actuator side. Refer to EM-17, "AIR CLEANER AND AIR DUCT" . EM Removal engine rear lower slinger, and install engine rear slinger to sling engine assembly for positioning. Refer to EM-8, "Special Service Tools" . C Slinger bolts: : 28.0 N·m (2.9 kg-m, 21 ft-lb)

10. Remove front suspension member. Refer to FSU-17, "FRONT SUSPENSION MEMBER" . 11. Remove drive belt for alternator and power steering pump and A/C compressor. Refer to EM-15, "DRIVE BELTS" . 12. Remove alternator stay. Refer to SC-23, "CHARGING SYSTEM" . 13. Remove starter motor. Refer to SC-10, "STARTING SYSTEM" . 14. Remove alternator and power steering pump and A/C compressor idler pulley and bracket assembly. Refer to EM-15, "DRIVE BELTS" . 15. Disconnect A/T fluid cooler hoses, and remove oil cooler water pipe mounting bolt. Refer to LU-14, "OIL COOLER" . 16. Disconnect A/T fluid cooler tube. 17. Remove crankshaft position sensor (POS). CAUTION: ● Handle carefully to avoid dropping and shocks. ● Do not disassemble. ● Do not allow metal powder to adhere to magnetic part at sensor tip. ● Do not place sensors in a location where they are exposed to magnetism. 18. Remove oil filter, as necessary. Refer to LU-10, "OIL FILTER" . 19. Remove oil cooler, as necessary. Refer to LU-14, "OIL COOLER" . 20. Remove oil pan (lower) as the following: a. Loosen bolts in reverse order as shown in the figure to remove.

D

E

F

G

H

I

J

K

L

M PBIC0782E

b. c.

Insert seal cutter (SST) between oil pan (upper) and oil pan (lower). Slide seal cutter by tapping on the side of tool with hammer. Remove oil pan (lower). CAUTION: ● Be careful not to damage the mating surface. ● Do not insert flat-bladed screwdriver, this will damage the mating surface. SEM960F

21. Remove oil strainer. Revision; 2004 April

EM-29

2003 FX


OIL PAN AND OIL STRAINER [VQ35DE] 22. Remove transmission joint bolts which pierce oil pan (upper). Refer to AT-269, "TRANSMISSION ASSEMBLY" . 23. Remove rear cover plate. 24. Loosen oil pan (upper) bolts with power tool in the reverse order as shown in the figure to remove. ● Insert seal cutter [SST: KV10111100 (J-37228)] between oil pan (upper) and cylinder block. Slide seal cutter by tapping on the side of the tool with a hammer. Remove oil pan (upper). CAUTION: ● Be careful not to damage the mating surface. ● Do not insert a screwdriver, this will damage the mating surfaces. PBIC0783E

INSPECTION AFTER REMOVAL Clean oil strainer if any object attached.

INSTALLATION 1. a.

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

MEM108A

b.

Apply liquid gasket to oil pan gaskets as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to Refer to Service Manual .

SEM964E

To install, align protrusion of oil pan gasket with notches of front timing chain case and rear oil seal retainer. Install oil pan gasket with smaller arc to front timing chain case side.

PBIC1145E

Revision; 2004 April

EM-30

2003 FX


OIL PAN AND OIL STRAINER [VQ35DE] c.

Install new O-rings on cylinder block and oil pump side. A

EM

C PBIC1144E

D

d.

e.

Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( – )] to the cylinder block mating surface of oil pan (upper) to a limited portion as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to Refer to Service Manual . CAUTION: ● For bolt holes with marks (5 locations), apply liquid gasket outside the holes. ● Apply a bead of 4.5 to 5.5 mm (0.177 to 0.217 in) in diameter to area “A”. ● Attaching should be done within 5 minutes after coating.

E

F

G PBIC2300E

H

Install oil pan (upper). CAUTION: Install avoiding misalignment of both oil pan gasket and O-rings. ● Tighten bolts in numerical order as shown in the figure. ● There are two types of mounting bolts. Refer to the following for locating bolts. M8 × 100 mm (3.97 in) M8 × 25 mm (0.98 in)

I

J

: 5, 7, 8, 11 : Except the above

K

PBIC0783E

f. 2. 3. a.

Tighten transmission joint bolts. Refer to Refer to Service Manual . Install oil strainer to oil pump. Install oil pan (lower) as the following: Use scraper to remove old liquid gasket from mating surfaces. ● Also remove old liquid gasket from mating surface of oil pan (upper).

M

SEM958F

Revision; 2004 April

EM-31

L

2003 FX


OIL PAN AND OIL STRAINER [VQ35DE] b.

Apply liquid gasket thoroughly with tube presser [SST: WS39930000 ( – )] as in illustration. Use Genuine RTV Silicone Sealant or equivalent. Refer to Refer to Service Manual . NOTE: Attaching should be done within 5 minutes after coating.

PBIC1146E

c.

Tighten bolts in numerical order as shown in the figure.

PBIC0782E

4. 5.

Install oil pan drain plug. ● Refer to illustration of components of former page for installation direction of washer. Install in the reverse order of removal after this step. NOTE: At least 30 minutes after oil pan is installed, pour engine oil.

INSPECTION AFTER INSTALLATION 1. 2. 3. 4.

Check engine oil level and add engine oil. Refer to LU-7, "ENGINE OIL" . Start engine, and check there is no leak of engine oil. Stop engine and wait for 10 minutes. Check engine oil level again. Refer to LU-7, "ENGINE OIL" .

Revision; 2004 April

EM-32

2003 FX


OIL PAN AND OIL STRAINER [VQ35DE] AWD MODEL Models Produced Before May 2003

A

EM

C

D

E

F

G

H

I

J SBIA0467E

1.

Oil pan gasket (Rear)

2.

Oil pan (Upper)

3.

O-ring

4.

Oil pan gasket (Front)

5.

Oil filter

6.

Connector bolt

7.

Oil cooler

8.

O-ring

9.

Relief valve

10. Oil filter bracket

11. Oil filter bracket gasket

12. Oil strainer

13. Drain plug

14. Drain plug washer

15. Oil pan (Lower)

16. Rear plate

17. Crankshaft position sensor (POS)

18

19. O-ring (Small)

20. O-ring (Large)

21. Axle pipe

Revision; 2004 April

EM-33

K

L

Seal rubber

M

2003 FX


OIL PAN AND OIL STRAINER [VQ35DE] Models Produced After June 2003

SBIA0567E

1.

Oil pan gasket (Rear)

2.

Oil pan (Upper)

3.

O-ring

4.

Oil pan gasket (Front)

5.

Oil filter

6.

Connector bolt

7.

Oil cooler

8.

O-ring

9.

Relief valve

10. Oil filter bracket

11. Oil filter bracket gasket

12. Oil strainer

13. Drain plug

14. Drain plug washer

15. Oil pan (Lower)

16. Rear plate

17. Crankshaft position sensor (POS)

18

19. O-ring (Large)

20. Axle pipe

O-ring (Small)

REMOVAL CAUTION: To avoid the danger of being scalded, never drain engine oil when engine is hot. NOTE: To remove oil pan (lower) only, take step 5, then step 24. Removal of step 1, hood assembly (step 2) and step 4 are unnecessary. 1. Remove front tire. 2. Remove hood assembly. Refer to BL-14, "HOOD" . 3. Remove front and rear engine undercover with power tool. 4. Remove front cross bar with power tool. Refer to FSU-17, "FRONT SUSPENSION MEMBER" . 5. Drain engine oil. Refer to LU-9, "Changing Engine Oil" . 6. Drain engine coolant. Refer to CO-11, "Changing Engine Coolant" . CAUTION: Perform when engine is cold. 7. Remove engine cover with power tool. Refer to EM-19, "INTAKE MANIFOLD COLLECTOR" . Revision; 2004 April

EM-34

2003 FX


OIL PAN AND OIL STRAINER [VQ35DE] 8.

Remove air hose from air duct to mass air flow sensor side and electric throttle control actuator side. Refer to EM-17, "AIR CLEANER AND AIR DUCT" . A 9. Remove drive belt for alternator and power steering pump and A/C compressor. Refer to EM-15, "DRIVE BELTS" . 10. Remove front drive shaft (LH and RH) and side shaft. Refer to FAX-12, "FRONT DRIVE SHAFT" . EM 11. Remove side shaft. Refer to FFD-10, "FRONT FINAL DRIVE ASSEMBLY" . 12. Removal engine rear lower slinger, and install engine rear slinger to sling engine assembly for positioning. C Refer to EM-8, "Special Service Tools" . Slinger bolts: : 28.0 N·m (2.9 kg-m, 21 ft-lb)

D

13. Remove front suspension member. Refer to FSU-17, "FRONT SUSPENSION MEMBER" . 14. Remove engine mounting bracket, engine mounting bracket (lower) and insulator. Refer to EM-108, "ENGINE ASSEMBLY" . 15. Remove front propeller shaft. Refer to PR-4, "FRONT PROPELLER SHAFT" . 16. Remove oil filter and oil filter bracket. Refer to LU-12, "OIL FILTER BRACKET (AWD)" . 17. Remove alternator stay. Refer to SC-23, "CHARGING SYSTEM" . 18. Remove alternator and power steering pump and A/C compressor idler pulley and bracket. Refer to EM15, "DRIVE BELTS" . 19. Disconnect A/T fluid cooler hoses, and remove oil cooler water pipe mounting bolt. Refer to LU-14, "OIL COOLER" . 20. Disconnect A/T fluid cooler tube. 21. Remove front final drive assembly. Refer to FFD-10, "FRONT FINAL DRIVE ASSEMBLY" . 22. Remove starter motor. Refer to SC-10, "STARTING SYSTEM" . 23. Remove crankshaft position sensor (POS). CAUTION: ● Handle carefully to avoid dropping and shocks. ● Do not disassemble. ● Do not allow metal powder to adhere to magnetic part at sensor tip. ● Do not place sensors in a location where they are exposed to magnetism. 24. Remove oil pan (lower) as the following: a. Loosen bolts in reverse order as shown in the figure to remove.

E

F

G

H

I

J

K

L

M

PBIC0782E

b. c.

Insert seal cutter (SST) between oil pan (upper) and oil pan (lower). Slide seal cutter by tapping on the side of tool with hammer. Remove oil pan (lower). CAUTION: ● Be careful not to damage the mating surface. ● Do not insert flat-bladed screwdriver, this will damage the mating surface. SEM960F

Revision; 2004 April

EM-35

2003 FX


OIL PAN AND OIL STRAINER [VQ35DE] 25. Remove oil strainer. 26. Remove transmission joint bolts which pierce oil pan (upper). Refer to AT-269, "TRANSMISSION ASSEMBLY" . 27. Loosen oil pan (upper) bolts with power tool in the reverse order as shown in the figure to remove. ● Insert seal cutter [SST: KV10111100 (J-37228)] between oil pan (upper) and cylinder block. Slide seal cutter by tapping on the side of the tool with a hammer. Remove oil pan (upper). CAUTION: ● Be careful not to damage the mating surface. ● Do not insert a screwdriver, this will damage the mating surfaces. PBIC0783E

28. Remove axle pipe, as necessary. ● Remove axle pipe from oil pan (upper) using a suitable drift [37 mm (1.46 in)].

SBIA0469E

INSPECTION AFTER REMOVAL Clean oil strainer if any object attached.

INSTALLATION 1.

Install axle pipe to oil pan, if removed. ● Lubricate O-ring groove of axle pipe, O-ring, and O-ring joint of oil pan with new engine oil. Unit: mm (in)

Item

O-ring inner diameter

Final drive side (RH side)

32 (1.26)

Axle pipe flange side (LH side)

34 (1.34)

SBIA0470E

Install axle pipe to oil pan from axle pipe flange side (LH side) using a suitable drift [43 - 57 mm (1.69 - 2.24 in)]. CAUTION: Insert it with care to prevent O-ring from sliding.

SBIA0471E

Revision; 2004 April

EM-36

2003 FX


OIL PAN AND OIL STRAINER [VQ35DE] 2. a.

Install oil pan (upper) in the order below. Install O-ring to cylinder block and oil pump side.

A

EM

C PBIC0925E

D

b.

Install oil pan gasket. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .

E

F

G SEM964E

To install, align protrusion of oil pan gasket with notches of front timing chain case and rear oil seal retainer. Install oil pan gasket with smaller arc to front timing chain case side.

H

I

J

PBIC0784E

c.

Apply liquid gasket thoroughly as in illustration. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . CAUTION: ● For bolt holes with marks (5 locations), apply liquid gasket outside the holes. ● Apply a bead of 4.5 to 5.5 mm (0.177 to 0.217 in) in diameter to area “A”. ● Attaching should be done within 5 minutes after coating.

L

M

PBIC2300E

d.

Tighten bolts in numerical order as shown in the figure. CAUTION: Install avoiding misalignment of both oil pan gasket and O-rings.

Revision; 2004 April

EM-37

K

2003 FX


OIL PAN AND OIL STRAINER [VQ35DE] ●

● ●

Install oil pan gasket and O-ring while maintaining proper position. Be careful not to damage oil strainer during installation. There are three types of mounting bolts. Refer to the following for locating bolts. M8 × 27 mm (1.06 in) M8 × 52 mm (2.05 in) M8 × 98 mm (3.86 in)

e. 3. 4. a.

: 1, 2, 3, 4 and 9 :8 : 5, 6, 7, 10, 11 and 12

Tighten transmission joint bolts. Refer to AT-269, "TRANSMISSION ASSEMBLY" . Install oil strainer to oil pump. Install oil pan (lower) in the order below. Apply liquid gasket thoroughly with tube presser [SST: WS39930000 ( – )] as in illustration. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . NOTE: Attaching should be done within 5 minutes after coating.

PBIC0783E

PBIC1146E

b.

Tighten bolts in numerical order as shown in the figure.

PBIC0782E

5. 6. 7.

Install oil pan drain plug. ● Refer to illustration of components of former page for installation direction of washer. Install in the reverse order of removal after this step. At least 30 minutes after oil pan is installed, pour engine oil.

INSPECTION AFTER INSTALLATION 1. 2. 3.

Check engine oil level and add engine oil. Refer to LU-7, "ENGINE OIL" . Start engine, and check there is no leak of engine oil. Stop engine and wait for 10 minutes.

Revision; 2004 April

EM-38

2003 FX


OIL PAN AND OIL STRAINER [VQ35DE] 4.

Check engine oil level again. Refer to LU-7, "ENGINE OIL" A

EM

C

D

E

F

G

H

I

J

K

L

M

Revision; 2004 April

EM-39

2003 FX


IGNITION COIL [VQ35DE]

IGNITION COIL Removal and Installation

PFP:22448 ABS004U6

SBIA0568E

1.

Ignition coil

2.

Spark plug

REMOVAL 1. 2. 3. 4. 5.

Remove engine cover with power tool. Refer to EM-19, "INTAKE MANIFOLD COLLECTOR" . Remove air duct (for ignition coil of LH bank side). Refer to EM-17, "AIR CLEANER AND AIR DUCT" . Move aside harness, harness bracket, and hoses located above ignition coil. Disconnect harness connector from ignition coil. Remove ignition coil. CAUTION: Do not shock it.

INSTALLATION Install in the reverse order of removal.

Revision; 2004 April

EM-40

2003 FX


SPARK PLUG (PLATINUM-TIPPED TYPE) [VQ35DE]

SPARK PLUG (PLATINUM-TIPPED TYPE) Removal and Installation

PFP:22401

A ABS004WI

EM

C

D

E

F

G SBIA0568E

1.

Ignition coil

2.

Spark plug

REMOVAL

H

1. 2. 3.

I

Remove engine cover with power tool. Refer to EM-19, "INTAKE MANIFOLD COLLECTOR" . Remove ignition coil. Refer to EM-40, "IGNITION COIL" . Remove spark plug with spark plug wrench (commercial service tool).

J

K

L 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 Make

NGK

Standard type

PLFR5A-11

Hot type

PLFR4A-11

Cold type

PLFR6A-11

Gap (Nominal)

Revision; 2004 April

: 1.1 mm (0.043 in)

EM-41

2003 FX

M


SPARK PLUG (PLATINUM-TIPPED TYPE) [VQ35DE] 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

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

SMA806CA

INSTALLATION Install in the reverse order of removal.

Revision; 2004 April

EM-42

2003 FX


FUEL INJECTOR AND FUEL TUBE [VQ35DE]

FUEL INJECTOR AND FUEL TUBE Removal and Installation

PFP:16600

A ABS004U8

EM

C

D

E

F

G

H

I

J

SBIA0580E

1.

Fuel damper

2.

O-ring

3.

Fuel sub-tube

4.

EVAP hose

5.

Intake manifold collector (Lower)

6.

Fuel feed hose (With damper)

7.

Fuel tube

8.

Spacer

9.

Clip

10. O-ring (Black)

11. Fuel injector

12. O-ring (Green)

13. Hose clamp

14. Bracket

15. Quick connector cap

L

16. Centralized under-floor piping

M

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

Revision; 2004 April

K

EM-43

2003 FX


FUEL INJECTOR AND FUEL TUBE [VQ35DE] REMOVAL 1. 2. 3.

Remove engine cover with power tool. Refer to EM-19, "INTAKE MANIFOLD COLLECTOR" . Release fuel pressure. Refer to EC-65, "FUEL PRESSURE RELEASE" . Remove fuel feed hose (with damper) from fuel sub-tube. NOTE: There is no fuel return route. CAUTION: ● While hoses are disconnected, plug them to prevent fuel from draining. ● Do not separate damper and hose.

KBIA1293E

4.

a. b.

When separating fuel feed hose and centralized under-floor piping connection, disconnect quick connector with the following procedure. Disconnect quick connector cap from quick connector connection on right member side. Disconnect fuel feed hose from bracket hose clamp.

KBIA1294E

c.

i.

Disconnect quick connector from centralized under-floor piping as follows: CAUTION: Disconnect quick connector by using quick connector release [SST: — (J-45488)], not by picking out retainer tabs. With the sleeve side of quick connector release facing quick connector, install quick connector release onto fuel tube.

ii.

Insert quick connector release into quick connector until sleeve contacts and goes no further. Hold quick connector release on that position. CAUTION: Inserting quick connector release hard will not disconnect quick connector. Hold quick connector release where it contacts and goes no further. iii. Draw and pull out quick connector straight from centralized under-floor piping. CAUTION: PBIC1898E ● Pull quick connector holding “A” position as shown in 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 hose (with damper) during installation/removal.

Revision; 2004 April

EM-44

2003 FX


FUEL INJECTOR AND FUEL TUBE [VQ35DE] ●

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

A

EM

C PBIC1899E

D

5. 6. 7.

Remove intake manifold collector (upper and lower). Refer to EM-19, "INTAKE MANIFOLD COLLECTOR" . Disconnect harness connector from fuel injector. Loosen mounting bolts in the reverse order in the figure, and remove fuel tube and fuel injector assembly. CAUTION: Do not tilt it, or remaining fuel in pipes may flow out from pipes.

E

F

G

H KBIA1296E

8. 9. a. b.

Remove spacers on intake manifold. Remove fuel injector from fuel tube with following procedure. 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. 10. Remove fuel sub-tube and fuel damper.

I

J

K

L

M

SBIA0364E

INSTALLATION 1.

Install fuel damper and fuel sub-tube. ● When handling O-rings, be careful of the following: CAUTION: ● Handle O-ring with bare hands. Never wear gloves. ● Lubricate O-ring with new engine oil.

Revision; 2004 April

EM-45

2003 FX


FUEL INJECTOR AND FUEL TUBE [VQ35DE] 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 quickly into fuel tube. ● Insert O-ring straight into fuel tube. Do not decenter or twist it. ● Insert fuel damper and fuel sub-tube straight into fuel tube. ● Tighten mounting bolts evenly in turn. ● After tightening mounting bolts, make sure that there is no gap between flange and fuel tube. 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. ● ●

2.

Fuel tube side Nozzle side

: Black : Green

Handle O-ring with bare hands. Never wear gloves. ● Lubricate O-ring with new engine oil. ● Do not clean O-ring with solvent. ● Make sure that O-ring and its mating part are free of 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 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 procedure. Insert clip into clip mounting groove on fuel injector. ● Insert clip so that lug “A” of fuel injector matches notch “A” of the clip. CAUTION: ● Do not reuse clip. Replace it with a new one. ● 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. ● 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 checking that fuel injector does not rotate or come off. ●

3. a.

b.

c.

SBIA0439E

4.

Install spacers on intake manifold.

Revision; 2004 April

EM-46

2003 FX


FUEL INJECTOR AND FUEL TUBE [VQ35DE] 5.

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. ● Tighten mounting bolts in two steps in numerical order shown in figure.

A

EM

1st step: 10.1 N·m (1.0 kg-m, 7 ft-lb)

C

2nd step: 23.6 N·m (2.4 kg-m, 17 ft-lb) 6. 7.

KBIA1296E Connect injector sub-harness. Install intake manifold collector (upper and lower). Refer to EM19, "INTAKE MANIFOLD COLLECTOR" . 8. Install fuel sub-tube on rear end of intake manifold collector (lower). 9. Connect fuel feed hose (with damper). ● Handling procedure of O-ring is the same as that of fuel damper and fuel sub-tube. ● Insert fuel damper straight into fuel sub-tube. ● Tighten mounting bolts evenly in turn. ● After tightening mounting bolts, make sure that there is no gap between flange and fuel sub-tube. 10. Connect quick connector between fuel feed hose and centralized under-floor piping connection with the following procedure: a. Check the connection for damage and foreign materials. b. Align the connector with the tube, then insert the connector straight into the tube until a click is heard. c. After connecting quick connector, use the following method to make sure it is full connected. ● Visually confirm that the two retainer tabs are connected to the connector. ● Pull the tube and the connector to make sure they are securely connected.

D

E

F

G

H

I

J

K KBIA1297E

d.

Install quick connector cap to quick connector connection. ● Install quick connector cap with arrow on surface facing in direction of quick connector (fuel feed hose side). CAUTION: If cap cannot be installed smoothly, quick connector may have not been installed correctly. Check connection again. e. Secure fuel feed hose to clamp. 11. Install in the reverse order of removal after this step.

L

M

KBIA1298E

INSPECTION AFTER INSTALLATION Check on Fuel Leakage ●

After installing fuel tubes, make sure there is no fuel leakage at connections in the following steps. a) Apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine stopped). Then check for fuel leaks at connections. b) Start engine and rev it up and check for fuel leaks at connections. NOTE: Use mirrors for checking on invisible points.

Revision; 2004 April

EM-47

2003 FX


FUEL INJECTOR AND FUEL TUBE [VQ35DE] CAUTION: Do not touch the engine immediately after stopped, as engine becomes extremely hot.

Revision; 2004 April

EM-48

2003 FX


ROCKER COVER [VQ35DE]

ROCKER COVER Removal and Installation

PFP:13264

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1.

PCV hose

2.

Oil filler cap

3.

Oil catcher

4.

Rocker cover (right bank)

5.

PCV control valve

6.

O-ring

7.

Rocker cover gasket

8.

Rocker cover (left bank)

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REMOVAL 1. 2. 3. 4. 5.

Remove intake manifold collectors (upper and lower). Refer to EM-19, "INTAKE MANIFOLD COLLECTOR" . Remove ignition coil. Refer to EM-40, "IGNITION COIL" . Remove PCV hoses from rocker covers. Remove PCV valve and O-ring from rocker cover (right bank), if necessary. Remove oil filler cap from rocker cover (left bank), if necessary.

Revision; 2004 April

EM-49

2003 FX

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ROCKER COVER [VQ35DE] 6.

Loosen bolts in the reverse order shown in the figure (with power tool).

KBIA0985E

7. 8.

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

INSTALLATION 1.

Apply liquid gasket of 3.0 mm (0.12 in) diameter to position shown in the figure (both edges of No. 1 camshaft bracket) (on both banks). ● First, apply it to engine longitudinal direction [5.0 mm (0.197 in) + 5.0 mm (0.197 in) side in figure]. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .

PBIC0786E

2. 3.

Install new rocker cover gasket to rocker cover. Install rocker cover. ● Check if rocker cover gasket is dropped from installation groove of rocker cover.

Revision; 2004 April

EM-50

2003 FX


ROCKER COVER [VQ35DE] 4.

Tighten bolts two steps separately in order numbers in illustration.

A

1st step: 1.96 N·m (0.20 kg-m, 17 in-lb) 2nd step: 8.33 N·m (0.85 kg-m, 74 in-lb)

EM

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5. 6. 7.

8.

Install oil filer cap to rocker cover (left bank), if removed. Install new O-ring and PCV valve to rocker cover (right bank), if removed. Install PCV hose. ● Insert PCV hose by 25 to 30 mm (0.98 to 1.18 in) from connector end. ● When installing, be careful not to twist or come in contact with other parts. ● Install PCV hose between right and left rocker covers with its identification paint facing upward (right rocker cover side). Refer to component figure in EM-49, "Removal and Installation" . Install in the reverse order of removal after this step.

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Revision; 2004 April

EM-51

2003 FX


FRONT TIMING CHAIN CASE [VQ35DE]

FRONT TIMING CHAIN CASE Removal and Installation

PFP:13599 ABS00BYT

NOTE: ● This section describes removal/installation procedure of front timing chain case and timing chain related parts without removing oil pan (upper) on vehicle. ● When oil pan (upper) needs to be removed or installed, or when rear timing chain case is removed or installed, remove oil pans (upper and lower) first. Then remove front timing chain case, timing chain related parts, and rear timing chain case in this order, and install in reverse order of removal. Refer to EM61, "TIMING CHAIN" . ● Refer to EM-61, "TIMING CHAIN" for component parts location.

REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Place vehicle onto lift. Disconnect negative battery terminal. Remove engine cover with power tool. Refer to EM-19, "INTAKE MANIFOLD COLLECTOR" . Remove air cleaner case assembly. Refer to EM-17, "AIR CLEANER AND AIR DUCT" . Remove front and rear engine undercover with power tool. Drain engine coolant from radiator. Refer to CO-11, "Changing Engine Coolant" . Drain engine oil from oil pan. Refer to LU-9, "Changing Engine Oil" . Remove engine harnesses. Remove intake manifold collectors (upper and lower) with power tool. Refer to EM-19, "INTAKE MANIFOLD COLLECTOR" . Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside. Refer to PS-31, "POWER STEERING OIL PUMP" . Remove power steering oil pump bracket. Refer to PS-31, "POWER STEERING OIL PUMP" . Remove alternator. Refer to SC-23, "CHARGING SYSTEM" . Remove water bypass hose, water hose clamp and idler pulley bracket and alternator and power steering oil pump and A/C compressor belt tensioner from front timing chain case. Remove right and left intake valve timing control covers with power tool. ● Loosen bolts in reverse order as shown in the figure. ● Use seal cutter [SST: KV10111100 (J-37228)] or an equivalent tool to cut liquid gasket for removal. CAUTION: Shaft is internally jointed with intake camshaft sprocket center hole. When removing, keep it horizontal until it is completely disconnected. SEM728G

15. Remove collared O-rings from front timing chain case (left and right side).

PBIC2045E

16. Remove right and left rocker covers. Refer to EM-49, "ROCKER COVER" . NOTE: When secondary timing chain is not removed/installed, this step is not required. Revision; 2004 April

EM-52

2003 FX


FRONT TIMING CHAIN CASE [VQ35DE] 17. Obtain compression TDC of No. 1 cylinder as follows: NOTE: When timing chain is not removed/installed, this step is not required. a. Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator.

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b.

Make sure intake and exhaust cam noses on No. 1 cylinder (engine front side of right bank) are located as shown in the figure. � If not, turn crankshaft one revolution (360°) and align as shown. NOTE: When only primary timing chain is removed, rocker cover does not need to be removed. To confirm that No. 1 cylinder is at its compression TDC, remove front timing chain case first. Then check mating marks on camshaft sprockets. Refer to EM-61, "TIMING CHAIN" .

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18. Remove crankshaft pulley with the following procedure: a. Remove rear cover plate (2WD) or starter motor (AWD) and set ring gear stopper (SST) as shown in the figure. Refer to SC-10, "STARTING SYSTEM" .

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b.

Loosen crankshaft pulley bolt and locate bolt seating surface as 10 mm (0.39 in) from its original position. CAUTION: Do not remove crankshaft pulley bolt as it will be used as a supporting point for suitable puller.

M

PBIC1103E

Revision; 2004 April

EM-53

2003 FX


FRONT TIMING CHAIN CASE [VQ35DE] c.

Place suitable puller tab on holes of crankshaft pulley, and pull crankshaft pulley through. CAUTION: Do not put suitable puller tab on crankshaft pulley periphery, as this will damage internal damper.

EMQ0477D

19. Remove oil pan (lower). Refer to EM-28, "OIL PAN AND OIL STRAINER" . 20. Loosen two mounting bolts in front of oil pan (upper) with power tool in reverse order as shown in the figure.

PBIC1116E

21. Remove front timing chain case. a. Loosen mounting bolts with power tool in reverse order as shown in the figure.

KBIA1303E

b. c.

Insert suitable tool into the notch at the top of front timing chain case as shown (1) in the figure. Pry off case by moving tool as shown (2) in the figure. ● Use seal cutter [SST: KV10111100 (J-37228)] or an equivalent tool to cut liquid gasket for removal. CAUTION: ● Do not use screwdrivers or something similar. ● After removal, handle it carefully so it does not tilt, cant, or warp under a load. SEM156F

Revision; 2004 April

EM-54

2003 FX


FRONT TIMING CHAIN CASE [VQ35DE] 22. Remove O-rings from rear timing chain case. A

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23. Remove oil pan gasket front side. Refer to EM-28, "OIL PAN AND OIL STRAINER" . 24. Remove water pump cover and chain tensioner cover from front timing chain case. ● Use seal cutter [SST: KV10111100 (J-37228)] or an equivalent tool to cut liquid gasket for removal. 25. Remove front oil seal from front timing chain case using a suitable tool. ● Use flat-bladed screwdriver for removal. CAUTION: Exercise care not to damage front timing chain case.

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26. Remove timing chain and related parts. Refer to EM-61, "TIMING CHAIN" . 27. Use a scraper to remove all traces of old liquid gasket from front and rear timing chain cases and oil pan (upper), and liquid gasket mating surfaces. CAUTION: Be careful not to allow gasket fragments to enter oil pan.

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Remove old liquid gasket from bolt hole and thread.

PBIC2084E

Revision; 2004 April

EM-55

2003 FX


FRONT TIMING CHAIN CASE [VQ35DE] 28. Use a scraper to remove all traces of liquid gasket from water pump cover, chain tensioner cover and intake valve timing control covers.

SEM926E

INSTALLATION 1. 2.

Install timing chain and related parts. Refer to EM-61, "TIMING CHAIN" . Hammer dowel pins (left and left) into front timing chain case up to a point close to taper in order to shorten protrusion length.

PBIC1101E

3.

Install front oil seal on front timing chain case. ● Apply new engine oil to the oil seal edges. ● Install it so that each seal lip is oriented as shown in the figure.

SEM715A

Using suitable drift, press-fit oil seal until it becomes flush with front timing chain case end face. Make sure the garter spring is in position and seal lip is not inverted.

PBIC0790E

Revision; 2004 April

EM-56

2003 FX


FRONT TIMING CHAIN CASE [VQ35DE] 4.

Install water pump cover and chain tensioner cover to front timing chain case. ● Apply liquid gasket to front timing chain case front side as shown in the figure with tube presser [SST: WS39930000 ( – )]. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".

A

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5. a.

Install front timing chain case as follows: Apply liquid gasket to front timing chain case back side as shown in the figure with tube presser [SST: WS39930000 ( – )]. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".

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PBIC1133E

b.

Install oil pan gasket front side. ● Apply liquid gasket to oil pan gasket as shown in the figure with tube presser [SST: WS39930000 ( – )]. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".

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SEM964E

Align notch of front timing chain case with protrusion of oil pan gasket.

PBIC1114E

Revision; 2004 April

EM-57

K

2003 FX


FRONT TIMING CHAIN CASE [VQ35DE] ●

Apply liquid gasket to top surface of oil pan (upper) as shown in the figure with tube presser [SST: WS39930000 ( – )]. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".

PBIC1099E

c.

Install new O-rings on rear timing chain case.

SBIA0497E

d. i.

Assemble front timing chain case as follows. Fit lower end of front timing chain case tightly onto top face of oil pan (upper). From the fitting point, make entire front timing chain case contact rear timing chain case completely. CAUTION: Be careful that oil pan gasket is in place.

PBIC1100E

ii.

While pressing front timing chain case from its front and top as shown in the figure, install bolts and temporarily tighten them. For bolt length and positions, refer to the step 6. iii. Hammer dowel pin until the outer end becomes flush with surface.

PBIC1115E

6.

Tighten bolts to the specified torque in order as shown in the figure. 8 mm (0.31 in) dia. bolts

: 1, 2

: 28.4 N·m (2.9 kg-m, 21 ft-lb) 6 mm (0.24 in) dia. bolts : Except the above : 12.7 N·m (1.3 kg-m, 9 ft-lb) ●

After tightening, retighten them to specified torque in numerical order as shown in the figure. KBIA1303E

Revision; 2004 April

EM-58

2003 FX


FRONT TIMING CHAIN CASE [VQ35DE] 7.

Install two mounting bolts in front of oil pan (upper) in numerical order as shown in the figure.

A

: 17.2 N·m (1.8 kg-m, 13 ft-lb) EM

C

PBIC1116E

8. 9. a. b.

Install oil pan (lower). Refer to EM-28, "OIL PAN AND OIL STRAINER" . Install right and left intake valve timing control covers as follows: Install seal rings in shaft grooves. Apply liquid gasket to intake valve timing control covers with tube presser [SST: WS39930000 ( – )]. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".

D

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c.

H

Install collared O-ring in front timing chain case oil hole (left and right sides).

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d.

e.

Being careful not to move seal ring from the installation groove, align dowel pins on chain case with the holes to install intake valve timing control covers. Tighten bolts in the numerical order as shown in the figure.

L

M

: 11.3 N·m (1.2 kg-m, 8 ft-lb)

PBIC0918E

10. Install crankshaft pulley as follows: a. Fix crankshaft using ring gear stopper [SST: KV10117700 (J-44716)]. b. Install crankshaft pulley, taking care not to damage front oil seal. ● When press-fitting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference). c. Tighten bolt. : 44.1 N·m (4.5 kg-m, 33 ft-lb)

Revision; 2004 April

EM-59

2003 FX


FRONT TIMING CHAIN CASE [VQ35DE] d.

Put a paint mark on crankshaft pulley aligning with angle mark on crankshaft pulley bolt. Then, further retighten bolt by “60” degrees (equivalent to one graduation)].

SEM751G

11. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly. 12. For the following operations, perform steps in the reverse order of removal. NOTE: If hydraulic pressure inside chain tensioner drops after removal/installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.

INSPECTION AFTER INSTALLATION ●

● ●

● ●

Before starting engine, check the levels of engine coolant, lubrications and working fluid. If less than required quantity, fill to the specified level. Run engine to check for unusual noise and vibration. Warm up engine thoroughly to make sure there is no leakage of engine coolant, engine oil and working fluid, fuel and exhaust gas. Bleed air from passages in pipes and tubes of applicable lines, such as in cooling system. After cooling down engine, again check amounts of engine coolant, engine oil and working fluid. Refill to specified level, if necessary. Summary of the inspection items: Item

Before starting engine

Engine running

After engine stopped

Engine coolant

Level

Leakage

Level

Engine oil

Level

Leakage

Level

Working fluid

Level

Leakage

Level

Revision; 2004 April

EM-60

2003 FX


TIMING CHAIN [VQ35DE]

TIMING CHAIN Removal and Installation

PFP:13028

A ABS00BYU

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SBIA0588E

Revision; 2004 April

EM-61

2003 FX


TIMING CHAIN [VQ35DE] 1.

Timing chain tensioner (secondary)

2.

Internal chain guide

3.

Timing chain tensioner (secondary)

4.

Camshaft sprocket (EXH)

5.

Timing chain (secondary)

6.

Timing chain (primary)

7.

Camshaft sprocket (INT)

8.

Camshaft sprocket (EXH)

9.

Timing chain (secondary)

10. Camshaft sprocket (INT)

11. Slack guide

13. Timing chain tensioner (primary)

14. Intake valve timing control cover

12. Crankshaft sprocket 15. Collared O-ring

16. O-ring

17. Chain tensioner cover

18. Intake valve timing control cover

19. Water hose clamp

20. Idler pulley bracket

21. Idler pulley

22. Crankshaft pulley

23. Front oil seal

24. Idler pulley

25. A/C compressor bracket

26. Water pump cover

27. Bracket

28. Front timing chain case

29. Bracket

30. Rear timing chain case

31. O-ring

32. Tension guide

33. Water drain plug (front side)

NOTE: ● This section describes procedures for removing/installing front timing chain case and timing chain related parts, and rear timing chain case, when oil pan (upper) needs to be removed/installed for engine overhaul, etc. ● To remove/install front timing chain case, timing chain, and its related parts without removing oil pan (upper), refer to EM-52, "FRONT TIMING CHAIN CASE" .

REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

Place vehicle onto lift. Remove front tire. Disconnect negative battery terminal. Remove engine cover with power tool. Refer to EM-19, "INTAKE MANIFOLD COLLECTOR" . Remove air cleaner case assembly. Refer to EM-17, "AIR CLEANER AND AIR DUCT" . Remove front and rear engine undercover with power tool. Drain engine coolant from radiator. Refer to CO-11, "Changing Engine Coolant" . Drain engine oil from oil pan. Refer to LU-9, "Changing Engine Oil" . Remove engine harnesses. Remove intake manifold collectors (upper and lower) with power tool. Refer to EM-19, "INTAKE MANIFOLD COLLECTOR" . Remove radiator cooling fan assembly. Refer to CO-16, "Removal and Installation of Cooling Fan" . Remove A/C compressor from bracket with piping connected, and temporarily secure it aside. Refer to ATC-151, "Components" . Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside. Refer to PS-31, "POWER STEERING OIL PUMP" . Remove power steering oil pump bracket. Refer to PS-31, "POWER STEERING OIL PUMP" . Remove alternator. Refer to SC-23, "CHARGING SYSTEM" . Remove water bypass hose, water hose clamp and idler pulley bracket from front timing chain case. Remove right and left intake valve timing control covers with power tool. ● Loosen bolts in reverse order as shown in the figure. ● Use seal cutter [SST: KV10111100 (J-37228)] or an equivalent tool to cut liquid gasket for removal. CAUTION: Shaft is internally jointed with intake camshaft sprocket center hole. When removing, keep it horizontal until it is completely disconnected. SEM728G

Revision; 2004 April

EM-62

2003 FX


TIMING CHAIN [VQ35DE] 18. Remove collared O-ring from front timing chain case (left and right side).

A

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D

19. Remove right and left rocker covers. Refer to EM-49, "ROCKER COVER" . 20. Obtain compression TDC of No. 1 cylinder as follows: a. Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator.

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KBIA1717J

b.

Make sure intake and exhaust cam noses on No. 1 cylinder (engine front side of right bank) are located as shown in the figure. � If not, turn crankshaft one revolution (360°) and align as shown.

H

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21. Remove crankshaft pulley with the following procedure: a. Remove rear cover plate (2WD) or starter motor (AWD) and set ring gear stopper (SST) as shown in the figure. Refer to SC-10, "STARTING SYSTEM" .

M

PBIC1098E

Revision; 2004 April

EM-63

2003 FX


TIMING CHAIN [VQ35DE] b.

Loosen crankshaft pulley bolt and locate bolt seating surface as 10 mm (0.39 in) from its original position. CAUTION: Do not remove crankshaft pulley bolt as it will be used as a supporting point for suitable puller.

PBIC1103E

c.

Place suitable puller tab on holes of crankshaft pulley, and pull crankshaft pulley through. CAUTION: Do not put suitable puller tab on crankshaft pulley periphery, as this will damage internal damper.

EMQ0477D

22. Remove oil pans (upper and lower). Refer to EM-28, "OIL PAN AND OIL STRAINER" . 23. Remove front timing chain case. a. Loosen mounting bolts with power tool in reverse order as shown in the figure.

KBIA1303E

b. c.

Insert suitable tool into the notch at the top of front timing chain case as shown (1) in the figure. Pry off case by moving tool as shown (2) in the figure. ● Use seal cutter [SST: KV10111100 (J-37228)] or an equivalent tool to cut liquid gasket for removal. CAUTION: ● Do not use screwdrivers or something similar. ● After removal, handle it carefully so it does not tilt, cant, or warp under a load. SEM156F

Revision; 2004 April

EM-64

2003 FX


TIMING CHAIN [VQ35DE] 24. Remove O-rings from rear timing chain case. A

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25. Remove water pump cover and chain tensioner cover from front timing chain case. ● Use seal cutter [SST: KV10111100 (J-37228)] or an equivalent tool to cut liquid gasket for removal. 26. Remove front oil seal from front timing chain case using a suitable tool. ● Use screwdriver for removal. CAUTION: Be careful not to damage front timing chain case.

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EMQ0032D

27. Remove timing chain tensioner (primary) as the following: a. Pull lever down and release plunger stopper tab. ● Plunger stopper tab can be pushed up to release (coaxial structure with lever). b. Insert stopper pin into tensioner body hole to hold lever, and keep the tab released. NOTE: An Allen wrench [2.5 mm (0.098 in)] is used for a stopper pin as an example.

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c. d. e.

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Insert plunger into tensioner body by pressing slack guide. Keep slack guide pressed and hold it by pushing stopper pin through the lever hole and body hole. Remove mounting bolts and remove timing chain tensioner (primary).

M

SEM733G

Revision; 2004 April

EM-65

2003 FX


TIMING CHAIN [VQ35DE] 28. Remove internal chain guide, tension guide and slack guide. NOTE: Tension guide can be removed after removing timing chain (primary).

PBIC2266E

29. Remove timing chain (primary), tension guide and crankshaft sprocket. CAUTION: After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads. 30. Remove timing chain (secondary) and camshaft sprockets as the following: a. Attach a suitable stopper pin to right and left camshaft chain tensioners (for secondary timing chains). NOTE: For removal and installation of secondary chain tensioner, refer to EM-80, "CAMSHAFT" . (Removing No. 1 camshaft bracket is required.)

SEM923G

b.

Remove intake and exhaust camshaft sprocket bolts. ● Apply paint to timing chain and camshaft sprockets for alignment during installation. ● Secure the hexagonal portion of camshaft using a wrench to loosen mounting bolts.

KBIA1698J

c.

Remove timing chain (secondary) together with camshaft sprockets. ● Turn camshaft slightly to secure slackness of timing chain on timing chain tensioner (secondary) side.

Revision; 2004 April

EM-66

2003 FX


TIMING CHAIN [VQ35DE] ●

Insert 0.5 mm (0.020 in)-thick metal or resin plate between timing chain and timing chain tensioner plunger (guide). Remove timing chain (secondary) together with camshaft sprockets with timing chain loose from guide groove. CAUTION: Be careful of plunger coming-off when removing timing chain (secondary). This is because plunger of timing chain tensioner (secondary) moves during operation, leading to coming-off of fixed stopper pin. NOTE: Camshaft sprocket (INT) is two-for-one structure of primary and secondary sprockets. When handling camshaft sprocket (INT), be careful of the following: CAUTION: ● Handle carefully to avoid any shock to camshaft sprocket. ● Do not disassemble. (Do not loosen bolts “A” and “B” as shown in the figure).

A

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31. Remove rear timing chain case as follows: a. Loosen and remove mounting bolts in reverse order as shown in the figure. b. Cut sealant using a seal cutter [SST: KV10111100 (J-37228)] or an equivalent tool and remove rear timing chain case.

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SEM735G

CAUTION: ● Do not remove plate metal cover of engine oil passage. ● After removing chain case, do not apply any load which affects flatness.

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KBIA1307E

Revision; 2004 April

EM-67

2003 FX


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2003 INFINITI FX35 FX45 Service Repair Manual  
2003 INFINITI FX35 FX45 Service Repair Manual  
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