2004 INFINITI FX35 Exhaust System

EM-178
[VK45DE]
EXHAUST MANIFOLD AND THREE WAY CATALYST
Revision: 2004 November 2004 FX35/FX45
EXHAUST MANIFOLD AND THREE WAY CATALYSTPFP:14004
Removal and InstallationABS006ID
REMOVAL
WARNING:
Perform the work, when the exhaust and cooling system have completely cooled down.
1. Remove engine cover with power tool. Refer to EM-168, "
ENGINE ROOM COVER" .
2. Remove front and rear engine undercovers with power tool.
3. Remove air duct (inlet), air cleaner case and mass air flow sensor assembly, air duct and resonator
assembly. Refer to EM-172, "
AIR CLEANER AND AIR DUCT" .
4. Remove front cross bar. Refer to FSU-6, "
FRONT SUSPENSION ASSEMBLY" .
5. Drain engine coolant from radiator. Refer to CO-36, "
Changing Engine Coolant" .
CAUTION:

Perform this step when engine is cold.

Do not spill engine coolant on drive belts.
6. Remove radiator. Refer to CO-39, "
RADIATOR" .
7. Remove drive belts. Refer to EM-169, "
DRIVE BELTS" .
8. Remove heated oxygen sensors as follows:
a. Disconnect harness connector of each heated oxygen sensors.
1. Heated oxygen sensor 1 (bank 2) 2. Exhaust manifold cover (right bank) 3. Exhaust manifold (right bank)
4. Gasket 5. Exhaust manifold (left bank) 6. Exhaust manifold cover (left bank)
7. Heated oxygen sensor 1 (bank 1) 8. Three way catalyst cover (right bank) 9. Three way catalyst (right bank)
10. Heated oxygen sensor 2 (bank 2) 11. Gasket 12. Three way catalyst cover (left bank)
13. Heated oxygen sensor 2 (bank 1) 14. Three way catalyst (left bank) 15. Mounting bracket
16. Mounting bracket
PBIC3503E

EXHAUST MANIFOLD AND THREE WAY CATALYST
EM-179
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Revision: 2004 November 2004 FX35/FX45
b. Remove heated oxygen sensor 1 and 2 on both bank with
heated oxygen sensor wrench (SST).

Put marks to identify installation positions of each heated oxy-
gen sensor.
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
one.
9. Remove exhaust mounting bracket between three way catalysts (right and left bank) and transmission.
Refer to EX-3, "
EXHAUST SYSTEM" .
10. Disconnect A/C piping from A/C compressor, then remove A/C compressor with power tool. Refer to AT C -
139, "Components" .
11. Remove alternator and bracket. Refer to SC-23, "
CHARGING SYSTEM" .
12. Remove exhaust front tube with power tool. Refer to EX-3, "
EXHAUST SYSTEM" .
13. Remove steering lower joint at power steering gear assembly side, and release steering lower shaft.
Refer to PS-19, "
POWER STEERING GEAR AND LINKAGE" .
14. Remove three way catalysts (right and left bank).
15. Remove exhaust manifold covers. (right and left bank)
16. Loosen mounting nuts in reverse order as shown in the figure to
remove exhaust manifold.
NOTE:
Disregard the numerical order No. 9 to 12 in removal.
17. Remove exhaust manifold gaskets.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
PBIC2333E
PBIC2334E
PBIC1549E

EM-180
[VK45DE]
EXHAUST MANIFOLD AND THREE WAY CATALYST
Revision: 2004 November 2004 FX35/FX45
INSPECTION AFTER REMOVAL
Surface Distortion

Check the surface distortion of the each exhaust manifold flange
mating surface with straightedge and feeler gauge.

If it exceeds the limit, replace exhaust manifold.
INSTALLATION
Note the following, and install in the reverse order of removal.
Exhaust Manifold Gasket
Install exhaust manifold gasket with its directional protrusion set upward.
Refer to the figure of components on former page. Refer to EM-178, "
Removal and Installation" .
Exhaust Manifold

Install exhaust manifold in numerical order as shown in the fig-
ure.
NOTE:
Tighten mounting nuts No. 1 to 4 in two steps. The numerical
order No. 9 to 12 shown second steps.
Heated Oxygen Sensor

Install heated oxygen sensors in the original position.

Install referring the following if the installation positions cannot
be identified.
*: The length of glass tube of bank 2 is longer than the one
of bank 1.
CAUTION:

Before installing a new heated oxygen sensor, clean
exhaust system threads using oxygen sensor thread
cleaner (commercial service tool: J-43897-18 or J-43897-12), and apply anti-seize lubricant (com-
mercial service tool).

Do not over torque heated oxygen sensor. Doing so may cause damage to the heated oxygen sen-
sor, resulting in “MIL” coming on.Limit : 0.3 mm (0.012 in)
PBIC1550E
PBIC1549E
Glass tube color
Heated oxygen sensor 1* : Black
Heated oxygen sensor 2 : White
PBIC2652E

TIMING CHAIN
EM-207
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Revision: 2004 November 2004 FX35/FX45
f. Further tighten by 90 degrees. (Angle tightening)

Check the tightening angle by referencing to the notches. The
angle between two notches is 90 degrees.
15. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to confirm it turns
smoothly.
16. Install in the reverse order of removal after this step.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in guide may gen-
erate a pounding noise during and just after engine start. However, this does not indicate an unusualness.
Noise will stop after hydraulic pressure rises.
INSPECTION AFTER INSTALLATION

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:
PBIC2346E
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Working fluid Level Leakage Level

EM-236
[VK45DE]
ENGINE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
ENGINE ASSEMBLYPFP:10001
Removal and InstallationABS006IT
WARNING:

Situate vehicle on a flat and solid surface.

Place chocks at front and back of rear wheels.

For engines not equipped with engine slingers, attach proper slingers and bolts described in
PARTS CATALOG.
CAUTION:

Always be careful to work safely, avoid forceful or uninstructed operations.

Do not start working until exhaust system and engine coolant are cool enough.

If items or work required are not covered by the engine section, refer to the applicable sections.

Always use the support point specified for lifting.

Use either 2-point lift type or separate type lift as best you can. If board-on type is used for
unavoidable reasons, support at the rear axle jacking point with transmission jack or similar tool
before starting work, in preparation for the backward shift of center of gravity.

For supporting points for lifting and jacking point at rear axle, refer to GI-42, "Garage Jack and
Safety Stand" .
REMOVAL
Outline
At first, remove engine, transmission assembly and front final drive with front suspension member downward.
Then separate engine from transmission.
Preparation
1. Release fuel pressure. Refer to EC-700, "FUEL PRESSURE RELEASE" .
1. Engine mounting insulator (rear) 2. Engine rear member 3. Grommet
4. Collar 5. Plate 6. Engine mounting bracket (LH)
7. Engine mounting insulator (LH) 8. Engine mounting bracket (RH) 9. Engine mounting insulator (RH)
PBIC2364E

ENGINE ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45
2. Drain engine coolant from radiator. Refer to CO-36, "Changing Engine Coolant" .
3. Disconnect both battery terminal. Refer to SC-4, "
BATTERY" .
4. Remove crankshaft position sensor (POS) from transmission.
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.
5. Remove the following parts:

Hood assembly; Refer to BL-14, "HOOD" .

Engine cover; Refer to EM-168, "ENGINE ROOM COVER" .

Front and rear engine undercover

Air duct (inlet), air duct and air cleaner case assembly; Refer to EM-172, "AIR CLEANER AND AIR
DUCT" .

Drive belts; Refer to EM-169, "DRIVE BELTS" .

Radiator and radiator hoses (upper and lower); Refer to CO-39, "RADIATOR" .

Front road wheels and tires
6. Discharge refrigerant from A/C circuit. Refer to ATC-137, "
REFRIGERANT LINES" .
Engine Room LH
1. Disconnect engine room harness from the engine side and set it aside for easier work.
2. Disconnect heater hoses, and install plugs to avoid leakage of engine coolant.
3. Disconnect ground cable from exhaust manifold cover to vehicle.
4. Disconnect vacuum hose between vehicle and engine and set it aside.
5. Remove A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope. Refer to AT C -
139, "Components" .
Engine Room RH
1. Disconnect fuel feed hose and EVAP hose. Refer to EM-188, "FUEL INJECTOR AND FUEL TUBE" .
CAUTION:
Fit plugs onto disconnected hose to prevent fuel leak.
2. Disconnect engine room harness from the engine side and set it aside for easier work.
3. Disconnect ground cable from exhaust manifold cover to vehicle.
4. Disconnect vacuum hose between vehicle and engine and set it aside.
5. Disconnect reservoir tank of power steering oil pump from engine, and move it aside for easier work.
CAUTION:
When temporarily securing, keep reservoir tank upright to avoid a fluid leak.
Vehicle underbody
1. Remove front cross bar. Refer to FSU-6, "FRONT SUSPENSION ASSEMBLY" .
2. Disconnect power steering oil pump from engine. Move it from its location and secure with a rope for eas-
ier work. Refer to PS-33, "
Removal and Installation (VK45DE models)" .
3. Remove A/T fluid cooler tube. Refer to AT- 2 6 9 , "
Removal and Installation (AWD models)" .
4. Remove exhaust front tube and center muffler with power tool. Refer to EX-3, "
EXHAUST SYSTEM" .
5. Remove RH and LH transverse link mounting bolts and nuts. Refer to FSU-14, "
TRANSVERSE LINK" .
6. Disconnect stabilizer connecting rod lower. Refer to FSU-6, "
FRONT SUSPENSION ASSEMBLY" .
7. Remove A/T control rod at control device assembly side. Then temporarily secure it on transmission, so
that it does not sag. Refer to AT- 2 3 3 , "
SHIFT CONTROL SYSTEM" .
8. Remove rear plate cover, then remove drive plate to torque converter connecting bolts. Refer to AT- 2 6 9 ,
"Removal and Installation (AWD models)" .
9. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft.
Refer to PS-12, "
STEERING COLUMN" .
10. Remove rear propeller shaft. Refer to PR-6, "
REAR PROPELLER SHAFT" .

EM-238
[VK45DE]
ENGINE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45

After disconnection, plug the opening on transmission side.
11. Remove front drive shaft (both side). Refer to FAX-12, "
FRONT DRIVE SHAFT" .
12. Remove front propeller shaft. Refer to PR-4, "
FRONT PROPELLER SHAFT" .
13. Remove three way catalyst (both bank). Refer to EM-178, "
EXHAUST MANIFOLD AND THREE WAY
CATALYST" .
Removal Work
1. Install engine slingers into front of left bank cylinder head and
front of right bank cylinder head.
2. Lift with hoist and secure engine in position.
3. Use manual lift table caddy (commercial service tool) or equivalently rigid tool such as transmission jack.
Securely support bottom of suspension member and transmission.
CAUTION:
Put a piece of wood or something similar as the supporting surface, secure a completely stable
condition.
4. Remove front suspension member mounting nuts with power tool. Refer to FSU-6, "
FRONT SUSPEN-
SION ASSEMBLY" .
5. Carefully lower jack, or raise lift to remove engine, transmission
front final drive and front suspension member assembly. When
performing work, observe the following caution:
CAUTION:

Confirm there is no interference with vehicle.

Make sure that all connection points have been discon-
nected.

Keep in mind the center of vehicle gravity changes. If
necessary, use jack(s) to support vehicle at rear jacking
point(s) to prevent it from falling it off the lift.
Separation Work
1. Change engine slinger installing to cylinder head (right bank).
NOTE:
In order to keep secure position when hoisting engine.
2. Remove engine mounting insulators (RH and LH) under side nut with power tool.
3. Lift with hoist and separate engine and transmission assembly from front suspension member.
CAUTION:

Before and during this lifting, always check if any harnesses are left connected.

Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
4. Remove alternator. Refer to SC-23, "
CHARGING SYSTEM" . Slinger bolts:
:33.4 N·m (3.4 kg-m, 25 ft-lb)
PBIC1556E
PBIC1557E
Slinger bolts:
:33.4 N·m (3.4 kg-m, 25 ft-lb)
PBIC2447E

ENGINE ASSEMBLY
EM-239
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Revision: 2004 November 2004 FX35/FX45
5. Remove starter motor. Refer to SC-10, "STARTING SYSTEM" .
6. Separate engine from transmission assembly. Refer to AT- 2 6 9 , "
Removal and Installation (AWD models)"
.
7. Remove front final drive from engine. Refer to FFD-10, "
FRONT FINAL DRIVE ASSEMBLY" .
8. Remove engine mounting insulators (RH and LH) and brackets (RH and LH) from engine with power tool.
9. Remove engine rear member and engine mounting insulator (rear) from transmission.
INSTALLATION
Note to the following, and install in the reverse order of removal.

Where positioning pin is used, be sure to securely insert it into the hole of mating part.

When installing engine mount brackets (RH and LH) to cylinder
block, tighten two upper bolts (shown as “A” in the figure) first.
Then tighten two lower bolts (shown as “B” in the figure).
INSPECTION AFTER INSTALLATION

Before starting engine, check the levels of engine coolant, engine oil and working fluid. If less than
required quantity, fill to the specified level.

Use procedure below to check for fuel leakage.
–Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at connection points.
–Start engine. With engine speed increased, check again for fuel leakage at connection points.

Run engine to check for unusual noise and vibration.

Warm up engine thoroughly to make sure there is no leakage of engine coolant, engine oil, 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:
PBIC2365E
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Working fluid Level Leakage Level
Fuel — Leakage —
Exhaust gas — Leakage —