2006 infiniti g35 coupe service repair manual

QUICK REFERENCE INDEX Edition: August 2005 A GENERAL INFORMATION Revision: August 2006 Publication No. SM6E-1V35U2 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 CL MT AT PR RFD FAX RAX FSU RSU WT BR PB BRC PS STC SB SRS BL GW RF EI IP SE ATC SC LT DI WW BCS LAN AV

Engine Mechanical Engine Lubrication System Engine Cooling System Engine Control System Fuel System Exhaust System Accelerator Control System Clutch Manual Transmission Automatic Transmission Propeller Shaft 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 Steering Control System Seat Belts Supplemental Restraint System (SRS) Body, Lock & Security System Glasses, Window System & Mirrors Roof Exterior & Interior Instrument Panel Seat Automatic Air Conditioner

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 2006 INFINITI G35 Coupe.

In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task.

All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.

IMPORTANT SAFETY NOTICE The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle.

The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately.

Service varies with the procedures used, the skills of the technician and the tools and parts available. Accordingly, anyone using service procedures, tools or parts which are not specifically recommended

by NISSAN must first be completely satisfied that neither personal safety nor the vehicle’s safety will be jeopardized by the service method selected.

QUICK REFERENCE CHART G35 COUPE QUICK REFERENCE CHART G35 COUPE ENGINE TUNE-UP DATA (VQ35DE) Engine model

PFP:00000 ELS0003W

VQ35DE

Firing order

1-2-3-4-5-6

Idle speed M/T, A/T (In “N” position)

650 ± 50

rpm

Ignition timing (BTDC at idle speed)

15° ± 5°

CO% at idle

0.7 - 9.9 % and engine runs smoothly Deflection adjustment

Drive Belt

Unit: mm (in)

Used belt After adjustment

Alternator and power steering oil pump belt

7 (0.28)

4-5 (0.16 - 0.20)

A/C compressor belt

12 (0.47)

9 - 10 (0.35 - 0.39)

Applied pushing force

Tension adjustment

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 (10, 22)

Radiater cap relief pressure

Unit: N(kg, Ib)

Used belt

New belt

Limit

—

kPa (kg/cm2 , psi)

Standard

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

Limit

59 (0.6, 9)

Cooling system leakage testing pressure

kPa (kg/cm2 , psi)

Compression pressure

kPa (kg/cm2 , psi)/rpm

Spark plug (Platinum-tipped type)

2006

157 (1.6, 23)

Standard

1,270 (13.0, 184)/300

Minimum

980 (10.0, 142)/300

Standard type

PLFR5A-11

Hot type

PLFR4A-11

Cold type

PLFR6A-11

Gap (Nominal)

mm (in)

1.1 (0.043)

QUICK REFERENCE CHART G35 COUPE

2006

FRONT WHEEL ALIGNMENT (Unladen* ) Tire

ELS0003X

17inch

Camber Degree minute (Decimal degree)

18inch

Minimum

–1°15′ (–1.25°)

–1°10′ (–1.17°)

Nominal

–0°30′ (–0.50°)

–0°25′ (–0.42°)

0°15′ (0.25°)

0°20′ (0.33°)

Maximum Left and right difference

Caster Degree minute (Decimal degree)

45′ (0.75°)

Minimum

7°25′ (7.42°)

7°15′ (7.25°)

7°20′ (7.33°)

Nominal

8°10′ (8.17°)

8°00′ (8.00°)

8°05′ (8.08°)

Maximum

8°55′ (8.92°)

8°45′ (8.75°)

8°50′ (8.83°)

Left and right difference Kingpin inclination Degree minute (Decimal degree)

Distance Total toe-in Angle (left wheel or right wheel) Degree minute (Decimal degree)

45′ (0.75°)

Minimum

4°10′ (4.17°)

Nominal

4°55′ (4.92°)

Maximum

5°40′ (5.67°)

Minimum

0 mm (0 in)

Nominal

1 mm (0.04 in)

Maximum

2 mm (0.08 in)

Minimum

0°00′ (0.00°)

Nominal

0°02′30″ (0.04°)

Maximum

Wheel turning angle (Full turn)

Inner wheel Degree minute (Decimal degree) Outer wheel Degree minute (Decimal degree)

19inch

0°05′ (0.08°)

Minimum

35°45′ (35.8°)

Nominal

38°45′ (38.8°)

Maximum

39°45′ (39.8°)

Nominal

30°45′ (30.8°)

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

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

Distance Total toe-in Angle (left wheel or right wheel) Degree minute (Decimal degree)

ELS0003Y

Minimum

–1°45′ (–1.75°)

Nominal

–1°15′ (–1.25°)

Maximum

–0°45′ (–0.75°)

Minimum

0.1 mm (0.004 in)

Nominal

2.8 mm (0.110 in)

Maximum

5.5 mm (0.217 in)

Minimum

0°00′ (0°)

Nominal

0°07′ (0.12°)

Maximum

0°14′ (0.23°)

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

BRAKE

ELS0003Z

Unit : mm ( in ) Front brake

Rear brake

Pad repair limit thickness

2.0 (0.079)

Rotor repair limit thickness

26.0 (1.024)

Pad repair limit thickness

2.0 (0.079)

Rotor repair limit thickness

14.0 (0.551)

Brake pedal free height

M/T model

153.2 - 163.2 (6.03 - 6.43)

A/T model

161.5 - 171.5 (6.36 - 6.75)

QUICK REFERENCE CHART G35 COUPE Brake pedal depressed height*

M/T model

More than 90 (3.54)

A/T model

More than 95 (3.74)

2006

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

REFILL CAPACITIES

ELS00040

UNIT

Liter

US measure

Fuel tank

76

20 gal

Coolant ( With reservoir tank at “MAX” level )

8.7

9 - 1/4 qt

Drain and refill With oil filter change

4.7

5 qt

Without oil filter change

4.4

4-5/8 qt

Dry engine (Overhaul)

5.4

5-3/4 qt

A/T

10.3

10-7/8 qt

M/T

2.9

3-1/8 qt

Differential carrier

1.4

3 pt

Power steering system

1.0

1-1/8 qt

0.18

6.0 fl oz

0.55 kg

1.21 lb

Engine oil

Transmission

Air conditioning system

Compressor oil Refrigerant

GENERAL INFORMATION

A GENERAL INFORMATION GI

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SECTION

GENERAL INFORMATION

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CONTENTS PRECAUTIONS .......................................................... 3 Description ............................................................... 3 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 3 Precautions for NVIS/IVIS (NISSAN/INFINITI VEHICLE IMMOBILIZER SYSTEM - NATS) (If Equipped) ................................................................. 3 Precautions Necessary for Steering Wheel Rotation After Battery Disconnect .......................................... 4 OPERATION PROCEDURE ................................. 4 Precautions for Battery Service ................................ 4 General Precautions ................................................ 4 Precautions for Three Way Catalyst ......................... 6 Precautions for Fuel (Unleaded Premium Gasoline Required) ................................................................. 6 Precautions for Multiport Fuel Injection System or Engine Control System ............................................ 7 Precautions for Hoses .............................................. 7 HOSE REMOVAL AND INSTALLATION ............... 7 HOSE CLAMPING ................................................ 7 Precautions for Engine Oils ...................................... 8 HEALTH 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 MEASUREMENTS OR PROCEDURES ............................... 13 How to Read Wiring Diagrams ............................... 15

Revision: 2006 August

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 ............ 37 Checking Equipment .............................................. 38 CONSULT-II Start Procedure .................................. 38 CONSULT-II Data Link Connector (DLC) Circuit ... 39 INSPECTION PROCEDURE .............................. 39 CIRCUIT DIAGRAM ............................................ 40 LIFTING POINT ......................................................... 41 Commercial Service Tools ...................................... 41 Garage Jack and Safety Stand ............................... 41 2-Pole Lift ............................................................... 42 Board-On Lift .......................................................... 43 TOW TRUCK TOWING ............................................. 44 Tow Truck Towing ................................................... 44 Vehicle Recovery (Freeing a Stuck Vehicle) ........... 45 FRONT ................................................................ 45 REAR .................................................................. 45 TIGHTENING TORQUE OF STANDARD BOLTS ... 46 Tightening Torque Table ......................................... 46 RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ............................................................... 47 Recommended Chemical Products and Sealants... 47

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IDENTIFICATION INFORMATION ............................ 48 Model Variation ....................................................... 48 IDENTIFICATION NUMBER ................................ 49 IDENTIFICATION PLATE .................................... 49 ENGINE SERIAL NUMBER ................................ 50 AUTOMATIC TRANSMISSION NUMBER ........... 50

Revision: 2006 August

MANUAL TRANSMISSION NUMBER .................50 Dimensions .............................................................50 Wheels & Tires ........................................................51 TERMINOLOGY ........................................................52 SAE J1930 Terminology List ...................................52

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PRECAUTIONS PRECAUTIONS Description

PFP:00001

GI NAS00018

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

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

B

NAS00019

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.

Information necessary to service the system safely is included in the SRS and SB section of this Service Manual.

WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors.

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

NAS0001A

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: 2006 August

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PRECAUTIONS Precautions Necessary for Steering Wheel Rotation After Battery Disconnect NAS0009R

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.

Precautions for Battery Service

NAS0001B

Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interference between the window edge and the vehicle when the door is opened/closed. During normal operation, the window slightly raises and lowers automatically to prevent any window to vehicle interference. The automatic window function will not work with the battery disconnected.

General Precautions ●

NAS0001C

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 flammable materials. Special care should be taken when handling any flammable 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

Revision: 2006 August

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PRECAUTIONS ●

●

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.

GI

B

C SGI231

D ●

●

●

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.

Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

E

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●

●

●

●

● ● ●

● ● ● ●

●

To prevent serious burns: Avoid contact with hot metal parts.

Do not remove the radiator cap when the engine is hot.

Dispose of or recycle 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.

PBIC0190E

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PRECAUTIONS ●

Before servicing the vehicle: Protect fenders, upholstery and carpeting with appropriate covers.

Take caution that keys, buckles or buttons do not scratch paint.

SGI234

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

NAS0001D

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

Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three way catalyst.

Precautions for Fuel (Unleaded Premium Gasoline Required)

NAS0005S

Use unleaded premium gasoline with an octane rating of at least 91 AKI (Anti-Knock Index) number (Research octane number 96).

If unleaded premium gasoline is not available, unleaded regular gasoline with an octane rating of at least 87 AKI number (Research octane number 91) can be used, but only under the following precautions: ● have the fuel tank filled only partially with unleaded regular gasoline, and fill up with unleaded premium gasoline as soon as possible. ● avoid full throttle driving and abrupt acceleration.

However, for maximum vehicle performance, the use of unleaded premium gasoline is recommended.

CAUTION: Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Do not use E-85 fuel (85% fuel ethanol, 15% unleaded gasoline) unless the vehicle is specifically designed for E-85 fuel (i.e. Flexible Fuel Vehicle - FFV models). Using a fuel other than that specified could adversely affect the emission control devices and systems, and could also affect the warranty coverage validity.

Revision: 2006 August

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PRECAUTIONS Precautions for Multiport Fuel Injection System or Engine Control System ●

●

●

NAS0001F

GI

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.

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Precautions for Hoses

NAS0001G

HOSE REMOVAL AND INSTALLATION ●

E

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

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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.)

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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.

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Revision: 2006 August

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PRECAUTIONS ●

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

SMA022D

Precautions for Engine Oils

NAS0001H

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.

Precautions for Air Conditioning

NAS0001I

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: 2006 August

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HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL Description

PFP:00008

GI NAS0001J

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

Terms ●

NAS0001K

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 ●

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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.

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“Example” Range Outer Socket Lock Nut

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

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Standard Drive Shaft Installation Bolt

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: 44.3 N·m (4.5 kg-m, 33 ft-lb)

Contents

NAS0001M

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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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Revision: 2006 August

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HOW TO USE THIS MANUAL Components â—?

NAS0001N

THE LARGE ILLUSTRATIONS are exploded views (see the following) and contain tightening torques, lubrication points, section number of the PARTS CATALOG (e.g. SEC. 440) and other information necessary to perform repairs.

The illustrations should be used in reference to service matters only. When ordering parts, refer to the appropriate PARTS CATALOG .

Components shown in an illustration may be identified by a circled number. When this style of illustration is used, the text description of the components will follow the illustration.

SFIA2959E

1.

Union bolt

2.

Copper washer

3.

Brake hose

4.

Cap

5.

Bleed valve

6.

Sliding pin bolt

7.

Piston seal

Piston boot

8.

Piston

9.

10. Cylinder body

11.

Sliding pin

12. Torque member mounting bolt

13. Washer

14.

Sliding pin boot

15. Bushing

16. Torque member

17.

Inner shim cover

18. Inner shim

19. Inner pad

20.

Pad retainer

21. Pad wear sensor

22. Outer pad

23.

Outer shim

24. Outer shim cover

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

2: Rubber grease

: Brake fluid

Refer to GI section for additional symbol definitions.

SYMBOLS

SAIA0749E

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HOW TO USE THIS MANUAL How to Follow Trouble Diagnoses

NAS0001O

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.

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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

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SGI144A

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KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES J

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SAIA0750E

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HOW TO USE THIS MANUAL

SAIA0751E

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HOW TO USE THIS MANUAL How to Read Wiring Diagrams

NAS0001P

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

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

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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

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SGI942

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DESCRIPTION Number 1 2

Item Power condition

Fusible link/fuse location

4

Fuse

5

6

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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.

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The single line shows that this is a fuse.

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

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

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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

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

●

9

Page crossing

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

●

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

10

Common connector

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

11

Option abbreviation

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

12

Relay

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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

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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

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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

NAS0001Q

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

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

PFP:00000 NAS0001R

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

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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

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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

NAS0001S

GI

WORK FLOW

B

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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: 2006 August

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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.

Revision: 2006 August

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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

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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

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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: 2006 August

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT VOLTAGE CHECK METHOD To help in understanding the diagnosis of open circuits please refer to the previous schematic.

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

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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).

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT

●

●

no voltage; short is further down the circuit than SW1.

With SW1 closed, relay and solenoid disconnected and the DMM leads across both fuse terminals, check 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: 2006 August

GI-32

2006 G35 Coupe

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: 2006 August

GI-33

2006 G35 Coupe

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: 2006 August

GI-34

2006 G35 Coupe

SERVICE INFORMATION FOR ELECTRICAL INCIDENT Control Units and Electrical Parts

NAS0009U

GI

PRECAUTIONS ●

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.

B

C

D SAIA0253E

●

E

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.

F

G

H SAIA0254E

●

●

● ● ●

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.

I

J

K

SAIA0255E

L

M

Revision: 2006 August

GI-35

2006 G35 Coupe

SERVICE INFORMATION FOR ELECTRICAL INCIDENT ●

●

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: 2006 August

GI-36

2006 G35 Coupe

CONSULT-II CHECKING SYSTEM CONSULT-II CHECKING SYSTEM Description ●

●

PFP:00000

GI NAS0001U

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 AIR BAG

BCM

IVIS (NATS)*1

IPDM E/R

RAS/HICAS

AUTO DRIVE POS.

INTELLIGENT KEY

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

x

-

x

-

x

-

-

-

-

x

Self-diagnostic results

Self-diagnostic results can be read and erased quickly.

x

x

x

x

x

x

x

x

x

x

Trouble diagnostic record

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

-

-

-

x

-

-

-

-

-

-

Data monitor

Input/Output data in the ECU can be read.

x

x

x

-

x

-

x

x

x

x

Data monitor (spec)

Data monitor specification can be read.

x

-

-

-

-

-

-

-

-

-

CAN diagnosis support monitor

The condition of CAN communication line can be read.

x

x

x

-

x

-

x

x

x

x

Active test

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

x

-

x

-

x

-

x

x

x

x

DTC & SRT confirmation

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

x

-

-

-

-

-

-

-

-

-

DTC work support

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

x

x

-

-

-

-

-

-

-

-

ECU(ECM/TCM) part number

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

x

x

x

-

x

-

-

x

x

x

ECU discriminated No.

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

-

-

-

x

-

-

-

-

-

-

Function test

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

x

x

x

x

-

-

-

-

-

-

Control unit initialization

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

-

-

-

-

-

x

-

-

-

-

-

-

-

-

x

-

-

-

-

-

Function

Configuration *2

—

A/T

Work support

Diagnostic test mode

ENGINE

ABS (Including VDC)

NAS0001V

GI-37

D

E

F

H

I

J

K

L

NAS0001W

CONSULT-II contains a nickel metal hydride battery. When replacing the battery obey the following: WARNING: Replace the nickel metal hydride battery with Genuine CONSULT-II battery only. Use of another battery may present a risk of fire or explosion. The battery may present a fire or chemical burn hazard if mistreated. Do not recharge, disassemble or dispose of in fire.

Keep the battery out of reach of children and discard used battery conforming to the local regulations.

Revision: 2006 August

C

G

x: Applicable *1: IVIS (NATS) [INFINITI Vehicle Immobilizer System (Nissan Anti-theft System)] *2: This item is indicated, but it is what it does not use.

Nickel Metal Hydride Battery Replacement

B

2006 G35 Coupe

M

CONSULT-II CHECKING SYSTEM Checking Equipment

NAS0001X

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 UED05B and AEN04A-1 (For NATS) 3. CONSULT-II CONVERTER 4. “CONSULT-II Pigtail” Cable

SAIA0363E

CAUTION: ● Previous CONSULT-II “I” and “Y” DLC-I and DLC-II cables should NOT be used anymore because their DDL connector pins can be damaged during cable swapping. ● If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be detected in self- diagnosis depending on control unit which carry out CAN communication. ● If CONSULT-II CONVERTER is not connected with CONSULT-II, vehicle occur the “FAIL SAFE MODE” which is “LIGHT UP the HEAD LIGHT” and /or “COOLING FAN ROTATING” when CONSULT-II is started.

NOTE: ● The CONSULT-II must be used in conjunction with a program card.

CONSULT-II does not require loading (Initialization) procedure. ● Be sure the CONSULT-II is turned off before installing or removing a program card.

CONSULT-II Start Procedure

NAS0001Y

NOTE: Turning ignition switch off when performing CAN diagnosis could cause CAN memory to be erased.

1. Connect CONSULT-II and CONSULT-II CONVERTER to the data link connector.

PAIA0070E

2.

3.

If necessary, turn on the ignition switch.

Touch “START(NISSAN BASED VHCL)” or System Shortcut key (eg: ENGINE) on the screen.

SAIA0450E

Revision: 2006 August

GI-38

2006 G35 Coupe

CONSULT-II CHECKING SYSTEM 4.

Touch necessary system on "SELECT SYSTEM" screen.

If necessary system is not indicated, check power supply and ground of system control unit. If it is normal, refer to GI-39, "CONSULT-II Data Link Connector (DLC) Circuit" .

GI

B

C BCIA0030E

D

5.

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

E

F

G BCIA0031E

CONSULT-II Data Link Connector (DLC) Circuit

NAS0001Z

INSPECTION PROCEDURE

H

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

Symptom

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

●

CONSULT-II DLC cable and CONSULT-II CONVERTER.

●

CONSULT-II program card (Check the appropriate CONSULT-II program card for the system.

Refer to "Checking Equipment".)

●

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

●

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

●

Open or short circuit CAN communication. Refer to LAN-3, "Precautions When Using CONSULTII" .

CONSULT-II cannot access any system.

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

I

●

J

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

Revision: 2006 August

GI-39

2006 G35 Coupe

K

L

M

CONSULT-II CHECKING SYSTEM CIRCUIT DIAGRAM

TAWM0055E

Revision: 2006 August

GI-40

2006 G35 Coupe

LIFTING POINT LIFTING POINT Commercial Service Tools

PFP:00000

GI NAS00020

Tool name

Description

B

C

Board on attachment

D

S-NT001

E Safety stand attachment

F S-NT002

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

Garage Jack and Safety Stand

G

H

I

NAS00021

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

J

K

L

M

Revision: 2006 August

GI-41

2006 G35 Coupe

LIFTING POINT â—?

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

PIIB7681E

2-Pole Lift

NAS00022

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.

PAIA0074E

Revision: 2006 August

GI-42

2006 G35 Coupe

LIFTING POINT Board-On Lift

NAS00023

GI

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

B

C

D

PIIB7445E

E

F

G

H

I

J

K

L

M

Revision: 2006 August

GI-43

2006 G35 Coupe

TOW TRUCK TOWING TOW TRUCK TOWING Tow Truck Towing

PFP:00000 NAS00024

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.

NISSAN / INFINITI recommends that the vehicle be towed with the driving (rear) wheels off the ground as illustrated.

CAUTION: When towing with the front wheels on the ground (if a towing dollies does not be used), turn the ignition key to the OFF position, and secure the steering wheel in the straight-ahead position with a rope or similar device. Never place the ignition key in the LOCK position. This will result in damage to the steering lock mechanism.

SGI994

PAIA0063E

Revision: 2006 August

GI-44

2006 G35 Coupe

TOW TRUCK TOWING Vehicle Recovery (Freeing a Stuck Vehicle)

NAS00025

GI

FRONT After removing the front licence plate (if so equipped) or the recovery hook cover, securely install the recovery hook.

WARNING: ● Stand clear of a stuck vehicle. ● Do not spin your tires at high speed. This could cause them to explode and result in serious injury. Parts of your vehicle could also overheat and be damaged.

CAUTION: ● Tow chains or cables must be attached only to the vehicle recovery hooks or main structural members of the vehicle.

PAIA0075E Otherwise, the vehicle body will be damaged. ● Do not use the vehicle tie downs to free a vehicle stuck in sand, snow, mud, etc. Never tow the vehicle using the vehicle tie downs or recovery hooks. ● Always pull the cable straight out from the front of the vehicle. Never pull on the hook at an angle. ● Pulling devices should be routed so they do not touch any part of the suspension, steering, brake or cooling systems. ● Pulling devices such as ropes or canvas straps are not recommended for use in vehicle towing or recovery.

B

C

D

E

F

G

REAR ●

Recovery hook is not available.

H

I

J

K

L

M

Revision: 2006 August

GI-45

2006 G35 Coupe

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

4T

7T

9T

Bolt size

Bolt diameter * mm

PFP:00000 NAS00026

Tightening torque (Without lubricant) Pitch mm

Hexagon head bolt N·m

kg-m

Hexagon flange bolt

ft-lb

in-lb

N·m

kg-m

ft-lb

in-lb

M6

6.0

1.0

5.5

0.56

4

49

7

0.71

5

62

M8

8.0

1.25

13.5

1.4

10

—

17

1.7

13

—

1.0

13.5

1.4

10

—

17

1.7

13

—

M10

10.0

1.5

28

2.9

21

—

35

3.6

26

—

1.25

28

2.9

21

—

35

3.6

26

—

M12

12.0

1.75

45

4.6

33

—

55

5.6

41

—

1.25

45

4.6

33

—

65

6.6

48

—

M14

14.0

1.5

80

8.2

59

—

100

10

74

—

M6

6.0

1.0

9

0.92

7

80

11

1.1

8

97

1.25

22

2.2

16

—

28

2.9

21

—

M8

8.0

1.0

22

2.2

16

—

28

2.9

21

—

1.5

45

4.6

33

—

55

5.6

41

—

M10

10.0

1.25

45

4.6

33

—

55

5.6

41

—

1.75

80

8.2

59

—

100

10

74

—

M12

12.0

1.25

80

8.2

59

—

100

10

74

—

M14

14.0

1.5

130

13

96

—

170

17

125

—

M6

6.0

1.0

11

1.1

8

—

13.5

1.4

10

—

1.25

28

2.9

21

—

35

3.6

26

—

M8

8.0

1.0

28

2.9

21

—

35

3.6

26

—

1.5

55

5.6

41

—

80

8.2

59

—

M10

10.0

1.25

55

5.6

41

—

80

8.2

59

—

1.75

100

10

74

—

130

13

96

—

M12

12.0

1.25

100

10

74

—

130

13

96

—

M14

14.0

1.5

170

17

125

—

210

21

155

—

*: Nominal diameter 1. Special parts are excluded.

2. This standard is applicable to bolts having the following marks embossed on the bolt head.

MGI044A

Revision: 2006 August

GI-46

2006 G35 Coupe

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

PFP:00000

GI NAS00027

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

Product Description

1

2

3

Purpose

999MP-AM000P

99998-50505

Permatex 81844

Anaerobic Liquid Gasket

For metal-to-metal flange sealing.

Can fill a 0.38 mm (0.015 inch) gap and provide instant sealing for most powertrain applications.

999MP-AM001P

99998-50503

Permatex 51813 and 51817

High Performance Thread Sealant

Provides instant sealing on any threaded straight or parallel threaded fitting.

(Thread sealant only, no locking ability.)

999MP-AM002P

999MP-AM002P

Permatex 56521

Medium Strength Thread Locking Sealant (Blue)

Revision: 2006 August

C

D

99998-50506 (Ultra Grey)

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

F

Do not use on plastic.

999MP-AM003P (Ultra Grey)

Silicone RTV

High Temperature, High Strength Thread Locking Sealant (Red)

B

E

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

6

Aftermarket Crossreference Part Nos.

Used to permanently remount rear view mirrors to windows.

Gasket Maker

5

Nissan Canada Part No. (Canada)

Rear View Mirror Adhesive

●

4

Nissan North America Part No. (USA)

Threadlocker

Threadlocker (service tool removable)

–

999MP-AM004P

999MP-AM005P

GI-47

–

999MP-AM004P

999MP-AM005P

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

2006 G35 Coupe

G

H

I

J

K

L

M

IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION Model Variation Body Coupe

Engine VQ35DE

Transmission RE5R05A (5A/T)

FS6R31A (6M/T)

RE5R05A (5A/T)

FS6R31A (6M/T)

PFP:00010 NAS00028

Axle

Model

2WD

GLJALVN V35 EUA

2WD

GLJALFN V35 EUA

2WD (with rear active steer (RAS))

GLJBLVN V35 EUA

2WD

GLJALVY V35 EUA

2WD (with rear active steer (RAS))

GLJBLVY V35 EUA

2WD

GLJALVN V35 ENA

2WD

GLJALFN V35 ENA

2WD (with rear active steer (RAS))

GLJBLVN V35 ENA

2WD

GLJALVY V35 ENA

2WD (with rear active steer (RAS))

GLJBLVY V35 ENA

Destination

USA

Canada

Prefix and suffix designations:

SAIA0992E

Revision: 2006 August

GI-48

2006 G35 Coupe

IDENTIFICATION INFORMATION IDENTIFICATION NUMBER GI

B

C

D

E

F PAIA0254E

G

Vehicle Identification Number Arrangement

H

I

J

K

L

M SAIA0993E

IDENTIFICATION PLATE

SGI315

Revision: 2006 August

GI-49

2006 G35 Coupe

IDENTIFICATION INFORMATION ENGINE SERIAL NUMBER

PAIA0051E

AUTOMATIC TRANSMISSION NUMBER

PAIA0069E

MANUAL TRANSMISSION NUMBER

PAIA0068E

Dimensions

NAS00029

Unit: mm (in) Overall length

4,628 (182.2)

Overall width

1,815 (71.5)

Overall height

1,393(54.8), 1,399 (55.1)*1

Front tread

1,535 (60.4)

Rear tread

1,540 (60.6)*2, 1,545 (60.8)*3

Wheelbase

2,850 (112.2)

*1: For 18 inch and 19 inch road wheel models. *2: For models with road wheel size – 17 × 8 JJ and 19 × 8-1/2JJ [offset 1.30 in (33 mm)] *3: For models with road wheel size – 18 × 8 JJ [offset 1.18 in (30 mm)]

Revision: 2006 August

GI-50

2006 G35 Coupe

IDENTIFICATION INFORMATION Wheels & Tires

NAS0002A

GI Type

Size

Offset in (mm) 17 X7 - 1/2 JJ

Front

18 X 8 JJ

B

19 X 8 JJ

Road wheel Aluminum Rear

Tire

1.18 (30)

17 X 8 JJ

1.30 (33)

18 X 8 JJ

1.18 (30)

19 X 8 - 1/2 JJ

1.30 (33)

C

P225/50R17 93V 225/45R18 91W 225/40R19 89Y

D

Front

Rear

P235/50R17 95V 245/45R18 96W 245/40R19 94Y

E

Conventional

Spare

T145/80D17

F

G

H

I

J

K

L

M

Revision: 2006 August

GI-51

2006 G35 Coupe

TERMINOLOGY TERMINOLOGY SAE J1930 Terminology List

PFP:00011 NAS0002B

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

OLD TERM

ACL

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: 2006 August

GI-52

2006 G35 Coupe

TERMINOLOGY NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

GI

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

C

Flash electrically erasable programmable read only memory

FEEPROM

***

D

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

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

Exhaust gas recirculation temperature sensor

B

EGR temperature sensor

Revision: 2006 August

GI-53

E

F

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M

2006 G35 Coupe

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: 2006 August

GI-54

2006 G35 Coupe

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

GI

B

C

D

E

***: Not applicable

F

G

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M

Revision: 2006 August

GI-55

2006 G35 Coupe

TERMINOLOGY

Revision: 2006 August

GI-56

2006 G35 Coupe

ENGINE MECHANICAL

B ENGINE A

EM

SECTION

ENGINE MECHANICAL

C

D

E

CONTENTS PRECAUTIONS .......................................................... 4 Precautions for Battery Service ................................ 4 Precautions Necessary for Steering Wheel Rotation After Battery Disconnect .......................................... 4 OPERATION PROCEDURE ................................. 4 Precautions for Draining Engine Coolant ................. 4 Precautions for Disconnecting Fuel Piping .............. 4 Precautions for Removal and Disassembly ............. 4 Precautions for Inspection, Repair and Replacement ......................................................................... 5 Precautions for Assembly and Installation ............... 5 Parts Requiring Angle Tightening ............................. 5 Precautions for Liquid Gasket .................................. 5 REMOVAL OF LIQUID GASKET SEALING .......... 5 LIQUID GASKET APPLICATION PROCEDURE..... 6 PREPARATION ........................................................... 7 Special Service Tools (SST) ..................................... 7 Commercial Service Tools ........................................ 9 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .............................................. 12 NVH Troubleshooting —Engine Noise ................... 12 Use the Chart Below to Help You Find the Cause of the Symptom. ..................................................... 13 DRIVE BELTS ........................................................... 14 Checking Drive Belts .............................................. 14 Tension Adjustment ................................................ 14 ALTERNATOR AND POWER STEERING OIL PUMP BELT ........................................................ 15 A/C COMPRESSOR BELT ................................. 15 Removal and Installation ........................................ 15 REMOVAL ........................................................... 15 INSTALLATION ................................................... 15 AIR CLEANER AND AIR DUCT ............................... 16 Components ........................................................... 16 Removal and Installation ........................................ 16 REMOVAL ........................................................... 16

Revision: 2006 August

INSTALLATION ................................................... 16 Changing Air Cleaner Filter .................................... 17 INSPECTION ...................................................... 17 REMOVAL ........................................................... 17 INSTALLATION ................................................... 17 INTAKE MANIFOLD COLLECTOR .......................... 18 Components ........................................................... 18 Removal and Installation ........................................ 18 REMOVAL ........................................................... 18 INSPECTION AFTER REMOVAL ....................... 20 INSTALLATION ................................................... 21 INTAKE MANIFOLD ................................................. 23 Components ........................................................... 23 Removal and Installation ........................................ 23 REMOVAL ........................................................... 23 INSPECTION AFTER REMOVAL ....................... 24 INSTALLATION ................................................... 24 EXHAUST MANIFOLD AND THREE WAY CATALYST .......................................................................... 25 Components ........................................................... 25 Removal and Installation ........................................ 25 REMOVAL ........................................................... 25 INSPECTION AFTER REMOVAL ....................... 27 INSTALLATION ................................................... 27 OIL PAN AND OIL STRAINER ................................. 29 Components ........................................................... 29 Removal and Installation ........................................ 29 REMOVAL ........................................................... 29 INSPECTION AFTER REMOVAL ....................... 31 INSTALLATION ................................................... 31 INSPECTION AFTER INSTALLATION ................ 34 IGNITION COIL ......................................................... 35 Components ........................................................... 35 Removal and Installation ........................................ 35 REMOVAL ........................................................... 35 INSTALLATION ................................................... 35 SPARK PLUG (PLATINUM-TIPPED TYPE) ............. 36

EM-1

2006 G35 Coupe

F

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Components ........................................................... 36 Removal and Installation ........................................ 36 REMOVAL ........................................................... 36 INSPECTION AFTER REMOVAL ........................ 36 INSTALLATION .................................................... 37 FUEL INJECTOR AND FUEL TUBE ........................ 38 Components ........................................................... 38 Removal and Installation ........................................ 38 REMOVAL ........................................................... 38 INSTALLATION .................................................... 40 INSPECTION AFTER INSTALLATION ................ 42 ROCKER COVER ..................................................... 44 Components ........................................................... 44 Removal and Installation ........................................ 44 REMOVAL ........................................................... 44 INSTALLATION .................................................... 45 FRONT TIMING CHAIN CASE ................................. 47 Removal and Installation ........................................ 47 REMOVAL ........................................................... 47 INSTALLATION .................................................... 51 INSPECTION AFTER INSTALLATION ................ 57 TIMING CHAIN .......................................................... 59 Components (M/T Models) ..................................... 59 Components (A/T Models) ...................................... 61 Removal and Installation (M/T Models) .................. 62 REMOVAL ........................................................... 62 INSPECTION AFTER REMOVAL ........................ 69 INSTALLATION .................................................... 70 INSPECTION AFTER INSTALLATION ................ 81 Removal and Installation (A/T Models) ................... 81 REMOVAL ........................................................... 81 INSPECTION AFTER REMOVAL ........................ 88 INSTALLATION .................................................... 89 INSPECTION AFTER INSTALLATION ................ 99 CAMSHAFT ............................................................. 100 Components ......................................................... 100 Removal and Installation ...................................... 101 REMOVAL ......................................................... 101 INSPECTION AFTER REMOVAL ...................... 102 INSTALLATION .................................................. 105 INSPECTION AFTER INSTALLATION .............. 110 Valve Clearance .....................................................111 INSPECTION ......................................................111 ADJUSTMENT .................................................. 114 OIL SEAL ................................................................ 116 Removal and Installation of Valve Oil Seal ........... 116 REMOVAL ......................................................... 116 INSTALLATION .................................................. 116 Removal and Installation of Front Oil Seal ........... 117 REMOVAL ......................................................... 117 INSTALLATION .................................................. 117 Removal and Installation of Rear Oil Seal ............ 117 REMOVAL ......................................................... 117 INSTALLATION .................................................. 118 CYLINDER HEAD ................................................... 119 On-Vehicle Service ............................................... 119 CHECKING COMPRESSION PRESSURE ....... 119 Components ......................................................... 120 Removal and Installation ...................................... 120 Revision: 2006 August

REMOVAL .......................................................... 120 INSPECTION AFTER REMOVAL ...................... 121 INSTALLATION .................................................. 122 INSPECTION AFTER INSTALLATION .............. 123 Components .......................................................... 124 Disassembly and Assembly .................................. 124 DISASSEMBLY .................................................. 124 ASSEMBLY ........................................................ 125 Inspection After Disassembly ................................ 126 VALVE DIMENSIONS ........................................ 126 VALVE GUIDE CLEARANCE ............................ 127 VALVE GUIDE REPLACEMENT ....................... 127 VALVE SEAT CONTACT .................................... 129 VALVE SEAT REPLACEMENT .......................... 129 VALVE SPRING SQUARENESS ....................... 130 VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD .............................. 130 ENGINE ASSEMBLY ............................................... 131 Components .......................................................... 131 Removal and Installation ....................................... 131 REMOVAL .......................................................... 132 INSTALLATION .................................................. 134 INSPECTION AFTER INSTALLATION .............. 135 CYLINDER BLOCK ................................................. 137 Components .......................................................... 137 Disassembly and Assembly .................................. 138 DISASSEMBLY .................................................. 138 ASSEMBLY ........................................................ 143 How to Select Piston and Bearing ........................ 150 DESCRIPTION .................................................. 150 HOW TO SELECT PISTON ............................... 151 HOW TO SELECT CONNECTING ROD BEARING ..................................................................... 151 HOW TO SELECT MAIN BEARING .................. 152 Inspection After Disassembly ................................ 156 CRANKSHAFT END PLAY ................................ 156 CONNECTING ROD SIDE CLEARANCE ......... 156 PISTON TO PISTON PIN OIL CLEARANCE ..... 156 PISTON RING SIDE CLEARANCE ................... 157 PISTON RING END GAP .................................. 157 CONNECTING ROD BEND AND TORSION ..... 158 CONNECTING ROD BIG END DIAMETER ...... 158 CONNECTING ROD BUSHING OIL CLEARANCE ................................................................. 159 CYLINDER BLOCK DISTORTION .................... 160 MAIN BEARING HOUSING INNER DIAMETER.160 PISTON TO CYLINDER BORE CLEARANCE . 160 CRANKSHAFT MAIN JOURNAL DIAMETER ... 162 CRANKSHAFT PIN JOURNAL DIAMETER ...... 162 CRANKSHAFT OUT-OF-ROUND AND TAPER.162 CRANKSHAFT RUNOUT .................................. 162 CONNECTING ROD BEARING OIL CLEARANCE ................................................................. 163 MAIN BEARING OIL CLEARANCE ................... 163 CRUSH HEIGHT OF MAIN BEARING .............. 164 CRUSH HEIGHT OF CONNECTING ROD BEARING ........................................................... 164 MAIN BEARING CAP BOLT OUTER DIAMETER.164 CONNECTING ROD BOLT OUTER DIAMETER

EM-2

2006 G35 Coupe

(FOR A/T MODELS) ......................................... 164 FLYWHEEL DEFLECTION ............................... 165 MOVEMENT AMOUNT OF FLYWHEEL ........... 165 DRIVE PLATE (A/T MODELS) .......................... 166 OIL JET ............................................................. 166 OIL JET RELIEF VALVE ................................... 166 SERVICE DATA AND SPECIFICATIONS (SDS) .... 167 Standard and Limit ............................................... 167 GENERAL SPECIFICATIONS .......................... 167 DRIVE BELT ..................................................... 168 INTAKE MANIFOLD COLLECTOR, INTAKE

MANIFOLD AND EXHAUST MANIFOLD .......... 168 SPARK PLUG .................................................... 168 CAMSHAFT AND CAMSHAFT BEARING ........ 169 CYLINDER HEAD ............................................. 171 CYLINDER BLOCK ........................................... 174 PISTON, PISTON RING AND PISTON PIN ...... 175 CONNECTING ROD ......................................... 176 CRANKSHAFT .................................................. 177 MAIN BEARING ................................................ 178 CONNECTING ROD BEARING ........................ 179

A

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Revision: 2006 August

EM-3

2006 G35 Coupe

PRECAUTIONS PRECAUTIONS Precautions for Battery Service

PFP:00001 NBS000JC

Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interference between the window edge and the vehicle when the door is opened/closed. During normal operation, the window slightly raises and lowers automatically to prevent any window to vehicle interference. The automatic window function will not work with the battery disconnected.

Precautions Necessary for Steering Wheel Rotation After Battery Disconnect NBS006S7

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.

Precautions for Draining Engine Coolant

NBS000JD

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 ●

● ● ● ●

NBS000JE

NBS000JF

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 assembly.

When loosening bolts and nuts, 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.

Revision: 2006 August

EM-4

2006 G35 Coupe

PRECAUTIONS Precautions for Inspection, Repair and Replacement

NBS000JG

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

Precautions for Assembly and Installation ● ●

● ●

●

●

● ●

Use torque wrench to tighten bolts or nuts to specification.

When tightening bolts and nuts, 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 gasket, packing, oil seal or O-ring.

Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins, make sure that dowel pins are installed in the original position.

Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for any restriction and blockage.

Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.

Before assembly, oil sliding surfaces well.

Release air within route when refilling after draining engine coolant.

After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and exhaust systems for leakage.

– – – ● ● ●

EM

C

D

E

F

G

Parts Requiring Angle Tightening ●

NBS000JH

A

NBS000JI

Use 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 bolts 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

H

I

J

NBS000JJ

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.

In areas where seal cutter (SST) is difficult to use, use a plastic hammer to lightly tap (1) seal cutter where liquid gasket is applied. Use plastic hammer to slide seal cutter (2) by tapping on the side.

CAUTION: If for some unavoidable reason a tool such as flat-bladed screwdriver is used, be careful not to damage the mating surfaces.

Revision: 2006 August

EM-5

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PBIC0002E

2006 G35 Coupe

PRECAUTIONS LIQUID GASKET APPLICATION PROCEDURE 1.

2.

Using a scraper, remove the old liquid gasket adhering to the gasket application surface and the mating surface. ● Remove the liquid gasket completely from the groove of the 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 material.

PBIC0003E

3.

4. ●

Attach the liquid gasket tube to the tube presser [SST: WS39930000 ( — )].

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-47, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .

Apply liquid gasket without breaks to the specified location with the specified dimensions.

If there is a groove for the liquid gasket application, apply gasket to the groove.

EMA0622D

As for bolt holes, normally apply liquid gasket inside the holes.

Occasionally, it should be applied outside the holes. Make sure to read the text of this manual. ● Within five minutes of liquid gasket application, install the mating component. ● If 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. ●

Revision: 2006 August

EM-6

SEM159F

2006 G35 Coupe

PREPARATION PREPARATION Special Service Tools (SST)

PFP:00002

A NBS000JK

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

EM

Description Disassembling and assembling

C

D

NT042

E

KV10106500 ( — ) Engine stand shaft

F

G NT028

KV10117000 (J41262) Engine sub-attachment

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

H

I NT373

KV10117001 ( — ) Engine sub-attachment

Installing on the cylinder block

J

K NT372

KV10116200 (J26336-A) Valve spring compressor 1. KV10115900 (J26336-20) Attachment 2. KV10109220 ( — ) Adaptor

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

M

PBIC1650E

KV10107902 (J38959) Valve oil seal puller

Replacing valve oil seal

NT011

Revision: 2006 August

L

EM-7

2006 G35 Coupe

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

Description

KV10115600 (J-38958) Valve oil seal drift

Installing valve oil seal Use side A. a: 20 (0.79) dia. d: 8 (0.31) dia. b: 13 (0.51) dia. e: 10.7 (0.421) c: 10.3 (0.406) dia. f: 5 (0.20) Unit: mm (in) S-NT603

EM03470000 (J8037) Piston ring compressor

Installing piston assembly into cylinder bore

NT044

ST16610001 (J23907) Pilot bushing puller

Removing crankshaft pilot bushing

NT045

KV10111100 (J37228) Seal cutter

Removing oil pan (lower and upper), front and rear timing chain case, etc.

NT046

WS39930000 ( — ) Tube presser

Pressing the tube of liquid gasket

NT052

KV10112100 (BT8653-A) Angle wrench

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

NT014

KV10117100 (J3647-A) Heated oxygen sensor wrench

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

NT379

Revision: 2006 August

EM-8

2006 G35 Coupe

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

A

Description

KV10114400 (J38365) Heated oxygen sensor wrench

Loosening or tightening air fuel ratio sensor a: 22 mm (0.87 in)

EM

C NT636

KV10117700 (J44716) Ring gear stopper

Removing and installing crankshaft pulley

D

E

F

NT822

— (J-45488) Quick connector release

Removing fuel tube quick connectors in engine room

G

H PBIC0198E

Commercial Service Tools

NBS000JL

I (Kent-Moore No.) Tool name

Description

Power tool

Loosening bolts and nuts

J

K

PBIC0190E

TORX socket

L Removing and installing flywheel Size: T55

M

PBIC1113E

Manual lift table caddy

Removing and installing engine

ZZA1210D

Revision: 2006 August

EM-9

2006 G35 Coupe

PREPARATION (Kent-Moore No.) Tool name

Description

(BT3373-F) Belt tension gauge

Checking drive belt tension

AMA126

(J24239-01) Cylinder head bolt wrench

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

Spark plug wrench

Removing and installing spark plug

NT047

Valve seat cutter set

Finishing valve seat dimensions

NT048

Piston ring expander

Removing and installing piston ring

NT030

Valve guide drift

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

NT015

Valve guide reamer

Reaming valve guide 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: 2006 August

EM-10

2006 G35 Coupe

PREPARATION (Kent-Moore No.) Tool name

Description

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

AEM488

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

A

Reconditioning the exhaust system threads before installing a new heated oxygen sensor and air fuel ratio 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 Lubricating heated oxygen sensor and air fuel ratio sensor thread cleaning tool when reconditioning exhaust system threads

EM

C

D

E AEM489

F

G

H

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Revision: 2006 August

EM-11

2006 G35 Coupe

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

PFP:00003 NBS000JM

PBIC3605E

Revision: 2006 August

EM-12

2006 G35 Coupe

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

NBS000JN

A

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.

EM

C

Operating condition of engine Location of noise Top of engine Rocker cover Cylinder head

Type of noise

When idling

When racing

A

—

A

B

Rattle

C

A

—

A

B

Slap or rap

Knock

Front of engine

When starting

C

Knock

Front of engine Timing chain cover

After warmup

Ticking or clicking

Slap or knock

Crankshaft pulley Cylinder block (Side of engine) Oil pan

Before warmup

Tapping or ticking

—

A

A

A

A

A

—

B

B

A

—

—

C

—

—

B

B

B

A

B

B

B

B

B

B

While driving

Source of noise

Check item

D

—

Tappet noise

Valve clearance

EM-111

C

Camshaft bearing noise

Camshaft runout Camshaft journal oil clearance

EM-102 EM-103

—

Piston pin noise

Piston to piston pin oil clearance Connecting rod bushing oil clearance

EM-156 EM-159

A

Piston slap noise

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

EM-160 EM-157 EM-157 EM-158

B

Connecting rod bearing noise

Connecting rod bushing oil clearance Connecting rod bearing oil clearance

EM-159 EM-163

C

Main bearing noise

Main bearing oil clearance Crankshaft runout

EM-163 EM-162

B

Timing chain and chain tensioner noise

Timing chain cracks and wear Timing chain tensioner operation

EM-69 EM-62

C

Drive belts (Sticking or slipping)

Drive belts deflection

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: 2006 August

B

—

C: Sometimes related

B

—

Reference page

F

G

H

I

J

K

L

M EM-14

CO-23, "WATER PUMP"

—: Not related

EM-13

E

2006 G35 Coupe

DRIVE BELTS DRIVE BELTS Checking Drive Belts

PFP:02117 NBS000JO

WARNING: Be sure to perform when the 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 the belt tension with belt tension gauge (commercial service tool: BT3373-F or equivalent) at points marked shown in the figure.

When measuring deflection, apply 98 N (10 kg, 22 lb) at the marked point. ● Adjust if belt deflection exceeds the limit or if belt tension is KBIA1731J 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 the deflection or tension without looseness. ●

Belt deflection and tension Deflection adjustment Used belt Limit

After adjustment

Alternator and power steering oil pump belt

7 (0.28)

4-5 (0.16 - 0.20)

A/C compressor belt

12 (0.47)

9 - 10 (0.35 - 0.39)

Applied pushing force

Unit: mm (in)

Tension adjustment*1

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)

—

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

Tension Adjustment

NBS000JP

Portion

Belt tightening method for adjustment

Alternator and power steering oil pump belt

Adjusting bolt on idler pulley

A/C 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”. ● When checking belt deflection or tension immediately after installation, first adjust it to the specified value. Then, after turning 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 groove. ● Keep oil and water away from belt. ● Do not twist or bend belt excessively.

Revision: 2006 August

EM-14

2006 G35 Coupe

DRIVE BELTS ALTERNATOR AND POWER STEERING OIL PUMP BELT 1.

2.

3.

A

Remove 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-14, "Checking Drive Belts" .

Tighten nut (A).

EM

C

: 34.8 N·m (3.5 kg-m, 26 ft-lb) D

E

F

G

PBIC1406E

H

A/C COMPRESSOR BELT 1.

2.

3.

Remove 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-14, "Checking Drive Belts" .

Tighten nut (C).

I

J

: 34.8 N·m (3.5 kg-m, 26 ft-lb)

Removal and Installation

NBS000JQ

REMOVAL 1.

2.

3.

Remove undercover with power tool.

Remove alternator and power steering oil pump belt. Refer to EM-15, "ALTERNATOR AND POWER STEERING OIL PUMP BELT" .

Remove A/C compressor belt. Refer to EM-15, "A/C 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 the 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 groove.

Adjust belt tension. Refer to EM-14, "Tension Adjustment" .

Tighten each adjusting bolt and nut to the specified torque.

Make sure that tension of each belt is within the standard.

Revision: 2006 August

EM-15

2006 G35 Coupe

K

L

M

AIR CLEANER AND AIR DUCT AIR CLEANER AND AIR DUCT Components

PFP:16500 NBS000JR

PBIC2278E

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

Removal and Installation

12. Air cleaner case

NBS000JS

REMOVAL 1.

2.

3.

4.

5.

6.

7.

Remove engine cover with power tool. Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" . ● This work is unnecessary when parts located forward of mass air flow sensor are removed/installed.

Remove air duct (inlet).

Disconnect harness connector from mass air flow sensor.

Disconnect PCV hose.

Remove air cleaner case/mass air flow sensor assembly 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 fender, lifting left fender protector.

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

Revision: 2006 August

EM-16

2006 G35 Coupe

AIR CLEANER AND AIR DUCT ● ●

Align marks. Attach each joint. Screw clamps firmly.

To position air cleaner case, refer to EM-17, "Changing Air Cleaner Filter" .

Changing Air Cleaner Filter

A NBS000JT

INSPECTION ●

EM

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

C

D

E PBIC1217E

REMOVAL 1.

2.

3.

4.

Remove air duct (inlet) from air cleaner case.

Disconnect harness connector from mass air flow sensor.

Loosen clamp bolts of air hose.

Remove mounting bolts for air cleaner case. Remove air cleaner case/mass air flow sensor/air hose assembly.

F

G

H

PBIC0770E

5.

Unfasten clips and open air cleaner case, and remove air cleaner filter.

I

J

K

L PBIC1218E

M

INSTALLATION Note the following, and install in the reverse order of removal. ● 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: 2006 August

EM-17

KBIA0954E

2006 G35 Coupe

INTAKE MANIFOLD COLLECTOR INTAKE MANIFOLD COLLECTOR Components

PFP:14003 NBS000JU

KBIA3590J

Vacuum hose

2.

EVAP canister purge volume control solenoid valve

4.

Bracket

5.

Intake manifold collector (upper)

6.

Water hose

7.

Water hose

8.

Gasket

9.

Electric throttle control actuator

1.

3.

Vacuum hose

10. Bracket

11. PCV hose

12. Bracket

13. Gasket

14. Intake manifold collector (lower)

15. Gasket

B.

C.

16. Intake manifold collector cover

●

A.

To vacuum pipe

D.

To PCV valve

To water outlet

To heater pipe

Refer to GI-10, "Components" for symbol marks in the figure.

Removal and Installation

NBS000JV

REMOVAL WARNING: ● To avoid the danger of being scalded, do not drain the engine coolant when the engine is hot. ● 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: 2006 August

EM-18

2006 G35 Coupe

INTAKE MANIFOLD COLLECTOR 1.

Remove engine cover with power tool.

A

EM

C

D

E

F

G KBIA0956E

2.

3.

4. a. b.

Drain engine coolant, or when water hose is disconnected, attach plug to prevent engine coolant leakage.

Refer to CO-10, "Changing Engine Coolant" .

CAUTION: ● Perform this step when engine is cold. ● Do not spill engine coolant on drive belts.

Remove air cleaner case and air duct. Refer to EM-16, "AIR CLEANER AND AIR DUCT" .

Remove electric throttle control actuator as follows: Disconnect harness connector.

Loosen bolts in reverse order as shown in the figure.

CAUTION: ● Handle carefully to avoid any shock to electric throttle control actuator. ● Do not disassemble.

H

I

J

K

L

M KBIA0957E

5.

6.

7.

Remove fuel sub-tube mounting bolt to disconnect from rear of intake manifold collector (lower). Refer to EM-38, "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).

Revision: 2006 August

EM-19

2006 G35 Coupe

INTAKE MANIFOLD COLLECTOR 8.

Loosen bolts in reverse order as shown in the figure to remove intake manifold collector (upper) with power tool.

PBIC0773E

9. Remove PCV hose [between intake manifold collector (lower) and rocker cover (right bank)].

10. Loosen bolts in reverse order as shown in the figure, and remove the intake manifold collector cover, gasket, intake manifold collector (lower) and gasket with power tool.

PBIC0774E

INSPECTION AFTER REMOVAL Surface Distortion â—?

Check the surface distortion of both the intake manifold collector (upper and lower) mating surfaces with straightedge and feeler gauge.

Limit

â—?

: 0.1 mm (0.004 in)

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

PBIC0775E

Revision: 2006 August

EM-20

2006 G35 Coupe

INTAKE MANIFOLD COLLECTOR INSTALLATION A

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

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

EM

C

D

E

F

G

H PBIC0776E

Intake Manifold Collector (Lower)

I

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.

J

K

L PBIC0774E

Intake Manifold Collector (Upper) ●

M

If stud bolts were removed, install them and tighten to the torque specified below. : 4.9 - 6.9 N·m (0.5 - 0.7 kg-m, 44 - 61 in-lb)

●

Shank length under bolt head varies with bolt location. Install bolts while referring to numbers shown below and in the 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

Tighten in numerical order as shown in the figure.

PBIC0773E

Water Hose ●

Insert hose by 27 to 32 mm (1.06 to 1.26 in) from connector end.

Revision: 2006 August

EM-21

2006 G35 Coupe

INTAKE MANIFOLD COLLECTOR ●

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-79, "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-79, "Idle Air Volume Learning" .

KBIA0957E

Revision: 2006 August

EM-22

2006 G35 Coupe

INTAKE MANIFOLD INTAKE MANIFOLD Components

PFP:14003

A NBS000JW

EM

C

D

E

F

G KBIA1286E

1.

Harness bracket

2.

Intake manifold

Removal and Installation

3.

Gasket NBS000JX

H

REMOVAL 1.

2.

3.

4.

Release fuel pressure. Refer to EC-81, "FUEL PRESSURE RELEASE" .

Remove intake manifold collectors (upper and lower). Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .

Remove fuel tube and fuel injector assembly. Refer to EM-38, "FUEL INJECTOR AND FUEL TUBE" .

Loosen bolts and nuts in reverse order as shown in the figure to remove intake manifold.

I

J

K

L

M PBIC0778E

5.

Remove intake manifold gaskets.

CAUTION: Cover engine openings to avoid entry of foreign materials.

Revision: 2006 August

EM-23

2006 G35 Coupe

INTAKE MANIFOLD INSPECTION AFTER REMOVAL Surface Distortion ●

Check the surface distortion of the intake manifold mating surface with straightedge and feeler gauge.

Limit

●

: 0.1 mm (0.004 in)

If it exceeds the limit, replace intake manifold.

PBIC0870E

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

Intake Manifold ●

If stud bolts were removed, install them and tighten to the specified torque below. : 9.8 - 11.8 N·m (1.0 - 1.2 kg-m, 87 - 104 in-lb)

●

Tighten all mounting bolts and nuts to the specified torque in two or more steps in numerical order shown in the figure.

1st step : 4.9 - 9.8 N·m (0.5 - 1.0 kg-m, 4 - 7 ft-lb) 2nd step and after : 26.5 - 31.4 N·m (2.7 - 3.2 kg-m, 20 - 23 ft-lb)

PBIC0778E

Revision: 2006 August

EM-24

2006 G35 Coupe

EXHAUST MANIFOLD AND THREE WAY CATALYST EXHAUST MANIFOLD AND THREE WAY CATALYST Components

PFP:14004

A NBS002UK

EM

C

D

E

F

G

H

I

J

PBIC4924E

1.

Heated oxygen sensor 2 (bank 1)

2.

Three way catalyst (right bank)

3.

4.

Air fuel ratio 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. Air fuel ratio sensor 1 (bank 2)

L

11. Heated oxygen sensor 2 (bank 2)

Removal and Installation

NBS002UL

M

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-18, "INTAKE MANIFOLD COLLECTOR" .

2. Remove air cleaner case and air duct. Refer to EM-16, "AIR CLEANER AND AIR DUCT" .

3. Remove undercover with power tool.

4. Drain engine coolant. Refer to CO-10, "Changing Engine Coolant" .

CAUTION: ● Perform this step when engine is cold. ● Do not spill engine coolant on drive belts.

Revision: 2006 August

K

Gasket

EM-25

2006 G35 Coupe

EXHAUST MANIFOLD AND THREE WAY CATALYST 5.

Disconnect harness connector and remove heated oxygen sensor 2 on both banks using heated oxygen sensor wrench (SST).

CAUTION: ● Be careful not to damage heated oxygen sensor 2. ● Discard any heated oxygen sensor 2 which has been dropped onto a hard surface such as a concrete floor.

Replace with a new sensor.

PBIC2298E

6.

7.

8.

Remove exhaust mounting bracket between three way catalyst (right and left bank) and transmission.

Refer to EX-3, "EXHAUST SYSTEM" .

Remove three way catalyst.

Disconnect harness connector and remove air fuel ratio sensor 1 on both banks using heated oxygen sensor wrench (SST).

CAUTION: ● Be careful not to damage heated oxygen sensor 1. ● Discard any heated oxygen sensor 1 which has been dropped onto a hard surface such as a concrete floor.

Replace with a new sensor.

PBIC2299E

9.

Remove water pipe and heater pipe on both right and left side. Refer to CO-30, "WATER OUTLET AND WATER PIPING" .

10. Remove exhaust manifold cover.

11. Loosen nuts in 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.

PBIC2042E

12. Remove exhaust manifold gaskets.

Revision: 2006 August

EM-26

2006 G35 Coupe

EXHAUST MANIFOLD AND THREE WAY CATALYST INSPECTION AFTER REMOVAL Surface Distortion ●

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

Limit

●

A

EM

: 0.3 mm (0.012 in)

If it exceeds the limit, replace exhaust manifold.

C

D PBIC1096E

INSTALLATION

E

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

Exhaust Manifold Gasket ●

●

●

F

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 (C) in thick side of port connecting part above center level line of port.

A

: Right bank

B

: Left bank

G

H

: Engine front PBIC4925E

I

Exhaust Manifold ●

J

If stud bolts were removed, install them and tighten to the specified torque below. : 14.7 N·m (1.5 kg-m, 11 ft-lb)

●

K

Install exhaust manifold in numerical order as shown in the figure.

NOTE: Tighten nuts No. 1 and No. 2 in two steps. The numerical order No. 7 and No. 8 shows second step.

L

M

PBIC2042E

Revision: 2006 August

EM-27

2006 G35 Coupe

EXHAUST MANIFOLD AND THREE WAY CATALYST Air Fuel Ratio Sensor and Heated Oxygen Sensor CAUTION: ● Before installing a new air fuel ratio sensor or a new heated oxygen sensor, clean exhaust system threads using heated oxygen sensor thread cleaner tool (commercial service tool: J-43897-18 or J43897-12) and apply anti-seize lubricant (commercial service tool). ● Do not over torque the air fuel ratio sensor and the heated oxygen sensor. Doing so may cause damage to the air fuel ratio sensor or the heated oxygen sensor, resulting in the “MIL” coming on.

Revision: 2006 August

EM-28

2006 G35 Coupe

OIL PAN AND OIL STRAINER OIL PAN AND OIL STRAINER Components

PFP:11110

A NBS000K0

EM

C

D

E

F

G

H

I

J

K

L

PBIC4922E

1.

Oil pan gasket

4.

Oil pan gasket

5.

O-ring

6.

Connector bolt

7.

Oil filter

8.

Oil cooler

9.

Relief valve

11. Bracket

12.

Washer (M/T models)

14. Oil strainer

15. Drain plug

16. Drain plug washer

17. Oil pan (lower)

18. Baffle plate

19. Rear plate cover

20. Crankshaft position sensor (POS)

21. O-ring

10. Oil pressure switch 13.

Oil temperature sensor (M/T models)

2.

Oil pan (upper)

3.

O-ring

22. Rear cover plate

Removal and Installation

NBS000K1

REMOVAL WARNING: To avoid the danger of being scalded, do not drain the engine oil when the engine is hot.

Revision: 2006 August

EM-29

2006 G35 Coupe

M

OIL PAN AND OIL STRAINER NOTE: To remove oil pan (lower) only, take step 4 and step 5, then step 20. Step 1 to 3 and 6 to 19 are unnecessary.

1. Remove hood assembly. Refer to BL-13, "HOOD" .

2. Remove engine cover with power tool. Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .

3. Remove air duct. Refer to EM-16, "AIR CLEANER AND AIR DUCT" .

4. Remove undercover with power tool.

5. Drain engine oil. Refer to LU-9, "Changing Engine Oil" .

CAUTION: ● Perform this step when engine is cold. ● Do not spill engine oil on drive belts.

6. Drain engine coolant. Refer to CO-10, "Changing Engine Coolant" .

CAUTION: ● Perform this step when engine is cold. ● Do not spill engine coolant on drive belts.

7. Install engine slinger to sling engine assembly for positioning. Refer to EM-131, "ENGINE ASSEMBLY" .

8. Remove front suspension member. Refer to FSU-19, "FRONT SUSPENSION MEMBER" .

9. Remove drive belts. Refer to EM-14, "DRIVE BELTS" .

10. Remove alternator. Refer to SC-21, "CHARGING SYSTEM" .

11. Remove starter motor. Refer to SC-10, "STARTING SYSTEM" .

12. Remove idler pulley and bracket assembly. Refer to EM-59, "TIMING CHAIN" .

13. Disconnect oil cooler water hoses, and remove oil cooler water pipe mounting bolt. Refer to LU-11, "OIL COOLER" .

14. Disconnect A/T fluid cooler hoses, and remove A/T fluid cooler tube (A/T models). Refer to AT-253, "TRANSMISSION ASSEMBLY" .

15. 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.

16. Remove oil filter, as necessary. Refer to LU-10, "OIL FILTER" .

17. Remove oil cooler, as necessary. Refer to LU-11, "OIL COOLER" .

18. Remove oil pressure switch, as necessary. Refer to LU-8, "OIL PRESSURE CHECK" .

19. Remove oil temperature sensor, as necessary. (M/T models) 20. Remove oil pan (lower) as follows: a. Loosen bolts in reverse order as shown in the figure to remove.

PBIC0782E

Revision: 2006 August

EM-30

2006 G35 Coupe

OIL PAN AND OIL STRAINER b.

c.

Insert seal cutter (SST) between oil pan (upper) and oil pan (lower).

CAUTION: ● Be careful not to damage the mating surface. ● Do not insert screwdriver, this will damage the mating surface.

Slide seal cutter by tapping on the side of tool with hammer.

Remove oil pan (lower).

A

EM

C SEM365E

D

21. Remove baffle plate.

22. Remove oil strainer.

23. Remove transmission joint bolts which pierce oil pan (upper). Refer to MT-18, "TRANSMISSION ASSEMBLY" (M/T models) or AT-253, "TRANSMISSION ASSEMBLY" (A/T models).

24. Remove rear plate cover.

25. Loosen mounting bolts with power tool in reverse order as shown in the figure to remove oil pan (upper). ● Insert seal cutter [SST: KV10111100 (J37228)] between oil pan (upper) and cylinder block. Slide seal cutter by tapping on the side of tool with hammer. Remove oil pan (upper).

CAUTION: ● Be careful not to damage the mating surface. ● Do not insert screwdriver, this will damage the mating surfaces.

PBIC0783E

E

F

G

H

I

26. Remove O-rings from bottom of cylinder block and oil pump.

J

K

L PBIC1144E

M

27. Remove oil pan gaskets.

PBIC1145E

INSPECTION AFTER REMOVAL Clean oil strainer if any object attached.

INSTALLATION 1.

Install oil pan (upper) as follows:

Revision: 2006 August

EM-31

2006 G35 Coupe

OIL PAN AND OIL STRAINER a.

Use scraper to remove old liquid gasket from mating surfaces. ● Also remove the old liquid gasket from mating surface of cylinder block. ● Remove old liquid gasket from the bolt holes and threads.

CAUTION: Do not scratch or damage the mating surfaces when cleaning off old liquid gasket.

MEM108A

b.

Apply liquid gasket to oil pan gaskets as shown in the figure.

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-47, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .

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

c.

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

PBIC1144E

d.

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 GI-47, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .

CAUTION: ● For bolt holes with marks (five 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”.

Revision: 2006 August

EM-32

PBIC2300E

2006 G35 Coupe

OIL PAN AND OIL STRAINER ●

Attaching should be done within 5 minutes after coating.

A

e.

Install the oil pan (upper). ● 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)

EM

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

C

D PBIC0783E

f.

2.

3. a.

Tighten transmission joint bolts. Refer to MT-18, "TRANSMISSION ASSEMBLY" (M/T models) or AT-253, "TRANSMISSION ASSEMBLY" (A/T models).

Install oil strainer to oil pump.

Install oil pan (lower) as follows: Use scraper to remove old liquid gasket from mating surfaces. ● Also remove old liquid gasket from mating surface of oil pan (upper). ● Remove old liquid gasket from the bolt holes and thread.

CAUTION: Do not scratch or damage the mating surfaces when cleaning off old liquid gasket.

E

F

G

H

I SEM958F

b.

J

Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( — )] to the oil pan (lower) as shown in the figure.

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-47, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .

CAUTION: Attaching should be done within 5 minutes after coating.

K

L

M

PBIC2657E

c.

Install oil pan (lower).

Revision: 2006 August

EM-33

2006 G35 Coupe

OIL PAN AND OIL STRAINER ●

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

PBIC0782E

4.

5.

Install oil pan drain plug. ● Refer to the figure of components of former page for installation direction of drain plug washer. Refer to EM-29, "Components" .

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 adjust 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: 2006 August

EM-34

2006 G35 Coupe

IGNITION COIL IGNITION COIL Components

PFP:22448

A NBS000K2

EM

C

D

E

F

G PBIC4751E

1.

Ignition coil

2.

Spark plug

Removal and Installation

NBS000K3

H

REMOVAL 1.

2.

3.

4.

5.

Remove engine cover with power tool. Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .

Remove air cleaner case and air duct (for ignition coil of left bank side). Refer to EM-16, "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.

I

J

K

INSTALLATION Install in the reverse order of removal.

L

M

Revision: 2006 August

EM-35

2006 G35 Coupe

SPARK PLUG (PLATINUM-TIPPED TYPE) SPARK PLUG (PLATINUM-TIPPED TYPE) Components

PFP:22401 NBS000K4

PBIC4751E

1.

Ignition coil

2.

Spark plug

Removal and Installation

NBS000K5

REMOVAL 1.

2.

3.

Remove engine cover with power tool. Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .

Remove ignition coil. Refer to EM-35, "IGNITION COIL" .

Remove spark plug using spark plug wrench (commercial service tool).

SEM294A

INSPECTION AFTER REMOVAL Use standard type spark plug for normal condition.

Hot type spark plug is suitable when fouling occurs with standard type spark plug under conditions such as: ● Frequent engine starts ● Low ambient temperatures Cold type spark plug is suitable when spark plug knock occurs with 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: 2006 August

: 1.1 mm (0.043 in)

EM-36

2006 G35 Coupe

SPARK PLUG (PLATINUM-TIPPED TYPE) CAUTION: ● Do not drop or shock spark plug. ● Do not use wire brush for cleaning. ● If plug tip is covered with carbon, spark plug cleaner may be used.

A

EM

Cleaner air pressure: Less than 588 kPa (6 kg/cm2 , 85 psi) Cleaning time: Less than 20 seconds

C

D SMA773C

●

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

E

F

G

SMA806CA

H

INSTALLATION Install in the reverse order of removal.

I

J

K

L

M

Revision: 2006 August

EM-37

2006 G35 Coupe

FUEL INJECTOR AND FUEL TUBE FUEL INJECTOR AND FUEL TUBE Components

PFP:16600 NBS000K6

PBIC2044E

1.

Fuel damper

2.

O-ring

3.

Fuel sub-tube

4.

EVAP hose

5.

Intake manifold collector (lower) rear right side

6.

Fuel feed hose (with damper)

7.

Fuel tube

8.

Spacer

9.

Clip

10. O-ring (blue)

11. Fuel injector

12. O-ring (brown)

13. Hose clamp

14. Bracket

15. Quick connector cap

16. Centralized under-floor piping

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

Removal and Installation

NBS000K7

REMOVAL WARNING: ● Put a “CAUTION: FLAMMABLE” sign in the workshop. ● Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher. ● Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area. ● To avoid the danger of being scalded, do not drain engine coolant when engine is hot.

1. Remove engine cover with power tool. Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .

2. Release fuel pressure. Refer to EC-81, "FUEL PRESSURE RELEASE" .

Revision: 2006 August

EM-38

2006 G35 Coupe

FUEL INJECTOR AND FUEL TUBE 3.

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 fuel damper and fuel feed hose.

A

EM

C KBIA1293E

D

4. a. b.

When separating fuel feed hose (with damper) and centralized under-floor piping connection, disconnect quick connector as follows: Remove quick connector cap from quick connector connection on right member side.

Disconnect fuel feed hose (with damper) from bracket hose clamp.

E

F

G

PBIC2083E

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.

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.

H

I

J

ii.

Revision: 2006 August

EM-39

2006 G35 Coupe

K

L

M

FUEL INJECTOR AND FUEL TUBE ●

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

PBIC1899E

5.

6.

7.

Remove intake manifold collectors (upper and lower). Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .

Disconnect harness connector from fuel injector.

Loosen mounting bolts in reverse order as shown 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.

KBIA1296E

8.

9. a. b.

Remove spacers on intake manifold.

Remove fuel injector from fuel tube as follows: 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.

SBIA0364E

10. Remove fuel sub-tube and fuel damper.

INSTALLATION 1.

Install fuel damper and fuel sub-tube.

When handling O-rings, be careful of the following caution.

CAUTION: ● Handle O-ring with bare hands. Do not wear gloves.

●

Revision: 2006 August

EM-40

2006 G35 Coupe

FUEL INJECTOR AND FUEL TUBE Lubricate O-ring with new engine oil.

A 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 EM quickly into fuel tube. ● Insert O-ring straight into fuel tube. Do not decenter or twist it.

C ● 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.

D Note the following, and install O-rings to fuel injector.

CAUTION: ● Upper and lower O-rings are different. Be careful not to confuse them.

E Fuel tube side : Blue Nozzle side : Brown F ● Handle O-ring with bare hands. Do not wear gloves. ● Lubricate O-ring with new engine oil. ● Do not clean O-ring with solvent.

G ● 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 H quickly into fuel tube. ● Insert O-ring straight into fuel tube. Do not decenter or twist it.

Install fuel injector to fuel tube as follows: I Insert clip into clip mounting groove on fuel injector. ● Insert clip so that lug “A” of fuel injector matches notch “A” of clip.

J CAUTION: ● Do not reuse clip. Replace it with a new one. ● Be careful to keep clip from interfering with O-ring. If K interference occurs, replace O-ring.

Insert fuel injector into fuel tube with clip attached.

L ● 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.

M ● 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. ● ●

2.

3. a.

b.

c.

PBIC1931E

4.

5.

Install spacers on intake manifold.

Install fuel tube and fuel injector assembly to intake manifold.

CAUTION: Be careful not to let tip of injector nozzle come in contact with other parts.

Revision: 2006 August

EM-41

2006 G35 Coupe

FUEL INJECTOR AND FUEL TUBE ●

Tighten mounting bolts in two steps in numerical order as shown in the figure.

1st step : 9.3 - 10.8 N·m (0.95 - 1.1 kg-m, 6.9 - 7.9 ft-lb) 2nd step : 20.6 - 26.5 N·m (2.1 - 2.7 kg-m, 16 - 19 ft-lb)

KBIA1296E

6.

7.

8.

9.

Connect fuel injector harness connector.

Install intake manifold collectors (upper and lower). Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .

Install fuel sub-tube on rear end of intake manifold collector (lower).

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 (with damper) and centralized under-floor piping connection as follows: a. Check the connection for damage and foreign materials. b. Align the connector with 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.

KBIA1297E

d.

e.

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.

Secure fuel feed hose (with damper) to clamp.

KBIA1298E

11. Install in the reverse order of removal after this step.

INSPECTION AFTER INSTALLATION Check on Fuel Leakage 1.

Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.

2. Start engine. With engine speed increased, check again for fuel leakage at connection points.

NOTE: Use mirrors for checking at points out of clear sight.

Revision: 2006 August

EM-42

2006 G35 Coupe

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

A

EM

C

D

E

F

G

H

I

J

K

L

M

Revision: 2006 August

EM-43

2006 G35 Coupe

ROCKER COVER ROCKER COVER Components

PFP:13264 NBS000K8

PBIC2303E

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)

Removal and Installation

NBS000K9

REMOVAL 1.

2.

3.

4.

Remove intake manifold collectors (upper and lower) with power tool. Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .

Separate engine harness removing their brackets from rocker covers.

Remove ignition coil. Refer to EM-35, "IGNITION COIL" .

Remove PCV hoses from rocker covers.

Revision: 2006 August

EM-44

2006 G35 Coupe

ROCKER COVER 5.

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

A

EM

C

D

E

F

G KBIA0985E

6.

Use scraper to remove all traces of liquid gasket from cylinder head and camshaft bracket (No. 1).

INSTALLATION 1.

Apply liquid gasket of 3.0 mm (0.12 in) diameter to position shown in the figure [both edges of camshaft bracket (No. 1)] (on both banks).

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-47, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . ● First, apply it to engine longitudinal direction [5.0 mm (0.197 in) + 5.0 mm (0.197 in) side in figure].

H

I

J

K PBIC0786E

2.

L

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

M

Revision: 2006 August

EM-45

2006 G35 Coupe

ROCKER COVER 3.

Tighten bolts in two steps separately in numerical order as shown in the figure.

1st step : 0.96 - 2.96 N·m (0.10 - 0.30 kg-m, 9 - 26 in-lb) 2nd step : 7.33 - 9.33 N·m (0.75 - 0.95 kg-m, 65 - 82 in-lb)

KBIA0985E

4.

5.

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-44, "Components" .

Install in the reverse order of removal after this step.

Revision: 2006 August

EM-46

2006 G35 Coupe

FRONT TIMING CHAIN CASE FRONT TIMING CHAIN CASE Removal and Installation

PFP:13599

A NBS002UM

NOTE: ● This section describes removal/installation procedure of front timing chain case and timing chain (primary) EM 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 (pri- C mary) related parts, and rear timing chain case in this order, and install in the reverse order of removal.

Refer to EM-59, "TIMING CHAIN" . ● Refer to EM-59, "TIMING CHAIN" for component parts location.

D

REMOVAL 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Remove engine cover with power tool. Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .

Remove undercover with power tool.

Release the fuel pressure. Refer to EC-81, "FUEL PRESSURE RELEASE" .

Disconnect the battery cable from the negative terminal.

Drain engine oil. Refer to LU-9, "Changing Engine Oil" .

CAUTION: ● Perform this step when engine is cold. ● Do not spill engine oil on drive belts.

Drain engine coolant from radiator. Refer to CO-10, "Changing Engine Coolant" .

CAUTION: ● Perform this step when engine is cold. ● Do not spill engine coolant on drive belts.

Separate engine harnesses removing their brackets from front timing chain case.

Remove radiator cooling fan assembly. Refer to CO-21, "COOLING FAN" .

Remove drive belts. Refer to EM-14, "DRIVE BELTS" .

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-21, "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. (A/T models) ● Loosen bolts in reverse order as shown in the figure. ● Use seal cutter [SST: KV10111100 (J37228)] 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 left and right valve timing control covers (including magnet retarder and cover) with the following procedure. (M/T models)

Revision: 2006 August

EM-47

2006 G35 Coupe

E

F

G

H

I

J

K

L

M

FRONT TIMING CHAIN CASE a.

Loosen mounting bolts in reverse order as shown in the figure.

PBIC3560E

b.

Shaft is engaged with intake side camshaft sprocket center hole on inside. Pull straight out so as not to tilt until the joint is disengaged. ● The mating surface of magnet retarder may be fitted with the exhaust side camshaft sprocket via the engine oil. Open valve timing control cover carefully. ● If the mating surface of magnet retarder is fitted with the camshaft sprocket, open the cover within the range that the load is not applied to the harness. And then, remove it so as to prevent magnet retarder from dropping.

PBIC3561E CAUTION: ● Be careful not to damage magnet retarder. ● When carrying valve timing control cover, face the magnet retarder side up to prevent the cover from falling from magnet retarder. ● Do not remove magnet retarder from valve timing control cover. (Disassembly prohibited parts) 16. Remove collared O-ring from front timing chain case (left and right side).

PBIC2045E

17. Remove rocker covers (right and left banks) with power tool. Refer to EM-44, "ROCKER COVER" .

NOTE: When only timing chain (primary) is removed, rocker cover does not need to be removed.

18. Obtain No. 1 cylinder at TDC of its compression stroke 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.

KBIA1717J

Revision: 2006 August

EM-48

2006 G35 Coupe

FRONT TIMING CHAIN CASE b.

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

NOTE: When only timing chain (primary) is removed, rocker cover does not need to be removed. To make sure 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-70, "INSTALLATION" (M/T models) or EM-89, "INSTALLATION" (A/ T models).

A

EM

C SEM418G

D

19. Remove crankshaft pulley as follows: a. Remove starter motor and set ring gear stopper (SST) as shown in the figure. Refer to SC-10, "STARTING SYSTEM" .

E

F

G

PBIC1098E

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.

H

I

J

K PBIC1103E

c.

L

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.

M

EMQ0477D

20. Remove oil pan (lower). Refer to EM-29, "OIL PAN AND OIL STRAINER" .

Revision: 2006 August

EM-49

2006 G35 Coupe

FRONT TIMING CHAIN CASE 21. Loosen two mounting bolts in front of oil pan (upper) in reverse order as shown in the figure.

PBIC1116E

22. Remove front timing chain case as follows: a. Loosen mounting bolts in reverse order as shown in the figure.

NOTE: Figure shows A/T models.

KBIA1303E

b. c.

Insert suitable tool into the notch at the top of the front timing chain case as shown (1).

Pry off case by moving tool as shown (2). ● Use seal cutter [SST: KV10111100 (J37228)] or equivalent tool to cut liquid gasket for removal.

CAUTION: ● Do not use screwdriver or something similar. ● After removal, handle front timing chain case carefully so it does not tilt, cant, or warp under a load.

SEM156F

23. Remove O-rings from rear timing chain case.

NOTE: Figure shows A/T models.

PBIC2548E

24. Remove oil pan gasket. Refer to EM-29, "OIL PAN AND OIL STRAINER" .

25. Remove water pump cover and chain tensioner cover from front timing chain case. ● Use seal cutter [SST: KV10111100 (J37228)] or equivalent tool to cut liquid gasket for removal.

Revision: 2006 August

EM-50

2006 G35 Coupe

FRONT TIMING CHAIN CASE 26. Remove front oil seal from front timing chain case using suitable tool. â—? Use screwdriver for removal.

CAUTION: Be careful not to damage front timing chain case.

A

EM

C EMQ0032D

D

27. Remove timing chain (primary) and related parts. Refer to EM-59, "TIMING CHAIN" .

28. Use 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.

E

F

G SEM737G

H â—?

Remove old liquid gasket from bolt hole and thread.

I

J

K PBIC2084E

29. Use scraper to remove all traces of liquid gasket from water pump cover, chain tensioner cover and intake valve timing control covers.

L

M

SEM926E

INSTALLATION 1.

Install timing chain (primary) and related parts. Refer to EM-59, "TIMING CHAIN" .

Revision: 2006 August

EM-51

2006 G35 Coupe

FRONT TIMING CHAIN CASE 2.

Hammer dowel pins (right 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 the front timing chain case. Apply new engine oil to the oil seal lip, dust seal lip and outer round of oil seal. ● Install it so that each seal lip is oriented as shown in the figure.

SEM715A

●

●

Using suitable drift [outer diameter: 60 mm (2.36 in)], 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

4.

Install water pump cover and chain tensioner cover to front timing chain case. ● Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( — )] to front timing chain case as shown in the figure.

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-47, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .

SEM744GA

5.

Install front timing chain case as follows:

Revision: 2006 August

EM-52

2006 G35 Coupe

FRONT TIMING CHAIN CASE a.

Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( — )] to front timing chain case back side as shown in the figure.

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-47, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .

NOTE: Figure shows A/T models.

A

EM

C

D

E

F

G PBIC2658E

b.

Install new oil pan gasket. (front) ● Apply liquid gasket to oil pan gasket (front) as shown in the figure.

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-47, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .

H

I

J

SEM964E

●

K

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

L

M

PBIC1114E

●

Apply liquid gasket to top surface of oil pan (upper) as shown in the figure.

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-47, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .

PBIC1099E

Revision: 2006 August

EM-53

2006 G35 Coupe

FRONT TIMING CHAIN CASE c.

Install new O-rings on rear timing chain case.

NOTE: Figure shows A/T models.

PBIC2548E

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.

Since front timing chain case is offset for difference of bolt holes, tight bolts temporarily with holding front timing chain case from front and top as shown in the figure. iii. Same as the step ii, insert dowel pin with holding front timing chain case from front and top completely.

PBIC1115E

e.

Tighten mounting bolts to the specified torque in numerical order as shown in the figure. ● There are two type of mounting bolts. Refer to the following for locating bolts.

M8 bolts

: 1, 2

: 25.5 - 31.3 N·m (2.6 - 3.2 kg-m, 19 - 23 ft-lb) M6 bolts : Except the above : 11.7 - 13.7 N·m (1.2 - 1.4 kg-m, 9 - 10 ft-lb)

f.

KBIA1303E NOTE: Figure shows A/T models.

After all bolts tightened, retighten them to the specified torque in numerical order as shown in the figure.

Revision: 2006 August

EM-54

2006 G35 Coupe

FRONT TIMING CHAIN CASE 6.

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

A

: 15.7 - 18.6 N¡m (1.6 - 1.9 kg-m, 12 - 13 ft-lb) EM

C PBIC1116E

7.

8. a. b.

D

Install oil pan (lower). Refer to EM-29, "OIL PAN AND OIL STRAINER" .

Install right and left intake valve timing control covers as follows. (A/T models) Install seal rings in shaft grooves.

Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( — )] to intake valve timing control covers as shown in the figure.

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-47, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .

E

F

G

H SBIA0492E

c.

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

I

J

K

PBIC2045E

d. e.

Being careful not to move seal ring from the installation groove, align dowel pins on front timing chain case with the holes to install intake valve timing control covers.

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

PBIC0918E

9.

Install right and left valve timing control covers as follows. (M/T models)

Revision: 2006 August

EM-55

2006 G35 Coupe

L

M

FRONT TIMING CHAIN CASE a.

Install new seal rings in shaft grooves.

PBIC3571E

b.

Install magnet retarder aligning the dowel pins of the back with the cover side dowel pin holes securely. Simultaneously insert the harness into the installation groove securely.

NOTE: Figure shows the structure of the parts. Therefore, magnet retarder is being removed from the cover in this figure. But, if magnet retarder is in the correct position, omit step “b” and perform step “c”.

PBIC3572E

c.

To check the joint between dowel pins and dowel pin holes, check the looseness in the axle direction by pushing the mating surface of magnet retarder at several places and the circumferential looseness (between dowel pins and dowel pin holes) by twisting in the circumferential direction.

CAUTION: Always perform this procedure when removing because the gap between dowel pins and dowel pin holes may not be caused on purpose.

PBIC3573E

d.

Install valve timing control cover to front timing chain case.

CAUTION: ● Do not face the magnet retarder side down to prevent magnet retarder from dropping. ● Check the mating surface of magnet retarder and the drum of exhaust side camshaft sprocket for foreign materials. ● Align the center of both shaft holes of the shaft and the intake side camshaft sprocket, and then insert them. ● Be careful not to drop the seal ring from the shaft groove.

PBIC3561E ● When setting the valve timing control cover in position by hand, if valve timing control cover is not contacting with the front timing chain case, the dowel pin of magnet retarder may not be aligned with the dowel pin holes of cover. In this case, return to step “b”.

Revision: 2006 August

EM-56

2006 G35 Coupe

FRONT TIMING CHAIN CASE e.

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

CAUTION: Completely tighten the mounting bolts with the seat surface of valve timing control cover contacting with front timing chain case.

A

EM

C PBIC3560E

D

10. Install crankshaft pulley as follows: a. Fix crankshaft using ring gear stopper [SST: KV10117700 (J44716)]. b. Install crankshaft pulley, taking care not to damage front oil seal. ● When press-fitting crankshaft pulley with plastic hammer, tap on its center portion (not circumference). c. Tighten crankshaft pulley bolt.

E

F

: 44.1 N·m (4.5 kg-m, 33 ft-lb) d.

Place a matching mark (A) on crankshaft pulley (1) aligning with the matching (B) of crankshaft pulley bolt (2). Tighten the bolt 90 degrees (one marks).

G

H

I PBIC4627J

J

11. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.

12. Install in the reverse order of removal after this step.

INSPECTION AFTER INSTALLATION Inspection for Leaks The following are procedures for checking fluid leak, lubricates leak and exhaust gases leak. ● Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to MA-10, "RECOMMENDED FLUIDS AND LUBRICANTS" . ● Run engine to check for unusual noise and vibration.

NOTE: If hydraulic pressure inside timing 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. ● Warm up engine thoroughly to make sure there is no leakage of exhaust gases, or any oil/fluids including engine oil and engine coolant. ● Bleed air from lines and hoses of applicable lines, such as in cooling system. ● After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.

Revision: 2006 August

EM-57

2006 G35 Coupe

K

L

M

FRONT TIMING CHAIN CASE Summary of the inspection items: Items

Before starting engine

Engine running

After engine stopped

Engine coolant

Level

Leakage

Level

Engine oil

Level

Leakage

Level

Other oils and fluid*

Level

Leakage

Level

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

Revision: 2006 August

EM-58

2006 G35 Coupe

TIMING CHAIN TIMING CHAIN Components (M/T Models)

PFP:13028

A NBS002UN

EM

C

D

E

F

G

H

I

J

K

L

M

PBIC4208E

Revision: 2006 August

EM-59

2006 G35 Coupe

TIMING CHAIN

â—?

1.

O-ring

2.

Timing chain tensioner (secondary)

3.

Internal chain guide

4.

Timing chain tensioner (secondary)

5.

Camshaft sprocket (EXH)

6.

Timing chain (secondary)

7.

Timing chain (primary)

8.

Camshaft sprocket (INT)

9.

Slack guide

10. Timing chain tensioner (primary)

11. Crankshaft sprocket

12. Camshaft sprocket (INT)

13. Timing chain (secondary)

14. Camshaft sprocket (EXH)

15. O-ring

16. Rear timing chain case

17. Tension guide

18. Water drain plug (front)

19. O-ring

20. O-ring

21. Bracket

22. Bracket

23. Clip

24. Bracket

25. Chain tensioner cover

26. Gasket

27. Seal ring

28. Valve timing control cover

29. Idler pulley

30. Idler pulley bracket

31. Idler pulley

32. Crankshaft pulley

33. Front oil seal

34. Water pump cover

35. Crankshaft pulley bolt

36. Valve timing control cover

37. Seal ring

38. Gasket

39. Idler pulley

40. A/C compressor bracket

41. Front timing chain case

A.

B.

Refer to EM-70

Refer to ATC-137

Refer to GI-10, "Components" for symbol marks in the figure.

Revision: 2006 August

EM-60

2006 G35 Coupe

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