ON BOARD REFUELING VAPOR RECOVERY (ORVR) EC-707
[VK45DE]
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Revision: 2006 July 2007 FX35/FX45
ON BOARD REFUELING VAPOR RECOVERY (ORVR)PFP:00032
System DescriptionNBS0041E
From the beginning of refueling, the air and vapor inside the fuel tank go through refueling EVAP vapor cut
valve and EVAP/ORVR line to the EVAP canister. The vapor is absorbed by the EVAP canister and the air is
released to the atmosphere.
When the refueling has reached the full level of the fuel tank, the refueling EVAP vapor cut valve is closed and
refueling is stopped because of auto shut-off. The vapor which was absorbed by the EVAP canister is purged
during driving.
WARNING:
When conducting inspections below, be sure to observe the following:
Put a “CAUTION: FLAMMABLE” sign in workshop.
Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
Be sure to furnish the workshop with a CO2 fire extinguisher.
CAUTION:
Before removing fuel line parts, carry out the following procedures:
–Put drained fuel in an explosion-proof container and put lid on securely.
–Release fuel pressure from fuel line. Refer to EC-747, "FUEL PRESSURE RELEASE" .
–Disconnect battery ground cable.
Always replace O-ring when the fuel gauge retainer is removed.
Do not kink or twist hose and tube when they are installed.
Do not tighten hose and clamps excessively to avoid damaging hoses.
After installation, run engine and check for fuel leaks at connection.
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.
PBIB1068E
EI-1
EXTERIOR & INTERIOR
I BODY
CONTENTS
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SECTION
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Revision: 2006 July 2007 FX35/FX45
EXTERIOR & INTERIOR
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” ............................................................. ..... 3
Precautions for Procedures without Cowl Top Cover ..... 3
Precautions for Work ........................................... ..... 3
PREPARATION ...................................................... ..... 4
Special Service Tools .......................................... ..... 4
Commercial Service Tools ................................... ..... 4
SQUEAK AND RATTLE TROUBLE DIAGNOSES ..... 5
Work Flow ........................................................... ..... 5
CUSTOMER INTERVIEW ................................ ..... 5
DUPLICATE THE NOISE AND TEST DRIVE .. ..... 6
CHECK RELATED SERVICE BULLETINS ...... ..... 6
LOCATE THE NOISE AND IDENTIFY THE
ROOT CAUSE ................................................. ..... 6
REPAIR THE CAUSE ...................................... ..... 6
CONFIRM THE REPAIR .................................. ..... 7
Generic Squeak and Rattle Troubleshooting ...... ..... 7
INSTRUMENT PANEL ..................................... ..... 7
CENTER CONSOLE ........................................ ..... 7
DOORS ............................................................ ..... 7
TRUNK ............................................................. ..... 8
SUNROOF/HEADLINING ................................ ..... 8
SEATS .............................................................. ..... 8
UNDERHOOD .................................................. ..... 8
Diagnostic Worksheet ......................................... ..... 9
CLIP AND FASTENER .......................................... ....11
Clip and Fastener ................................................ .... 11
FRONT BUMPER .................................................. ... 14
Removal and Installation ..................................... ... 14
REMOVAL ........................................................ ... 15
INSTALLATION ................................................ ... 16
REMOVAL AND INSTALLATION OF FILLET
MOLDING ........................................................ ... 16
REMOVAL AND INSTALLATION OF BUMPER
CENTER MOLDING ......................................... ... 16 REAR BUMPER .....................................................
... 17
Removal and Installation ..................................... ... 17
REMOVAL ........................................................ ... 18
INSTALLATION ................................................ ... 19
DISASSEMBLY AND ASSEMBLY OF REAR
BUMPER FASCIA ............................................ ... 19
REMOVAL AND INSTALLATION OF REAR
BUMPER CLOSING ......................................... ... 20
REMOVAL AND INSTALLATION OF DRAFTER
GUARD ............................................................ ... 20
REMOVAL AND INSTALLATION OF REAR FIL-
LET MOLDING ASSEMBLY ............................. ... 21
FRONT GRILLE ..................................................... ... 22
Removal and Installation ..................................... ... 22
REMOVAL ........................................................ ... 22
INSTALLATION ................................................ ... 22
COWL TOP ............................................................ ... 23
Removal and Installation ..................................... ... 23
REMOVAL ........................................................ ... 23
INSTALLATION ................................................ ... 23
FENDER PROTECTOR ......................................... ... 24
Removal and Installation ..................................... ... 24
REMOVAL ........................................................ ... 24
INSTALLATION ................................................ ... 24
DOOR OUTSIDE MOLDING .................................. ... 25
Removal and Installation ..................................... ... 25
FRONT DOOR OUTSIDE MOLDING ............... ... 25
REAR DOOR OUTSIDE MOLDING ................. ... 25
DOOR OUTSIDE LOWER MOLDING ................... ... 26
Removal and Installation ..................................... ... 26
FRONT AND REAR DOOR OUTSIDE LOWER
MOLDING ......................................................... ... 26
DOOR PARTING SEAL ......................................... ... 27
Removal and Installation ..................................... ... 27
REMOVAL ........................................................ ... 27
INSTALLATION ................................................ ... 28
CENTER MUD GUARD ......................................... ... 29
Removal and Installation ..................................... ... 29
REMOVAL ........................................................ ... 29
INSTALLATION ................................................ ... 29
EI-2Revision: 2006 July 2007 FX35/FX45
WINDSHIELD MOLDING .......................................
... 30
Removal and Installation ..................................... ... 30
REMOVAL ........................................................ ... 30
INSTALLATION ................................................. ... 30
BACK DOOR WINDOW MOLDING ....................... ... 31
Removal and Installation ..................................... ... 31
REMOVAL ........................................................ ... 31
INSTALLATION ................................................. ... 31
ROOF SIDE MOLDING .......................................... ... 33
Removal and Installation ..................................... ... 33
REMOVAL ........................................................ ... 33
INSTALLATION ................................................. ... 33
ROOF RAIL ............................................................ ... 34
Removal and Installation ..................................... ... 34
REMOVAL ........................................................ ... 34
INSTALLATION ................................................. ... 34
REMOVAL AND INSTALLATION OF ROOF RAIL
BRACKET ......................................................... ... 34
BACK DOOR FINISHER ........................................ ... 35
Removal and Installation ..................................... ... 35
REMOVAL ........................................................ ... 35
INSTALLATION ................................................. ... 35
DOOR FINISHER ................................................... ... 36
Removal and Installation ..................................... ... 36
DOOR FINISHER (FRONT AND REAR) .......... ... 36 BODY SIDE TRIM ..................................................
... 38
Removal and Installation ...................................... ... 38
CENTER PILLAR LOWER GARNISH .............. ... 38
CENTER PILLAR UPPER GARNISH ............... ... 39
DASH SIDE FINISHER ..................................... ... 39
FRONT PILLAR GARNISH ............................... ... 40
KICKING PLATE ............................................... ... 40
CENTER MUDGUARD FINISHER (FRONT/
REAR) ............................................................... ... 40
FLOOR TRIM .......................................................... ... 41
Removal and Installation ...................................... ... 41
REMOVAL ......................................................... ... 41
INSTALLATION ................................................. ... 42
HEADLINING .......................................................... ... 43
Removal and Installation ...................................... ... 43
REMOVAL ......................................................... ... 44
INSTALLATION ................................................. ... 44
LUGGAGE FLOOR TRIM ...................................... ... 45
Removal and Installation ...................................... ... 45
REMOVAL ......................................................... ... 46
INSTALLATION ................................................. ... 46
BACK DOOR TRIM ................................................ ... 47
Removal and Installation ...................................... ... 47
REMOVAL ......................................................... ... 47
INSTALLATION ................................................. ... 47
EI-8
SQUEAK AND RATTLE TROUBLE DIAGNOSES
Revision: 2006 July 2007 FX35/FX45
TRUNK
Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner.
In addition look for:
1. Trunk lid dumpers out of adjustment
2. Trunk lid striker out of adjustment
3. The trunk lid torsion bars knocking together
4. A loose license plate or bracket
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-
ing the noise.
SUNROOF/HEADLINING
Noises in the sunroof/headlining area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sun-visor shaft shaking in the holder
3. Front or rear windshield touching headlining and squeaking
Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these
incidents. Repairs usually consist of insulating with felt cloth tape.
SEATS
When isolating seat noise it's important to note the position the seat is in and the load placed on the seat when
the noise is present. These conditions should be duplicated when verifying and isolating the cause of the
noise.
Cause of seat noise include:
1. Headrest rods and holder
2. A squeak between the seat pad cushion and frame
3. The rear seatback lock and bracket
These noises can be isolated by moving or pressing on the suspected components while duplicating the con-
ditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component
or applying urethane tape to the contact area.
UNDERHOOD
Some interior noise may be caused by components under the hood or on the engine wall. The noise is then
transmitted into the passenger compartment.
Causes of transmitted under-hood noise include:
1. Any component mounted to the engine wall
2. Components that pass through the engine wall
3. Engine wall mounts and connectors
4. Loose radiator mounting pins
5. Hood bumpers out of adjustment
6. Hood striker out of adjustment
These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best
method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM
or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or
insulating the component causing the noise.
ROOF SIDE MOLDING EI-33
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Revision: 2006 July 2007 FX35/FX45
ROOF SIDE MOLDINGPFP:73854
Removal and InstallationNIS001TZ
REMOVAL
Disconnect molding from roof side clip and remove roof side molding.
INSTALLATION
Install in the reverse order of removal.
CAUTION:
To install roof side molding, check if all clips are matched over holes of panel on vehicle, then push it.
PIIA4951E
1. Roof side molding
EI-34
ROOF RAIL
Revision: 2006 July 2007 FX35/FX45
ROOF RAILPFP:73820
Removal and InstallationNIS001U0
REMOVAL
1. Remove cover roof rail (front/rear).
2. Remove nuts of roof rail and remove roof rail assembly.
INSTALLATION
Install in the reverse order of removal.
REMOVAL AND INSTALLATION OF ROOF RAIL BRACKET
Removal
1. Remove roof rail assembly.
2. Remove roof side molding. Refer to EI-33, "
ROOF SIDE MOLDING" .
3. Remove headlining. Refer to EI-43, "
HEADLINING" .
4. Remove nuts of roof rail bracket assembly and remove roof rail bracket assembly.
Installation
Install in the reverse order of removal.
CAUTION:
Replace sealing washer.
1. Cover roof rail (front) 2. Nut 3. Roof rail assembly
4. Rubber seal (front) 5. Roof side molding 6. Roof rail bracket assembly
7. Seal 8. Nut 9. Rubber seal (rear)
10. Cover roof rail (rear)
PIIA4948E
EI-44
HEADLINING
Revision: 2006 July 2007 FX35/FX45
REMOVAL
1. Remove front pillar garnish. Refer to EI-38, "Removal and Installation" .
2. Remove kicking plate (front/rear). Refer to EI-38, "
Removal and Installation" .
3. Remove body side welt. Refer to EI-38, "
Removal and Installation" .
4. Remove seat belt shoulder anchor (front/rear). Refer to SB-4, "
Removal and Installation of Front Seat
Belt" and SB-6, "Removal and Installation of Rear Seat Belt" .
5. Remove center pillar garnish (lower/upper) and luggage side finisher assembly and rear pillar upper gar- nish assembly. Refer to EI-38, "
Removal and Installation" and EI-45, "Removal and Installation" .
6. Remove assist grip caps and screw. Remove assist grip.
7. Remove sun-visor (RH/LH), and disconnect harness connector with lamp model.
8. Remove sun-visor holder.
9. Remove DVD display rear. Refer to AV- 1 7 2 , "
Removal and Installation for DVD Display Unit" .
10. Remove roof console.
11. Remove LDW camera unit. Refer to DI-104, "
Removal and Installation for LDW Camera Unit" .
12. Disconnect harness connector at front left side of headlining.
13. Put front seat to front most and recline seat back to backward.
14. Remove headlining, turn and take out from back door. CAUTION:
Always remove or install in a pair.
Cover surroundings with waste to avoid scratches or damages.
Do not bend headlining too hard.
15. Remove following parts after removing headlining.
Room lamp
Personal lamp
INSTALLATION
Install in the reverse order of removal.
1. Headlining 2. Assist grip (rear) 3. Assist grip (front)
4. Sun-visor holder (RH) 5. Sun-visor (RH) 6. Sun-visor cover (RH)
7. Roof console (without LDW camera unit) 8. Sun-visor (LH) 9. Sun-visor cover (LH)
10. Sun-visor holder (LH) 11. Finisher 12. Room lamp
13. Personal lamp 14. Fastener 15. DVD display rear
16. Roof console (with LDW cam- era unit)
PIIA4952E
EI-46
LUGGAGE FLOOR TRIM
Revision: 2006 July 2007 FX35/FX45
REMOVAL
1. Remove tonneau cover.
2. Remove luggage side hook and remove net hook (RH/LH).
3. Remove luggage floor board assembly. Remove bolt with power tool.
4. Remove luggage floor side board assembly (RH/LH).
5. Remove back door weather strip.
6. Remove rear plate assembly.
7. Remove roof rear garnish assembly.
8. Remove luggage floor cover assembly (RH/LH).
9. Remove rear door kicking plate (RH/LH).
10. Remove rear body side welt.
11. Remove rear seat cushion and seatback. Refer to SE-104, "
Removal and Installation" .
12. Remove rear wheel house finisher assembly (RH/LH).
13. Remove luggage side finisher assembly bolt and remove luggage side finisher assembly (RH/LH).
14. Remove bolt, and then remove parcel shelf holder.
15. Remove rear parcel shelf cap.
16. Remove bolt, and then remove rear parcel hook.
17. Remove rear seat belt anchor (RH/LH). Refer to SB-6, "
Removal and Installation of Rear Seat Belt" .
18. Remove rear pillar upper garnish assembly cap and bolt, then remove rear pillar upper garnish assembly (RH/LH).
19. Remove spare tire clamp.
20. Remove sub-woofer box connector and remove sub-woofer box.
21. Remove spare tire.
22. Remove towing hook, wheel nut wrench, spanner, tire stopper, jack rod and jack complete.
23. Remove luggage side box bolt and luggage side box assembly (RH/LH).
INSTALLATION
Install in the reverse order of removal.
1. Roof rear garnish assembly 2. Rear pillar upper garnish assembly (LH) 3. Bolt
4. Cap 5. Luggage floor cover assembly (RH) 6. Luggage floor cover assembly (LH)
7. Luggage floor side board assembly (LH) 8. Rear wheel house finisher assembly
(LH) 9. Luggage side finisher assembly
(LH)
10. Clamp 11. Sub woofer box 12. Spare tire
13. Luggage side box (LH) 14. Rear plate assembly 15. Luggage side box (RH)
16. Cap 17. Luggage floor board assembly 18. Luggage floor board assembly (option for Canada)
19. Luggage floor side board assembly (RH) 20. Net hook 21. Luggage side finisher assembly
(RH)
22. Rear parcel shelf hook 23. Rear parcel shelf cap 24. Rear parcel shelf holder
25. Rear wheel house finisher assembly (RH) 26. Rear pillar upper garnish assembly
(RH) 27. Luggage finisher mask (RH)
28. Luggage finisher mask (LH) 29. Tonneau cover 30. Net
31. Luggage floor center front board (Run flat type) 32. Luggage floor center rear board
(Run flat type) 33. Luggage floor box assembly
(Run flat type)
Clip Pawl Metal clip