2008 infiniti ex35 service repair manual by 1639701yu

Edition: November 2007 Publication No. SM8E-1J50U0

QUICK REFERENCE INDEX A GENERAL INFORMATION B ENGINE

C HYBRID

D TRANSMISSION & DRIVELINE

E SUSPENSION

F BRAKES

G STEERING H RESTRAINTS

VENTILATION, HEATER & AIR CONDITIONER

J BODY INTERIOR

K BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY

L DRIVER CONTROLS

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.

M ELECTRICAL & POWER CONTROL

N DRIVER INFORMATION & MULTIMEDIA

O CRUISE CONTROL P MAINTENANCE

GI EM LU CO EC FL EX STR ACC HBC HBB HBR CL TM DLN FAX RAX FSU RSU SCS WT BR PB BRC ST STC SB SBC SR SRC VTL HA HAC INT IP SE ADP DLK SEC GW PWC RF EXT BRM MIR EXL INL WW DEF HRN PWO BCS LAN PCS CHG PG MWI WCS SN AV CCS MA

General Information Engine Mechanical Engine Lubrication System Engine Cooling System Engine Control System Fuel System Exhaust System Starting System Accelerator Control System Hybrid Control System Hybrid Battery System Hybrid Brake System Clutch Transaxle & Transmission Driveline Front Axle Rear Axle Front Suspension Rear Suspension Suspension Control System Road Wheels & Tires Brake System Parking Brake System Brake Control System Steering System Steering Control System Seat Belt Seat Belt Control System SRS Airbag SRS Airbag Control System Ventilation System Heater & Air Conditioning System Heater & Air Conditioning Control System Interior Instrument Panel Seat Automatic Drive Positioner Door & Lock Security Control System Glass & Window System Power Window Control System Roof Exterior Body Repair Mirrors Exterior Lighting System Interior Lighting System Wiper & Washer Defogger Horn Power Outlet Body Control System LAN System Power Control System Charging System Power Supply, Ground & Circuit Elements Meter, Warning Lamp & Indicator Warning Chime System Sonar System Audio, Visual & Navigation System Cruise Control System Maintenance

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

This manual contains maintenance and repair procedure for the 2008 INFINITI EX35. 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 vehicleâ&#x20AC;&#x2122;s safety will be jeopardized by the service method selected.

QUICK REFERENCE CHART EX35 QUICK REFERENCE CHART EX35 ENGINE TUNE-UP DATA (VQ35HR) Engine model

PFP:00000 ELS0003W

VQ35HR

Firing order

1-2-3-4-5-6

Idle speed A/T (In “N” position)

rpm

650 ± 50 16° ± 5° (without 4WAS) 11° ± 5° (with 4WAS)

Ignition timing (BTDC at idle speed) CO% at idle

0.7 - 9.9 % and engine runs smoothly

Tensions of drive belts

Auto adjustment by auto tensioner kPa (kg/cm2 , psi)

Radiator cap relief pressure Standard

122.3 - 151.7 (1.2 - 1.5, 18 - 22)

Limit

107 (1.1, 16) 2

Cooling system leakage testing pressure

kPa (kg/cm , psi)

Compression pressure

kPa (kg/cm2 , psi)/rpm

157 (1.6, 23)

Standard

1,275 (13.0, 185)/300

Minimum

981 (10.0, 142)/300

Differential limit between cylinders Make Spark plug (Iridium-tipped type)

2008

DENSO

Standard type Gap (Nominal)

98 (1.0, 14)/300

FXE22HR11 mm (in)

1.1 (0.043)

QUICK REFERENCE CHART EX35

2008

FRONT WHEEL ALIGNMENT

ELS0003X

2WD Item

Camber Degree minute (Decimal degree)

Standard Minimum

–0° 40′ (–0.66°)

Nominal

0° 05′ (0.08°)

Maximum

0° 50′ (0.83°)

Left and right difference

Caster Degree minute (Decimal degree)

Minimum

3° 30′ (3.50°)

Nominal

4° 15′ (4.25°)

Maximum

5° 00′ (5.00°)

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

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

0° 33′ (0.55°) or less

0° 39′ (0.65°) or less

Minimum

6° 05′ (6.09°)

Nominal

6° 50′ (6.83°)

Maximum

7° 35′ (7.58°)

Minimum

0 mm (0 in)

Nominal

In 1 mm (0.04 in)

Maximum

In 2 mm (0.08 in)

Minimum

0° 00 (0.00°)

Nominal

In 0° 02′ 24″ (0.04°)

Maximum

In 0° 04′ 48″ (0.08°)

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

AWD

Camber Degree minute (Decimal degree)

Minimum

–1° 05′ (–1.08°)

Nominal

–0° 20′ (–0.33°)

Maximum Left and right difference

Caster Degree minute (Decimal degree)

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

0° 33′ (0.55°) or less

Minimum

3° 25′ (3.42°)

Nominal

4° 10′ (4.17°)

Maximum Left and right difference

Kingpin inclination Degree minute (Decimal degree)

0° 25′ (0.42°)

4° 55′ (4.91°) 0° 39′ (0.65°) or less

Minimum

6° 35′ (6.58°)

Nominal

7° 20′ (7.33°)

Maximum

8° 05′ (8.08°)

Minimum

0 mm (0 in)

Nominal

In 1 mm (0.04 in)

Maximum

In 2 mm (0.08 in)

Minimum

0° 00′ (0.00°)

Nominal

In 0° 02′ 24″ (0.04°)

Maximum

In 0° 04′ 48″(0.08°)

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

QUICK REFERENCE CHART EX35

2008

REAR WHEEL ALIGNMENT

ELS0003Y

Item

Standard

Camber Degree minute (Decimal degree)

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

Minimum

–1° 05′ (–1.08°)

Nominal

–0° 35′ (–0.58°)

Maximum

–0° 05′ (–0.09°)

Minimum

0 mm (0 in)

Nominal

In 2.9 mm (0.114 in)

Maximum

In 5.8 mm (0.228 in)

Minimum

0° 00′ (0.00°)

Nominal

In 0° 07′ (0.12°)

Maximum

In 0° 14′ (0.23°)

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

BRAKE PEDAL Unit: mm (in) Item

Standard

Brake pedal height

171.5 – 181.5 (6.75 – 7.15)

Clearance between the stop lamp switch and ASCD brake switch threaded end and the stopper rubber

0.74 – 1.96 (0.0291 – 0.0772)

Brake pedal play

3.0 – 11.0 (0.118 – 0.433)

Depressed brake pedal height [Depressing 490 N (50 kg, 110 lb) while turning the engine ON]

114.0 (4.49) or more

FRONT DISK BRAKE Unit: mm (in) Item Brake pad

Wear thickness

Disc rotor

Wear thickness

Limit 2.0 (0.079) 26.0 (1.024)

Thickness variation (measured at 8 positions)

0.015 (0.0006)

Runout (with it attached to the vehicle)

0.035 (0.0014)

REAR DISK BRAKE Unit: mm (in) Item

Limit

Brake pad

Wear thickness

2.0 (0.079)

Disc rotor

Wear thickness

14.0 (0.551)

Thickness variation (measured at 8 positions)

0.015 (0.0006)

Runout (with it attached to the vehicle)

0.055 (0.0022)

REFILL CAPACITIES UNIT Fuel tank Engine Coolant ( With reservoir tank ) at MAX level

ELS00040

Liter

US measure

Applox. 76

20 gal

8.6

9-1/8 qt

QUICK REFERENCE CHART EX35 UNIT

2008

Liter

US measure

With oil filter change

4.9

5-1/8 qt

Without oil filter change

4.6

4-7/8 qt

Dry engine (Overhaul)

5.7

6 qt

A/T

10.3

10-7/8 qt

1.25

2-5/8 pt

Front

0.65

1-3/8 pt

Rear

1.4

3 pt

1.0

1-1/8 qt

0.15

5.03 fl oz

0.55 kg

1.21 lb

Drain and refill Engine oil

Transmission Transfer Final drive Power steering system Air conditioning system

Compressor oil Refrigerant

GENERAL INFORMATION

SECTION

GENERAL INFORMATION

CONTENTS HOW TO USE THIS MANUAL ...................... 3

PRECAUTION .............................................. 23

HOW TO USE THIS MANUAL ............................ 3

PRECAUTIONS ................................................. 23

Description ................................................................ 3 Terms ........................................................................ 3 Units .......................................................................... 3 Contents .................................................................... 3 Relation between Illustrations and Descriptions ...... 4 Components .............................................................. 4

Description ...............................................................23 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" .................................................................23 Precautions For Xenon Headlamp Service .............23 Precaution Necessary for Steering Wheel Rotation after Battery Disconnect ...................................23 Precaution for Procedure without Cowl Top Cover....24 General Precautions ................................................24 Three Way Catalyst .................................................26 Multiport Fuel Injection System or Engine Control System .....................................................................26 Hoses ......................................................................26 Engine Oils ..............................................................27 Air Conditioning .......................................................27

HOW TO FOLLOW TROUBLE DIAGNOSES ..... 6 Description ................................................................ 6 How to Follow Test Groups in Trouble Diagnosis...... 6 Key to Symbols Signifying Measurements or Procedures ..................................................................... 7

HOW TO READ WIRING DIAGRAMS ................ 9 Connector Symbols ................................................... 9 Sample/Wiring Diagram -Example- ......................... 10 Description .............................................................. 11

ABBREVIATIONS ..............................................13 Abbreviation List ...................................................... 13

TIGHTENING TORQUE OF STANDARD BOLTS ................................................................14

FUEL ..........................................................................27 FUEL : Unleaded Premium Gasoline Recommended ....................................................................28

LIFTING POINT ................................................. 29 Commercial Service Tools .......................................29 Garage Jack and Safety Stand and 2-Pole Lift .......29 Board-On Lift ...........................................................30

Tightening Torque Table ......................................... 14

RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ................................................15

TOW TRUCK TOWING ..................................... 31

Recommended Chemical Products and Sealants.... 15

Tow Truck Towing ...................................................31 Vehicle Recovery (Freeing a Stuck Vehicle) ...........32

TERMINOLOGY .................................................16

BASIC INSPECTION ................................... 34

SAE J1930 Terminology List ................................... 16

FEATURES OF NEW MODEL ..................... 20

SERVICE INFORMATION FOR ELECTRICAL INCIDENT .......................................................... 34

IDENTIFICATION INFORMATION .....................20 Model Variation ....................................................... 20 Information About Identification or Model Code ...... 20 Dimensions ............................................................. 22 Wheels & Tires ........................................................ 22

Revision: 2007 November

GI-1

Work Flow ................................................................34 Control Units and Electrical Parts ............................34 How to Check Terminal ...........................................35 Intermittent Incident .................................................38 Circuit Inspection .....................................................41

2008 EX35

CONSULT-III/GST CHECKING SYSTEM ......... 46

INSPECTION AND ADJUSTMENT ................... 52

Description .............................................................. 46 CONSULT-III Function and System Application*1... 46 CONSULT-III/GST Data Link Connector (DLC) Circuit ..................................................................... 46 Wiring Diagram - CONSULT-III/GST CHECKING SYSTEM - ............................................................... 48

ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL .................................. 52 ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL : Required Procedure After Battery Disconnection ................... 52

Revision: 2007 November

GI-2

2008 EX35

HOW TO USE THIS MANUAL < HOW TO USE THIS MANUAL >

HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL Description

INFOID:0000000003131598

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

Terms

INFOID:0000000003131599

• 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

INFOID:0000000003131600

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

“Example” Range I

Outer Socket Lock Nut

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

Standard Drive Shaft Installation Bolt

: 44.3 N·m (4.5 kg-m, 33 ft-lb) K

Contents

INFOID:0000000003566430

• 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.

Revision: 2007 November

GI-3

2008 EX35

HOW TO USE THIS MANUAL < HOW TO USE THIS MANUAL >

Relation between Illustrations and Descriptions

INFOID:0000000003131602

The following sample explains the relationship between the part description in an illustration, the part name in the text and the service procedures.

SAIA0519E

Components

INFOID:0000000003131603

â&#x20AC;˘ 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.

Revision: 2007 November

GI-4

2008 EX35

HOW TO USE THIS MANUAL < HOW TO USE THIS MANUAL > GI

SFIA2959E

Union bolt

Copper washer

Brake hose

Cap

Bleed valve

Sliding pin bolt

Piston seal

Piston

Piston boot

10. Cylinder body

11.

Sliding pin

12.

Torque member mounting bolt

13. Washer

14.

Sliding pin boot

15.

Bushing

16. Torque member

17.

Inner shim cover

18.

Inner shim

19. Inner pad

20.

Pad retainer

21.

Pad wear sensor

22. Outer pad

23.

Outer shim

24.

Outer shim cover

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

2: Rubber grease

: Brake fluid

Refer to GI section for additional symbol definitions.

SYMBOLS K

SAIA0749E

Revision: 2007 November

GI-5

2008 EX35

HOW TO FOLLOW TROUBLE DIAGNOSES < HOW TO USE THIS MANUAL >

HOW TO FOLLOW TROUBLE DIAGNOSES Description

INFOID:0000000003131604

NOTICE: Trouble diagnoses indicate work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing. • Before performing trouble diagnoses, read the “Work Flow” in each section. • After repairs, re-check that the problem has been completely eliminated. • Refer to Component Parts and Harness Connector Location for the Systems described in each section for identification/location of components and harness connectors. • When checking circuit continuity, ignition switch should be OFF. • 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. • Before checking voltage at connectors, check battery voltage. • After accomplishing the Diagnosis Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as they were.

How to Follow Test Groups in Trouble Diagnosis

INFOID:0000000003131605

JPAIA0021GB

1. 2. 3. 4.

Test group number and test group title • Test group number and test group title are shown in the upper portion of each test group. Work and diagnosis procedure • Start to diagnose a problem using procedures indicated in enclosed test groups. Questions and results • Questions and required results are indicated in test group. Action • Next action for each test group is indicated based on result of each question.

Revision: 2007 November

GI-6

2008 EX35

HOW TO FOLLOW TROUBLE DIAGNOSES < HOW TO USE THIS MANUAL >

Key to Symbols Signifying Measurements or Procedures

INFOID:0000000003131606

I SAIA1539E

Revision: 2007 November

GI-7

2008 EX35

HOW TO FOLLOW TROUBLE DIAGNOSES < HOW TO USE THIS MANUAL >

SAIA1540E

Revision: 2007 November

GI-8

2008 EX35

HOW TO READ WIRING DIAGRAMS < HOW TO USE THIS MANUAL >

HOW TO READ WIRING DIAGRAMS Connector Symbols

GI INFOID:0000000003131607

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”.

H SAIA0257E

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

SGI363

Revision: 2007 November

GI-9

2008 EX35

HOW TO READ WIRING DIAGRAMS < HOW TO USE THIS MANUAL >

Sample/Wiring Diagram -Example-

INFOID:0000000003131608

â&#x20AC;¢ For detail, refer to following GI-11, "Description".

JCAWA0005GB

Revision: 2007 November

GI-10

2008 EX35

HOW TO READ WIRING DIAGRAMS < HOW TO USE THIS MANUAL >

Description

INFOID:0000000003131609

GI Number

Item

Description

Power supply

• This means the power supply of fusible link or fuse.

Fusible link

• “X” means the fusible link.

Number of fusible link/ fuse

• This means the number of fusible link or fuse location.

Fuse

• “/” means the fuse.

Current rating of fusible link/fuse

• This means the current rating of the fusible link or fuse.

Optional splice

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

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-78, "How To Read Harness Layout", PG-80, "Main Harness".

Splice

• The shaded circle “

Page crossing

• This circuit continues to an adjacent page.

Option abbreviation

• This means the vehicle specifications which layouts the circuit between “

Relay

• This shows an internal representation of the relay.

Option description

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

Switch

• 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.

Circuit (Wiring)

• This means the wiring.

System branch

• This shows that the circuit is branched to other systems.

Shielded line

• The line enclosed by broken line circle shows shield wire.

Component name

• This shows the name of a component.

Ground (GND)

• This shows the ground connection.

Connector

• This means the connector information. • This unit-side is described by the connector symbols.

Connectors

• This means that a transmission line bypasses two connectors or more.

” means the splice.

F ”.

• This shows a code for the color of the wire.

Wire color

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 22

Terminal number

• This means the terminal number of a connector.

SWITCH POSITIONS Switches are shown in wiring diagrams as if the vehicle is in the “normal” condition. A vehicle is in the “normal” condition when:

Revision: 2007 November

GI-11

2008 EX35

HOW TO READ WIRING DIAGRAMS < HOW TO USE THIS MANUAL > • ignition switch is “OFF”, • doors, hood and trunk lid/back door are closed, • pedals are not depressed, and • parking brake is released.

SGI860

MULTIPLE SWITCH The continuity of multiple switch is described in two ways as shown below. • The switch chart is used in schematic diagrams. • The switch diagram is used in wiring diagrams.

JSAIA0017GB

Revision: 2007 November

GI-12

2008 EX35

ABBREVIATIONS < HOW TO USE THIS MANUAL >

ABBREVIATIONS

Abbreviation List

INFOID:0000000003131610

The following ABBREVIATIONS are used:

ABBREVIATION

DESCRIPTION

A/C

Air Conditioner

A/T

Automatic Transaxle/Transmission

ATF

Automatic Transmission Fluid

Drive range 1st gear

Drive range 2nd gear

Drive range 3rd gear

Drive range 4th gear

FR, RR

Front, Rear

LH, RH

Left-Hand, Right-Hand

M/T

Manual Transaxle/Transmission

Overdrive

P/S

Power Steering

SAE

Society of Automotive Engineers, Inc.

SDS

Service Data and Specifications

SST

Special Service Tools

2WD

2-Wheel Drive

2nd range 2nd gear

2nd range 1st gear

1st range 2nd gear

1st range 1st gear

Revision: 2007 November

GI-13

2008 EX35

TIGHTENING TORQUE OF STANDARD BOLTS < HOW TO USE THIS MANUAL >

TIGHTENING TORQUE OF STANDARD BOLTS Tightening Torque Table

Grade

Bolt size

Bolt diameter * mm

INFOID:0000000003131611

Tightening torque (Without lubricant) Pitch mm

Hexagon head bolt N·m

6.0

8.0

M10

10.0

M12

12.0

1.25

M14

14.0

1.5

6.0

1.0

8.0

M10

10.0

M12

12.0

M14

kg-m

Hexagon flange bolt

ft-lb

in-lb

N·m

kg-m

ft-lb

in-lb

1.0

5.5

0.56

0.71

1.25

13.5

1.4

—

1.7

—

1.0

13.5

1.4

—

1.7

—

1.5

2.9

—

3.6

—

1.25

2.9

—

3.6

—

1.75

4.6

—

5.6

—

4.6

—

6.6

—

8.2

—

100

—

0.92

1.1

1.25

2.2

—

2.9

—

1.0

2.2

—

2.9

—

1.5

4.6

—

5.6

—

1.25

4.6

—

5.6

—

1.75

8.2

—

100

—

1.25

8.2

—

100

—

14.0

1.5

130

—

170

125

—

6.0

1.0

1.1

—

13.5

1.4

—

8.0

1.25

2.9

—

3.6

—

1.0

2.9

—

3.6

—

M10

10.0

1.5

5.6

—

8.2

—

1.25

5.6

—

8.2

—

M12

12.0

1.75

100

—

130

—

1.25

100

—

130

—

M14

14.0

1.5

170

125

—

210

155

—

*: Nominal diameter 1.

Special parts are excluded.

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

MGI044A

Revision: 2007 November

GI-14

2008 EX35

RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS < HOW TO USE THIS MANUAL >

RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS Recommended Chemical Products and Sealants

GI INFOID:0000000003131612

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

Product Description

Purpose

Rear View Mirror Adhesive

Used to permanently remount rear view mirrors to windows.

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.

High Performance Thread Sealant

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

Gasket Maker 4

Nissan North America Part No. (USA) 999MP-AM000P

99998-50505

Medium Strength Thread Locking Sealant (Blue)

Threadlocker

Threadlocker (service tool removable)

Permatex 81844

D 999MP-AM001P

99998-50503

Permatex 51813 and 51817

F 999MP-AM002P

999MP-AM002P

Permatex 56521

999MP-AM003P (Ultra Grey)

99998-50506 (Ultra Grey)

Silicone RTV

High Temperature, High Strength Thread Locking Sealant (Red)

Aftermarket Crossreference Part Nos.

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

Nissan Canada Part No. (Canada)

–

999MP-AM004P

999MP-AM005P

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

Three Bond 1281B or exact equivalent in its quality

999MP-AM004P

Permatex 27200; Three Bond 1360, 1360N, 1305 N&P, 1307N, 1335, 1335B, 1363B, 1377C, 1386B, D&E and 1388 Loctite 648

999MP-AM005P

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

–

Revision: 2007 November

GI-15

2008 EX35

TERMINOLOGY < HOW TO USE THIS MANUAL >

TERMINOLOGY SAE J1930 Terminology List

INFOID:0000000003131613

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

OLD TERM

Air cleaner

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

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

***

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

***

Engine control module

ECM

ECCS control unit

Engine coolant temperature

ECT

Engine temperature

Engine coolant temperature sensor

ECTS

Engine temperature sensor

Engine modification

***

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

Revision: 2007 November

GI-16

2008 EX35

TERMINOLOGY < HOW TO USE THIS MANUAL > NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Exhaust gas recirculation control-BPT valve

EGRC-BPT valve

BPT valve

Exhaust gas recirculation control-solenoid valve

EGRC-solenoid valve

EGR control solenoid valve

EGRT sensor

Exhaust gas temperature sensor

Flash electrically erasable programmable read only memory

FEEPROM

***

Flash erasable programmable read only memory

FEPROM

***

Flexible fuel sensor

FFS

***

Flexible fuel system

FF system

***

Fuel pressure regulator

***

Pressure regulator

Fuel pressure regulator control solenoid valve

***

PRVR control solenoid valve

Fuel trim

***

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

***

Ignition control module

ICM

***

Indirect fuel injection system

IFI system

***

Intake air

Air

Intake air temperature sensor

IAT sensor

Air temperature sensor

Knock

***

Detonation

Knock sensor

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

***

Exhaust gas recirculation temperature sensor

EGR temperature sensor

Manifold surface temperature

MST

***

Manifold surface temperature sensor

MSTS

***

Manifold vacuum zone

MVZ

***

Manifold vacuum zone sensor

MVZS

***

Mass air flow sensor

MAFS

Air flow meter

Mixture control solenoid valve

MC solenoid valve

Air-fuel ratio control solenoid valve

Multiport fuel injection system

MFI system

Fuel injection control

Revision: 2007 November

GI-17

2008 EX35

TERMINOLOGY < HOW TO USE THIS MANUAL > NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Nonvolatile random access memory

NVRAM

***

On board diagnostic system

OBD system

Self-diagnosis

Open loop

Oxidation catalyst

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

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

***

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

***

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

Throttle chamber SPI body

Throttle body fuel injection system

TBI system

Fuel injection control

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: 2007 November

GI-18

2008 EX35

TERMINOLOGY < HOW TO USE THIS MANUAL > NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Transmission control module

TCM

A/T control unit

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 sysWU-TWC system tem

***

Wide open throttle position switch

Full switch

WOTP switch

***: Not applicable

Revision: 2007 November

GI-19

2008 EX35

IDENTIFICATION INFORMATION < FEATURES OF NEW MODEL >

FEATURES OF NEW MODEL IDENTIFICATION INFORMATION Model Variation Dstination

Body

INFOID:0000000003131614

Engine

Transmission

Axle 2WD

USA Wagon

VQ35HR

5A/T AWD

Canada

Grade

Model

Base

TLTALQN-EUA

Journey

TLTALTN-EUA

Base

TLTNLQN-EUA

Journey

TLTNLTN-EUA

Base

TLTNLQN-ENA

Journey

TLTNLTN-ENA

Model variation code (Prefix and suffix designations)

JPAIA0240GB

Information About Identification or Model Code

INFOID:0000000003131615

IDENTIFICATION NUMBER

JPAIA0241ZZ

Revision: 2007 November

GI-20

2008 EX35

IDENTIFICATION INFORMATION < FEATURES OF NEW MODEL > 1.

Vehicle identification plate

2. Emission control information label

Vehicle identification number (Chassis number)

Vehicle identification number plate

5. Tire and loading information label

FMVSS certification label

Air conditioner specification labe

VEHICLE IDENTIFICATION NUMBER ARRANGEMENT C

G JPAIA0242GB

IDENTIFICATION PLATE

K JPAIA0004ZZ

Type

Vehicle identification number (Chassis number) 3.

Model variation code

Body color code

Trim color code

Engine model

Engine displacement

Transmission model

Axle model

ENGINE SERIAL NUMBER

P JPAIA0005ZZ

Revision: 2007 November

GI-21

2008 EX35

IDENTIFICATION INFORMATION < FEATURES OF NEW MODEL > AUTOMATIC TRANSMISSION NUMBER

PAIA0054E

Dimensions

INFOID:0000000003131616

Unit: mm (in)

Overall length

4,630 (182.3)

Overall width

1,800 (70.9) 1,570 (61.8)*5

Overall height

1,590 (62.6)*6 1,535 (60.4)*1 1,530 (60.2)*2

Front tread

1,545 (60.8)*3 1,540 (60.6)*4 1,550 (61.0)*1,*3

Rear tread

1,545 (60.8)*2,*4

Wheelbase

2,850 (112.2)

*1: 2WD 17-in tire models *2: 2WD 18-in tire models *3: AWD 17-in tire models *4: AWD 18-in tire models *5: Models without roof rack *6: Models with roof rack

Wheels & Tires

INFOID:0000000003131617

Application Road wheel/offset

Tire size

Revision: 2007 November

Conventional mm (in)

17 X 7-1/2J Aluminum/45 (1.77) 18 X 8J Aluminum/47 (1.85) P225/60R17 98V

Spare 17 Ã&#x2014; 4T Aluminum/30 (1.18)

T165/80R17

P225/55R18 97V

GI-22

2008 EX35

PRECAUTIONS < PRECAUTION >

PRECAUTION

PRECAUTIONS Description

INFOID:0000000003131618

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

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"

INFOID:0000000003566319

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 AIRBAG” and “SEAT BELT” 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 AIRBAG”. • 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 Xenon Headlamp Service

INFOID:0000000003131620

WARNING: Comply with the following warnings to prevent any serious accident. • Disconnect the battery cable (negative terminal) or the power supply fuse before installing, removing, or touching the xenon headlamp (bulb included). The xenon headlamp contains high-voltage generated parts. • Never work with wet hands. • Check the xenon headlamp ON-OFF status after assembling it to the vehicle. Never turn the xenon headlamp ON in other conditions. Connect the power supply to the vehicle-side connector. (Turning it ON outside the lamp case may cause fire or visual impairments.) • Never touch the bulb glass immediately after turning it OFF. It is extremely hot. CAUTION: Comply with the following cautions to prevent any error and malfunction. • Install the xenon bulb securely. (Insufficient bulb socket installation may melt the bulb, the connector, the housing, etc. by high-voltage leakage or corona discharge.) • Never perform HID circuit inspection with a tester. • Never touch the xenon bulb glass with hands. Never put oil and grease on it. • Dispose of the used xenon bulb after packing it in thick vinyl without breaking it. • Never wipe out dirt and contamination with organic solvent (thinner, gasoline, etc.).

Precaution Necessary for Steering Wheel Rotation after Battery Disconnect INFOID:0000000003691858

GI-23

2008 EX35

PRECAUTIONS < PRECAUTION > This vehicle is equipped with a push-button ignition switch and a steering lock unit. If the battery is disconnected or discharged, the steering wheel will lock and cannot be turned. If turning the steering wheel is required with the battery disconnected or discharged, follow the procedure below before starting the repair operation.

OPERATION PROCEDURE 1.

2. 3. 4. 5.

Connect both battery cables. NOTE: Supply power using jumper cables if battery is discharged. Turn the push-button ignition switch to ACC position. (At this time, the steering lock will be released.) Disconnect both battery cables. The steering lock will remain released with both battery cables disconnected and the steering wheel can be turned. Perform the necessary repair operation. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock when the push-button ignition switch is turned to LOCK position.) Perform self-diagnosis check of all control units using CONSULT-III.

Precaution for Procedure without Cowl Top Cover

INFOID:0000000003566320

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

PIIB3706J

General Precautions

INFOID:0000000003131623

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

SGI285

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

Revision: 2007 November

GI-24

2008 EX35

PRECAUTIONS < PRECAUTION > • 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.

C SEF289H

• To prevent serious burns: Avoid contact with hot metal parts. Do not remove the radiator cap when the engine is hot. • Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner. • Do not attempt to top off the fuel tank after the fuel pump nozzle shuts off automatically. Continued refueling may cause fuel overflow, resulting in fuel spray and possibly a fire. • Clean all disassembled parts in the designated liquid or solvent 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.

G SGI233

M PBIC0190E

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

SGI234

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) Revision: 2007 November

GI-25

2008 EX35

PRECAUTIONS < PRECAUTION > system. The connectors should be disconnected only when working according to the WORK FLOW of TROUBLE DIAGNOSES in EC and AT sections.

Three Way Catalyst

INFOID:0000000003131624

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.

Multiport Fuel Injection System or Engine Control System

INFOID:0000000003131625

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

Hoses

INFOID:0000000003131626

HOSE REMOVAL AND INSTALLATION • To prevent damage to rubber hose, do not pry off rubber hose with tapered tool or screwdriver.

SMA019D

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

SMA020D

HOSE CLAMPING

Revision: 2007 November

GI-26

2008 EX35

PRECAUTIONS < PRECAUTION > • 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.

C SMA021D

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

G SMA022D

Engine Oils

INFOID:0000000003131627

Prolonged and repeated contact with used engine oil may cause skin cancer. Try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible.

HEALTH PROTECTION PRECAUTIONS • • • • • • • • • • • •

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

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

Air Conditioning

INFOID:0000000003131628

Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to HA section “REFRIGERANT” for specific instructions.

FUEL Revision: 2007 November

GI-27

2008 EX35

PRECAUTIONS < PRECAUTION >

FUEL : Unleaded Premium Gasoline Recommended

INFOID:0000000003131629

INFINITI recommends the use of unleaded premium gasoline with an octane rating of at least 91 AKI (AntiKnock Index) number (Research octane number 96). If unleaded premium gasoline is not available, you may use unleaded regular gasoline with an octane rating of at least 87 AKI number (Research octane number 91), but you may notice a decrease in performance. 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: 2007 November

GI-28

2008 EX35

LIFTING POINT < PRECAUTION >

LIFTING POINT

Commercial Service Tools

INFOID:0000000003131630

B Tool name

Description

C Board on attachment

D S-NT001

Safety stand attachment

S-NT002

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

Garage Jack and Safety Stand and 2-Pole Lift

J INFOID:0000000003131631

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

Revision: 2007 November

GI-29

2008 EX35

LIFTING POINT < PRECAUTION >

JMAIA0085ZZ

Safety stand point and lift up point (front) 2.

Garage jack point (rear)

Safety stand point and lift up point (rear)

Garage jack point (front)

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

Board-On Lift

INFOID:0000000003131632

CAUTION: Make sure vehicle is empty when lifting. • The board-on lift attachment (A) 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. : Vehicle front

JMAIA0004ZZ

Revision: 2007 November

GI-30

2008 EX35

TOW TRUCK TOWING < PRECAUTION >

TOW TRUCK TOWING

Tow Truck Towing

INFOID:0000000003131633

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 powertrain are in good order. If any unit is damaged, dollies must be used. • Never tow 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.

2WD MODELS

J JMAIA0088ZZ

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

Revision: 2007 November

GI-31

2008 EX35

TOW TRUCK TOWING < PRECAUTION > AWD MODELS

JMAIA0089ZZ

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

Vehicle Recovery (Freeing a Stuck Vehicle)

INFOID:0000000003131634

FRONT Securely install the vehicle recovery hook stored with jacking tools. Make sure that the hook is properly secured in the stored place after use. 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. JMAIA0086ZZ 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.

REAR WARNING:

Revision: 2007 November

GI-32

2008 EX35

TOW TRUCK TOWING < PRECAUTION > â&#x20AC;˘ Rear hook is not available. GI

C JMAIA0087ZZ

AUTOMATIC TRANSMISSION To tow a vehicle equipped with an automatic transmission, an appropriate vehicle dolly MUST be placed under the towed vehicle's drive wheels. Always follow the dolly manufacture's recommendations when using their product. If the vehicle is stuck in sand, snow, mud, etc., use the following procedure: 1. Turn off the Vehicle Dynamic Control System. 2. Make sure the area in front and behind the vehicle is clear of obstructions. 3. Turn the steering wheel right and left to clear an area around the front tires. 4. Slowly rock the vehicle forward and backward. Shift back and forth between R (reverse) and D (drive). Apply the accelerator as little as possible to maintain the rocking motion. Release the accelerator pedal before shifting between R and D. Do not spin the tires above 35 mph (55 km/h). 5. If the vehicle can not be freed after a few tries, contact a professional towing service to remove the vehicle.

Revision: 2007 November

GI-33

2008 EX35

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION >

BASIC INSPECTION SERVICE INFORMATION FOR ELECTRICAL INCIDENT Work Flow

INFOID:0000000003131635

WORK FLOW

SGI838

STEP

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

STEP 1

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.

STEP 2

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

STEP 3

Get the proper diagnosis materials together including: • Power Supply Routing • System Operation Descriptions • Applicable Service Manual Sections • Check for any Service Bulletins 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.

Control Units and Electrical Parts

INFOID:0000000003131636

PRECAUTIONS • • • •

Never reverse polarity of battery terminals. Install only parts specified for a vehicle. Before replacing the control unit, check the input and output and functions of the component parts. Do not apply excessive force when disconnecting a connector.

Revision: 2007 November

GI-34

2008 EX35

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > • 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.

C SAIA0255E

• When using a DMM, be careful not to let test probes get close to each other to prevent the power transistor in the control unit from damaging battery voltage because of short circuiting. • When checking input and output signals of the control unit, use the specified check adapter.

SEF348N

How to Check Terminal

INFOID:0000000003131637

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.

Revision: 2007 November

GI-35

2008 EX35

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > 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

Revision: 2007 November

GI-36

2008 EX35

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > • Some connectors do not have a notch above each terminal. To probe each terminal, remove the connector retainer to make contact space for probing.

C SEL266V

D MALE TERMINAL

• Carefully probe the contact surface of each terminal using a “T” pin. CAUTION: Dot not bend terminal.

G SEL267V

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

L SEL270V

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

SEL271V

Revision: 2007 November

GI-37

2008 EX35

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > 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. 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. SEL275V

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

Intermittent Incident

INFOID:0000000003131638

DESCRIPTION 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 fol-

Revision: 2007 November

GI-38

2008 EX35

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > lowing section illustrates ways to simulate the conditions/environment under which the owner experiences an electrical incident. GI The section is broken into the six following topics:

• Vehicle vibration • Heat sensitive • 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. Connector & 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. Sensor & Relay 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.

L 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. Under Seating Areas

Revision: 2007 November

GI-39

2008 EX35

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

HEAT SENSITIVE • The customer's concern may occur during hot weather or after car has sat for a short time. In such cases you will want to check for a heat sensitive condition. • To determine if an electrical component is heat sensitive, heat the component with a heat gun or equivalent. CAUTION: Do not heat components above 60°C (140°). • If incident occurs while heating the unit, either replace or properly insulate the component. SGI842

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

SGI843

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

SGI844

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

SGI845

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. Revision: 2007 November

GI-40

2008 EX35

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION >

Circuit Inspection

INFOID:0000000003131639

DESCRIPTION • 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 GI-35, "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.

J 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. Voltage Check Method To help in understanding the diagnosis of open circuits please refer to the previous schematic. In any powered circuit, an open can be found by methodically checking the system for the presence of voltage. This is done by switching the DMM to the voltage function. • Connect one probe of the DMM to a known good ground. • Begin probing at one end of the circuit and work your way to the other end. • With SW1 open, probe at SW1 to check for voltage. voltage; open is further down the circuit than SW1.

Revision: 2007 November

GI-41

2008 EX35

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > no voltage; open is between fuse block and SW1 (point A). • Close SW1 and probe at relay. voltage; open is further down the circuit than the relay. no voltage; open is between SW1 and relay (point B). • Close the relay and probe at the solenoid. voltage; open is further down the circuit than the solenoid. no voltage; open is between relay and solenoid (point C). Any powered circuit can be diagnosed using the approach in the previous example.

TESTING FOR “SHORTS” IN THE CIRCUIT To simplify the discussion of shorts in the system, please refer to the following schematic.

SGI847-A

Resistance Check Method • Disconnect the battery negative cable and remove the blown fuse. • Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the fuse. • Connect one probe of the DMM to the load side of the fuse terminal. Connect the other probe to a known good ground. • With SW1 open, check for continuity. continuity; short is between fuse terminal and SW1 (point A). no continuity; short is further down the circuit than SW1. • Close SW1 and disconnect the relay. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. continuity; short is between SW1 and the relay (point B). no continuity; short is further down the circuit than the relay. • Close SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. continuity; short is between relay and solenoid (point C). no continuity; check solenoid, retrace steps. Voltage Check Method • Remove the blown fuse and disconnect all loads (i.e. SW1 open, relay disconnected and solenoid disconnected) powered through the fuse. • Turn the ignition key to the ON or START position. Verify battery voltage at the battery + side of the fuse terminal (one lead on the battery + terminal side of the fuse block and one lead on a known good ground). • With SW1 open and the DMM leads across both fuse terminals, check for voltage. voltage; short is between fuse block and SW1 (point A). 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. Revision: 2007 November

GI-42

2008 EX35

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > • When inspecting a ground connection follow these rules: - Remove the ground bolt or screw. GI - Inspect all mating surfaces for tarnish, dirt, rust, etc. - Clean as required to assure good contact. - Reinstall bolt or screw securely. B - 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. C • For detailed ground distribution information, refer to “Ground Distribution” in PG section. D

H 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. • If repairs are needed always use wire that is of the same or larger gauge. Measuring Voltage Drop — Accumulated Method • Connect the DMM across the connector or part of the circuit you want to check. The positive lead of the DMM should be closer to power and the negative lead closer to ground. • Operate the circuit. • The DMM will indicate how many volts are being used to “push” current through that part of the circuit.

Revision: 2007 November

GI-43

2008 EX35

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb.

SGI974

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

SAIA0258E

CONTROL UNIT CIRCUIT TEST System Description • When the switch is ON, the control unit lights up the lamp. CASE 1

MGI034A

Revision: 2007 November

GI-44

2008 EX35

SERVICE INFORMATION FOR ELECTRICAL INCIDENT < BASIC INSPECTION > INPUT-OUTPUT VOLTAGE CHART

Terminal No. +

−

Description Signal name

Body ground

Switch

Body ground

Lamp

Value (Approx.)

In case of high resistance such as single strand (V) *

Switch ON

Battery voltage

Lower than battery voltage Approx. 8 (Example)

Switch OFF

Switch ON

Battery voltage

Switch OFF

Condition

Input/ Output Input

Output

Approx. 0

Approx. 0 (Inoperative lamp) 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.

CASE 2

H MGI035A

INPUT-OUTPUT VOLTAGE CHART

Terminal No. +

−

Description Signal name

Condition

Input/ Output

Body ground

Lamp

Output

Body ground

Switch

Input

Value (Approx.)

In case of high resistance such as single strand (V) *

Battery voltage (Inoperative lamp)

Switch ON

Switch OFF

Battery voltage

Switch ON

Higher than 0 Approx. 4 (Example)

Switch OFF

Approx. 5

Battery voltage

• 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: 2007 November

GI-45

2008 EX35

CONSULT-III/GST CHECKING SYSTEM < BASIC INSPECTION >

CONSULT-III/GST CHECKING SYSTEM Description

INFOID:0000000003131640

• When CONSULT-III/GST is connected with a data link connector (A) equipped on the vehicle side, it will communicate with the control unit equipped in the vehicle and then enable various kinds of diagnostic tests. 1

: Instrument driver lower panel

• Refer to “CONSULT-III Software Operation Manual” for more information.

JPAIA0243ZZ

CONSULT-III Function and System Application*1

Function

ENGINE

TRANSMISSION

AIR BAG

METER/M&A

BCM

AUTO DRIVE POS.

ABS (Including VDC)

IPDM E/R

ALL MODE AWD/4WD

MULTI AV

ICC

LANE CAM

SONAR

ADAPTIVE LIGHT

INFOID:0000000003566328

Work Support

This mode enables a technician to adjust some devices faster and more accurately.

Self-Diagnostic Results

Retrieve DTC from ECU and display diagnostic items.

Data Monitor

Monitor the input/output signal of the control unit in real time.

CAN Diagnosis

This mode displays a network diagnosis result about CAN by a diagram.

CAN Diagnosis Support Monitor

It monitors the status of CAN communication.

Active Test

Send the drive signal from CONSULT-III to the actuator. The operation check can be performed.

DTC & SRT confirmation

The status of system monitoring tests and the selfdiagnosis status/result can be confirmed.

ECU Identification

Display the ECU identification number (part number etc.) of the selected system.

Function Test

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

Configuration

When ECU is replaced with a new one, etc., write the information and set the ECU to perform the control that is applicable to the vehicle.

Special Function

Other results or histories, etc. that are recorded in ECU are displayed.

Diagnostic test mode

x: Applicable *1: If GST application is equipped, functions in accordance with SAE J1979 and ISO 15031-5 can be used.

CONSULT-III/GST Data Link Connector (DLC) Circuit

INFOID:0000000003131642

INSPECTION PROCEDURE Revision: 2007 November

GI-46

2008 EX35

CONSULT-III/GST CHECKING SYSTEM < BASIC INSPECTION > If the CONSULT-III/GST cannot diagnose the system properly, check the following items. GI Symptom

Check item

CONSULT-III/GST cannot access any system.

• CONSULT-III/GST DLC power supply circuit (Terminal 8 and 16) and ground circuit (Terminal 4 and 5)

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

• 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-III DLC (For detailed circuit, refer to wiring diagram for each system.) • Open or short circuit CAN communication line. Refer to LAN-18, "Trouble Diagnosis Flow Chart".

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-III access to other systems. If the GST cannot operate properly, check the circuit based on the information of SAE J1962 and ISO 150313.

Revision: 2007 November

GI-47

2008 EX35

CONSULT-III/GST CHECKING SYSTEM < BASIC INSPECTION >

Wiring Diagram - CONSULT-III/GST CHECKING SYSTEM -

INFOID:0000000003131643

JCAWM0056GB

Revision: 2007 November

GI-48

2008 EX35

CONSULT-III/GST CHECKING SYSTEM < BASIC INSPECTION > GI

O JCAWM0057GB

Revision: 2007 November

GI-49

2008 EX35

CONSULT-III/GST CHECKING SYSTEM < BASIC INSPECTION >

JCAWM0058GB

Revision: 2007 November

GI-50

2008 EX35

CONSULT-III/GST CHECKING SYSTEM < BASIC INSPECTION > GI

O JCAWM0059GB

Revision: 2007 November

GI-51

2008 EX35

INSPECTION AND ADJUSTMENT < BASIC INSPECTION >

INSPECTION AND ADJUSTMENT ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL : Required Procedure After Battery Disconnection

INFOID:0000000003566327

SYSTEM

ITEM

REFERENCE HAC-8, "WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Temperature Setting Trimmer"

Temperature setting trimmer

Foot position setting trimmer

Automatic temperature control

Inlet port memory function

Without left and right ventilation temperature separately control system

HAC-9, "WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Foot Position Setting Trimmer"

HAC-13, "WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Temperature Setting Trimmer" With left and right ventilation temperature separately control system

HAC-10, "WITHOUT LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Inlet Port Memory Function"

HAC-14, "WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Foot Position Setting Trimmer" HAC-15, "WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM : Inlet Port Memory Function"

Inlet port memory function (FRE)*

—

Inlet port memory function (REC)*

—

Gas sensor sensitivity adjustment function*

—

Auto intake switch Interlocking movement change*

—

Clean switch interlocking movement change*

—

Automatic drive positioner

Automatic drive positioner system

ADP-8, "ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL : Description"

Power window control

Power window control system

PWC-5, "ADDITIONAL SERVICE WHEN REMOVING BATTERY NEGATIVE TERMINAL : Description"

Sunroof system*

Sunroof system

—

Sunshade system*

Sunshade system

—

Rear view monitor

Predicted course line center position adjustment

Revision: 2007 November

Base audio without navigation

AV-15, "PREDICTED COURSE LINE CENTER POSITION ADJUSTMENT : Description"

BOSE audio without navigation

AV-174, "PREDICTED COURSE LINE CENTER POSITION ADJUSTMENT : Description"

BOSE audio with navigation

AV-437, "PREDICTED COURSE LINE CENTER POSITION ADJUSTMENT : Description"

GI-52

2008 EX35

INSPECTION AND ADJUSTMENT < BASIC INSPECTION > SYSTEM

ITEM

Around view monitor

Predicted course line center position adjustment

Automatic back door system*

Automatic back door system

REFERENCE AV-437, "PREDICTED COURSE LINE CENTER POSITION ADJUSTMENT : Description"

BOSE audio with navigation

â&#x20AC;&#x201D;

*: Not equipped.

Revision: 2007 November

GI-53

2008 EX35

ENGINE

SECTION

ENGINE MECHANICAL

CONTENTS SYMPTOM DIAGNOSIS ............................... 3

Removal and Installation .........................................15

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ............................. 3

SPARK PLUG ................................................... 16

NVH Troubleshooting - Engine Noise .................... 3 Use the Chart Below to Help You Find the C ause of the Symptom .............................................. 3

Exploded View .........................................................16 Removal and Installation .........................................16 Inspection ................................................................17

CAMSHAFT VALVE CLEARANCE .................. 18

PRECAUTION ............................................... 5

Inspection and Adjustment ......................................18

PRECAUTIONS ................................................... 5

COMPRESSION PRESSURE ........................... 23

Precaution for Procedure without Cowl Top Cover...... 5 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ................................................................... 5 Precaution Necessary for Steering Wheel Rotation after Battery Disconnect ..................................... 5 Draining Engine Coolant .......................................... 6 Disconnecting Fuel Piping ....................................... 6 Removal and Disassembly ...................................... 6 Inspection, Repair and Replacement ...................... 6 Assembly and Installation ........................................ 6 Parts Requiring Angle Tightening ........................... 6 Liquid Gasket ........................................................... 7 Definitions of Bank Names ........................................ 8

Inspection ................................................................23

ENGINE COVER ............................................... 25 Exploded View .........................................................25 Removal and Installation .........................................25

DRIVE BELT AUTO TENSIONER AND IDLER PULLEY ............................................................. 26 Exploded View .........................................................26 Removal and Installation .........................................26

AIR CLEANER AND AIR DUCT ....................... 27

PREPARATION ............................................ 9 PREPARATION ................................................... 9

INTAKE MANIFOLD COLLECTOR .................. 29

Special Service Tools .............................................. 9 Commercial Service Tools ..................................... 10

Exploded View .........................................................29 Removal and Installation .........................................29

ON-VEHICLE MAINTENANCE .................... 13

INTAKE MANIFOLD ......................................... 32

DRIVE BELT .......................................................13

Exploded View .........................................................32 Removal and Installation .........................................32 Inspection ................................................................33

EXHAUST MANIFOLD ...................................... 34

AIR CLEANER FILTER ......................................15 Revision: 2007 November

ON-VEHICLE REPAIR ................................. 25

Exploded View .........................................................27 Removal and Installation .........................................27 Inspection ................................................................28

Exploded View ........................................................ 13 Checking ................................................................. 13 Tension Adjustment ................................................ 13 Removal and Installation ......................................... 13 Inspection ................................................................ 14

EM-1

Exploded View .........................................................34 Removal and Installation .........................................34 Inspection ................................................................36

2008 EX35

FUEL INJECTOR AND FUEL TUBE ................. 37

ENGINE UNIT .................................................... 91

Exploded View ........................................................ 37 Removal and Installation ........................................ 37 Inspection ............................................................... 42

Disassembly ............................................................ 91 Assembly ................................................................ 91

OIL PAN (LOWER) ............................................ 43 Exploded View (2WD) ............................................ 43 Exploded View (AWD) ............................................ 44 Removal and Installation ........................................ 44 Inspection ............................................................... 46

IGNITION COIL, SPARK PLUG AND ROCKER COVER ......................................................... 47 Exploded View ........................................................ 47 Removal and Installation ........................................ 47

TIMING CHAIN .................................................. 50 Exploded View ........................................................ 50 Removal and Installation ........................................ 51 Inspection ............................................................... 65

CAMSHAFT ....................................................... 67 Exploded View ........................................................ 67 Removal and Installation ........................................ 67 Inspection ............................................................... 71

OIL SEAL ........................................................... 76 VALVE OIL SEAL ..................................................... 76 VALVE OIL SEAL : Removal and Installation ......... 76 FRONT OIL SEAL ..................................................... 76 FRONT OIL SEAL : Removal and Installation ........ 76 REAR OIL SEAL ....................................................... 77 REAR OIL SEAL : Removal and Installation .......... 77

REMOVAL AND INSTALLATION ............... 79 ENGINE ASSEMBLY ......................................... 79 2WD ........................................................................... 79 2WD : Exploded View ............................................. 79 2WD : Removal and Installation ............................. 79 2WD : Inspection .................................................... 82 AWD .......................................................................... 83 AWD : Exploded View ............................................ 83 AWD : Removal and Installation ............................. 84 AWD : Inspection .................................................... 87

DISASSEMBLY AND ASSEMBLY ............. 89 ENGINE STAND SETTING ................................ 89

REAR TIMING CHAIN CASE ............................ 92 Exploded View ........................................................ 92 Disassembly ............................................................ 93 Assembly ................................................................ 94

OIL PAN (UPPER) AND OIL STRAINER .......... 97 2WD ........................................................................... 97 2WD : Exploded View ............................................. 97 2WD : Disassembly and Assembly ......................... 97 2WD : Inspection ..................................................... 99 AWD .......................................................................... 99 AWD : Exploded View ........................................... 100 AWD : Disassembly and Assembly ....................... 100 AWD : Inspection .................................................. 103

CYLINDER HEAD ............................................. 104 Exploded View ...................................................... 104 Disassembly and Assembly .................................. 104 Inspection .............................................................. 111

CYLINDER BLOCK .......................................... 114 Exploded View ...................................................... 114 Disassembly and Assembly .................................. 115 Inspection .............................................................. 123

HOW TO SELECT PISTON AND BEARING .. 133 Description ............................................................ 133 Piston .................................................................... 133 Connecting Rod Bearing ..................................... 134 Main Bearing ........................................................ 136

SERVICE DATA AND SPECIFICATIONS (SDS) ......................................................... 139 SERVICE DATA AND SPECIFICATIONS (SDS) ................................................................ 139 General Specification ........................................... 139 Drive Belt .............................................................. 139 Spark Plug ............................................................ 140 Intake Manifold ...................................................... 140 Exhaust Manifold .................................................. 140 Camshaft ............................................................... 140 Cylinder Head ...................................................... 142 Cylinder Block ...................................................... 144 Main Bearing ........................................................ 148 Connecting Rod Bearing ..................................... 149

Setting .................................................................... 89

Revision: 2007 November

EM-2

2008 EX35

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING < SYMPTOM DIAGNOSIS >

SYMPTOM DIAGNOSIS

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

INFOID:0000000003139068

JPBIA0001GB

Use the Chart Below to Help You Find the Cause of the Symptom 1.

INFOID:0000000003139069

Locate the area where noise occurs.

Revision: 2007 November

EM-3

2008 EX35

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING < SYMPTOM DIAGNOSIS > 2. Confirm the type of noise. 3. Specify the operating condition of the engine. 4. Check specified noise source. If necessary, repair or replace these parts. Operating condition of engine Location of noise

Type of noise

Top of engine Rocker cover Cylinder head

Front of engine Timing chain case

Front of engine

Reference page

After warmup

When starting

When idling

When racing

While driving

Ticking or clicking

—

Tappet noise

Valve clearance

EM-18

Rattle

—

Camshaft bearing noise

Camshaft runout Camshaft journal oil clearance

EM-140 EM-140

—

Piston pin noise

Piston to piston pin oil clearance Connecting rod bushing oil clearance

Piston slap noise

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

Slap or knock

Crankshaft pulley Cylinder block (Side of engine) Oil pan

Source of noise

Before warmup

—

Slap or rap

—

Check item

Knock

Connecting rod bearing noise

Knock

—

Main bearing oil clearMain bearance ing noise Crankshaft runout

Timing chain and timing chain tensioner noise

Timing chain cracks and wear Timing chain tensioner operation

Drive belt (Sticking or slipping)

Drive belt deflection

Tapping or ticking

—

Squeaking or fizzing

Creaking

Drive belt (Slipping)

Idler pulley bearing operation

Squall Creak

—

Water pump noise

Water pump operation

—

A: Closely related B: Related C: Sometimes related

Revision: 2007 November

—

EM-144 EM-144 EM-144 EM-144 EM-144 EM-144 EM-144 EM-149 EM-148 EM-144 EM-65 EM-51

EM-13

CO-18, "Exploded View"

—: Not related

EM-4

2008 EX35

PRECAUTIONS < PRECAUTION >

PRECAUTION

PRECAUTIONS Precaution for Procedure without Cowl Top Cover

INFOID:0000000003554244

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

E PIIB3706J

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"

Precaution Necessary for Steering Wheel Rotation after Battery Disconnect

INFOID:0000000003554243

INFOID:0000000003657647

NOTE: • Before removing and installing any control units, first turn the push-button ignition switch to the LOCK position, then disconnect both battery cables. • After finishing work, confirm that all control unit connectors are connected properly, then re-connect both battery cables. • Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results. This vehicle is equipped with a push-button ignition switch and a steering lock unit. If the battery is disconnected or discharged, the steering wheel will lock and cannot be turned. If turning the steering wheel is required with the battery disconnected or discharged, follow the procedure below before starting the repair operation.

OPERATION PROCEDURE 1.

Connect both battery cables. NOTE: Supply power using jumper cables if battery is discharged. Turn the push-button ignition switch to ACC position. (At this time, the steering lock will be released.)

Revision: 2007 November

EM-5

2008 EX35

PRECAUTIONS < PRECAUTION > 3. Disconnect both battery cables. The steering lock will remain released with both battery cables disconnected and the steering wheel can be turned. 4. Perform the necessary repair operation. 5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock when the push-button ignition switch is turned to LOCK position.) 6. Perform self-diagnosis check of all control units using CONSULT-III.

Draining Engine Coolant

INFOID:0000000003139073

Drain engine coolant and engine oil when the engine is cooled.

Disconnecting Fuel Piping

INFOID:0000000003139074

• Before starting work, check 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.

Removal and Disassembly

INFOID:0000000003139075

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

Inspection, Repair and Replacement

INFOID:0000000003139076

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

Assembly and Installation

INFOID:0000000003139077

• 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, check 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 the engine and increase engine speed to check engine coolant, fuel, engine oil, and exhaust gases for leakage.

Parts Requiring Angle Tightening • • • •

INFOID:0000000003139078

Use the angle wrench [SST: KV10112100 (BT8653-A)] for the final tightening of the following engine parts: Cylinder head bolts Lower cylinder block 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.

Revision: 2007 November

EM-6

2008 EX35

PRECAUTIONS < PRECAUTION >

Liquid Gasket

INFOID:0000000003139079

REMOVAL OF LIQUID GASKET SEALING • After removing mounting bolts and nuts, separate the mating surface using the seal cutter [SST: KV10111100 (J37228)] (A) and remove old liquid gasket sealing. CAUTION: Be careful not to damage the mating surfaces. • Tap the seal cutter [SST: KV10111100 (J37228)] to insert it (B), and then slide it (C) by tapping on the side as shown in the figure. • In areas where the seal cutter [SST: KV10111100 (J37228)] is difficult to use, use a plastic hammer to lightly tap the parts, to remove it. CAUTION: If for some unavoidable reason tool such as a screwdriver is used, be careful not to damage the mating surfaces.

D JPBIA0052ZZ

LIQUID GASKET APPLICATION PROCEDURE 1.

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

JPBIA0053ZZ

Attach liquid gasket tube to the tube presser (commercial service tool). Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-15, "Recommended Chemical Products and Sealants". Apply liquid gasket without breaks to the specified location with the specified dimensions. • If there is a groove for liquid gasket application, apply liquid gasket to the groove.

L EMA0622D

• As for bolt holes (B), normally apply liquid gasket inside the holes. Occasionally, it should be applied outside the holes. Check to read the text of this manual. A

: Groove : Inside

• Within five minutes of liquid gasket application, install the mating component. • If liquid gasket protrudes, wipe it off immediately. • Do not retighten mounting bolts or 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: 2007 November

EM-7

P JPBIA0010ZZ

2008 EX35

PRECAUTIONS < PRECAUTION >

Definitions of Bank Names

INFOID:0000000003139080

â&#x20AC;˘ In this manual, each bank name is defined as follows: A

: Bank 1 (The conventional right bank)

: Bank 2 (The conventional left bank) : Engine front

â&#x20AC;˘ For cylinder numbers and bank layout, refer to the illustration. Bank 1 Bank 2

: The bank side including cylinder No. 1 (odd-numbered cylinder side) : The other bank side of the above (even-numbered cylinder side)

Revision: 2007 November

EM-8

JPBIA1135ZZ

2008 EX35

PREPARATION < PREPARATION >

PREPARATION

PREPARATION Special Service Tools

INFOID:0000000003139081

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number (Kent-Moore No.) Tool name KV10116200 (J26336-A) Valve spring compressor 1. KV10115900 (J26336-20) Attachment 2.KV10109220 ( â&#x20AC;&#x201D; ) Adapter

Description

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

PBIC1650E

F Replacing valve oil seal

KV10107902 (J38959) Valve oil seal puller

H NT011

Installing valve oil seal Use side A (G). 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) H: side B Unit: mm (in)

KV10115600 (J-38958) Valve oil seal drift

JPBIA0396ZZ

Installing piston assembly into cylinder bore

EM03470000 (J8037) Piston ring compressor

NT044

Removing pilot converter

ST16610001 (J23907) Pilot bushing puller

O NT045

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

KV10111100 (J37228) Seal cutter

NT046

Revision: 2007 November

EM-9

2008 EX35

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

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

KV10112100 (BT8653-A) Angle wrench

NT014

Loosening or tightening air fuel ratio sensor 1 a: 22 mm (0.87 in)

KV10114400 (J38365) Heated oxygen sensor wrench

JPBIA0397ZZ

Removing and installing crankshaft pulley

KV10118600 (J-48641) Ring gear stopper

JPBIA0409ZZ

Commercial Service Tools

INFOID:0000000003139082

(Kent-Moore No.) Tool name

Description

( — ) Tube presser

Pressing the tube of liquid gasket

NT052

( — ) Power tool

Loosening bolts and nuts

PBIC0190E

( — ) Manual lift table caddy

Removing and installing engine

ZZA1210D

Revision: 2007 November

- 1 0

2008 EX35

PREPARATION < PREPARATION > (Kent-Moore No.) Tool name

Description

(J24239-01) Cylinder head bolt wrench

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

C JPBIA0398ZZ

Checking compression pressure

( — ) 1.Compression gauge 2.Adapter

ZZA0008D

( — ) Spark plug wrench

Removing and installing spark plug a: 14 mm (0.55 in)

H JPBIA0399ZZ

( — ) Valve seat cutter set

Finishing valve seat dimensions

J NT048

( — ) Piston ring expander

Removing and installing piston ring

NT030

( — ) Valve guide drift

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

O JPBIA0400ZZ

( — ) Valve guide reamer

A: Reaming valve guide inner hole B: Reaming hole for oversize valve guide Intake and Exhaust: c: 6.0 mm (0.236 in) dia. d: 10.2 mm (0.402 in) dia.

JPBIA0401ZZ

Revision: 2007 November

EM-11

2008 EX35

PREPARATION < PREPARATION > (Kent-Moore No.) Tool name

Description

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

JPBIA0238ZZ

Reconditioning the exhaust system threads before installing a new air fuel ratio sensor and heated oxygen sensor (Use with anti-seize lubricant shown below.) A: J-43897-18 [18 mm (0.71 in) dia.] for zirconia heated oxygen sensor and air fuel ratio sensor B: J-43897-12 [12 mm (0.47 in) dia.] for titania heated oxygen sensor C: Mating surface shave cylinder D: Flutes Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads

( â&#x20AC;&#x201D; ) Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907)

AEM489

Revision: 2007 November

EM-12

2008 EX35

DRIVE BELT < ON-VEHICLE MAINTENANCE >

ON-VEHICLE MAINTENANCE

DRIVE BELT Exploded View

INFOID:0000000003139083

G JPBIA0002ZZ

H 1.

Power steering oil pump

Alternator

Drive belt auto-tensioner

Crankshaft pulley

Drive belt

A/C compressor

Idler pulley

Possible use range

Range when new drive belt is installed

Indicator

View D

Checking

INFOID:0000000003139084

WARNING: Be sure to perform the this step when engine is stopped. • Check that the indicator (C) (notch on fixed side) of drive belt auto-tensioner is within the possible use range (A). NOTE: • Check the drive belt auto-tensioner indication when the engine is cold. • When new drive belt is installed, the indicator (notch on fixed side) should be within the range (B) in the figure. • Visually check entire drive belt for wear, damage or cracks. • If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.

Tension Adjustment

INFOID:0000000003139085

INFOID:0000000003139086

Refer to EM-139, "Drive Belt".

Removal and Installation REMOVAL 1.

Remove engine undercover with power tool.

Revision: 2007 November

EM-13

2008 EX35

DRIVE BELT < ON-VEHICLE MAINTENANCE > 2. While securely holding the square hole (A) in pulley center of auto tensioner (1) with a spinner handle, move spinner handle in the direction of arrow (loosening direction of drive belt). : Loosening direction of drive belt

CAUTION: Never place hand in a location where pinching may occur if the holding tool accidentally comes off. Under the above condition, insert a metallic bar of approximately 6 mm (0.24 in) in diameter [hexagonal wrench (C) shown as example in the figure] through the holding boss (B) to lock autotensioner pulley arm. Remove drive belt.

JPBIA0003ZZ

INSTALLATION Note the following, and install in the reverse order of removal. CAUTION: • Check drive belt is securely installed around all pulleys. • Check drive belt is correctly engaged with the pulley groove. • Check for engine oil and engine coolant are not adhered drive belt and pulley groove.

Inspection

INFOID:0000000003139087

INSPECTION AFTER INSTALLATION • Turn crankshaft pulley clockwise several times to equalize tension between each pulley, and then confirm tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to EM-13, "Exploded View".

Revision: 2007 November

EM-14

2008 EX35

AIR CLEANER FILTER < ON-VEHICLE MAINTENANCE >

AIR CLEANER FILTER

Removal and Installation

INFOID:0000000003139088

REMOVAL 1.

Unhook clips (A). 1

: Holder

: Air cleaner case

E JPBIA1597ZZ

Remove holder (3) from air cleaner case (2), and then remove air cleaner filter (1) from holder.

JPBIA1598ZZ

INSTALLATION Note the following, and install in the reverse order of removal. â&#x20AC;¢ Install the air cleaner filter by aligning the seal with the notch of air cleaner case.

Revision: 2007 November

EM-15

2008 EX35

SPARK PLUG < ON-VEHICLE MAINTENANCE >

SPARK PLUG Exploded View

INFOID:0000000003139089

JPBIA1622GB

PCV hose

Clamp

Ignition coil

Spark plug

PCV valve

O-ring

Rocker cover gasket (bank 1)

Rocker cover (bank 1)

O-ring

10.

Camshaft position sensor (PHASE) (bank 1)

11.

Exhaust valve timing control position Camshaft position sensor (PHASE) 12. sensor (bank 1) (bank 2)

13.

Exhaust valve timing control position 14. Rocker cover gasket (bank 2) sensor (bank 2)

15. Rocker cover (bank 2)

16.

PCV hose

17. Oil filler cap

18. PCV hose

To intake manifold collector

To air duct

Refer to EM-47

Camshaft bracket side

Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation

INFOID:0000000003139090

REMOVAL 1. 2. 3. 4.

Remove engine cover with power tool. Refer to EM-25, "Exploded View". Remove air duct (RH and LH). Refer to EM-27, "Exploded View". Remove electric throttle control actuator. Refer to EM-29, "Exploded View". Remove ignition coil. Refer to EM-47, "Removal and Installation".

Revision: 2007 November

EM-16

2008 EX35

SPARK PLUG < ON-VEHICLE MAINTENANCE > 5. Remove spark plug with a spark plug wrench (commercial service tool). a

: 14 mm (0.55 in)

C JPBIA0030ZZ

INSTALLATION Installation is the reverse order of removal.

Inspection

INFOID:0000000003139091

INSPECTION AFTER REMOVAL F

Use the standard type spark plug for normal condition. Spark plug (Standard type) : Refer to EM-140, "Spark Plug".

CAUTION: • Never drop or shock spark plug. • Never use a wire brush for cleaning. • If plug tip is covered with carbon, spark plug cleaner may be used.

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

J SMA773C

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

JPBIA0031ZZ

Revision: 2007 November

EM-17

2008 EX35

CAMSHAFT VALVE CLEARANCE < ON-VEHICLE MAINTENANCE >

CAMSHAFT VALVE CLEARANCE Inspection and Adjustment

INFOID:0000000003139092

INSPECTION Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if there is unusual engine conditions regarding valve clearance. In cases of removing/installing or replacing camshaft and valverelated parts, or of unusual engine conditions due to changes in valve clearance (found malfunctions during stating, idling or causing noise), perform inspection as follows: : Engine front

JPBIA0164ZZ

1. 2. a.

Remove rocker covers (bank 1 and bank 2). Refer to EM-47, "Removal and Installation". Measure the valve clearance as follows: Set No. 1 cylinder at TDC of its compression stroke. • Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator. : Timing mark (grooved line without color)

JPBIA0043ZZ

• Check that intake and exhaust cam nose on No. 1 cylinder (engine front side of bank 1) are located as shown in the figure. : Engine front

• If not, turn crankshaft one revolution (360 degrees) and align as shown in the figure.

JPBIA0044ZZ

Use a feeler gauge, measure the clearance between valve lifter and camshaft. Valve clearance

: Refer to EM-140, "Camshaft".

SEM139D

Revision: 2007 November

EM-18

2008 EX35

CAMSHAFT VALVE CLEARANCE < ON-VEHICLE MAINTENANCE > • By referring to the figure, measure the valve clearances at locations marked “×” as shown in the table below (locations indicated in the figure).

: Engine front

• No. 1 cylinder at compression TDC Measuring position [bank 1 (A)] No. 1 cylinder at compression TDC

INT (D)

No. 3 CYL.

× (E) No. 2 CYL.

D No. 4 CYL.

No. 6 CYL. × (F)

INT (D) EXH (C)

No. 5 CYL.

× (B)

EXH (C)

Measuring position [bank 2 (H)] No. 1 cylinder at compression TDC

No. 1 CYL.

× (G)

G JPBIA0165ZZ

Rotate crankshaft 240 degrees clockwise (when viewed from engine front) to align No. 3 cylinder at TDC its compression stroke. NOTE: Mark a position 240 degrees (b) from a corner of the hexagonal part of crankshaft pulley mounting bolt as shown in the figure. Use the hexagonal part as a guide. 1

: Crankshaft pulley

: Paint mark

K JPBIA0166ZZ

Revision: 2007 November

EM-19

2008 EX35

• No. 3 cylinder at compression TDC Measuring position [bank 1 (A)] No. 3 cylinder at compression TDC

No. 3 CYL.

No. 5 CYL. × (B)

EXH (C) × (E)

INT (D)

Measuring position [bank 2 (H)] No. 3 cylinder at compression TDC

No. 1 CYL.

INT (D) EXH (C)

No. 2 CYL.

No. 4 CYL.

No. 6 CYL.

× (F) × (G)

JPBIA0167ZZ

Rotate crankshaft 240 degrees clockwise (when viewed from engine front) to align No. 5 cylinder at TDC of compression stroke. NOTE: Mark a position 240 degrees (b) from a corner of the hexagonal part of crankshaft pulley mounting bolt as shown in the figure. Use the hexagonal part as a guide. 1

: Crankshaft pulley

: Paint mark

JPBIA0166ZZ

Revision: 2007 November

EM-20

2008 EX35

: Engine front

• No. 5 cylinder at compression TDC Measuring position [bank 1 (A)] No. 5 cylinder at compression TDC

EXH (C)

No. 3 CYL.

INT (D) EXH (C)

No. 5 CYL.

× (B) × (E)

INT (D)

Measuring position [bank 2 (H)] No. 5 cylinder at compression TDC

No. 1 CYL.

No. 2 CYL.

No. 4 CYL.

No. 6 CYL.

× (F) × (G)

G JPBIA0168ZZ

Perform adjustment if the measured value is out of the standard. Refer to “ADJUSTMENT”. H

ADJUSTMENT • Perform adjustment depending on selected head thickness of valve lifter. 1. Measure the valve clearance. Refer to “INSPECTION”. 2. Remove camshaft. Refer to EM-67, "Removal and Installation". 3. Remove valve lifters at the locations that are out of the standard. 4. Measure the center thickness of the removed valve lifters with a micrometer (A).

JPBIA0169ZZ

Use the equation below to calculate valve lifter thickness for replacement. N

Valve lifter thickness calculation: t = t1+ (C1 – C2) t = Valve lifter thickness to be replaced = Removed valve lifter thickness t1 C1 = Measured valve clearance C2 = Standard valve clearance: Intake : 0.30 mm (0.012 in) Exhaust : 0.33 mm (0.013 in)

Revision: 2007 November

EM-21

2008 EX35

CAMSHAFT VALVE CLEARANCE < ON-VEHICLE MAINTENANCE > â&#x20AC;˘ Thickness of new valve lifter can be identified by stamp marks on the reverse side (inside the cylinder). Stamp mark 788 indicates 7.88 mm (0.3102 in) in thickness. A

: Stamp

: Thickness of valve lifter

JPBIA0170ZZ

Available thickness of valve lifter: 27 sizes with range 7.88 to 8.40 mm (0.3102 to 0.3307 in) in steps of 0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-140, "Camshaft". 6. Install selected valve lifter. 7. Install camshaft. Refer to EM-67, "Removal and Installation". 8. Manually turn crankshaft pulley a few turns. 9. Check that the valve clearances for cold engine are within the specifications by referring to the specified values. Refer to EM-18, "Inspection and Adjustment". 10. Install all removal parts in the reverse order of removal. 11. Warm up the engine, and check for unusual noise and vibration.

Revision: 2007 November

EM-22

2008 EX35

COMPRESSION PRESSURE < ON-VEHICLE MAINTENANCE >

COMPRESSION PRESSURE

Inspection 1. 2. 3.

INFOID:0000000003139093

Warm up engine thoroughly. Then, stop it. Release fuel pressure. Refer to EC-538, "Inspection". Disconnect fuel pump fuse (1) from IPDM E/R (2) to avoid fuel injection during measurement.

E JMBIA0021ZZ

4. 5. 6. 7.

Remove engine cover with power tool. Refer to EM-25, "Exploded View". Remove ignition coil and spark plug from each cylinder. Refer to EM-16, "Exploded View". Connect engine tachometer (not required in use of CONSULT-III). Install compression gauge with an adapter (commercial service tool) onto spark plug hole.

J PBIC0900E

• Use the adapter whose picking up end inserted to spark plug hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it may be caught by cylinder head during removal.

L a

: 20 mm (0.79 in)

N JPBIA0171ZZ

With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each cylinder. Compression pressure

: Refer to EM-139, "General Specification".

CAUTION: Always use a fully charged battery to obtain the specified engine speed. • If the engine speed is out of the specified range, check battery liquid for proper gravity. Check the engine speed again with normal battery gravity. • If compression pressure is below minimum value, check valve clearances and parts associated with combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head gasket). After the checking, measure compression pressure again. Revision: 2007 November

EM-23

2008 EX35

COMPRESSION PRESSURE < ON-VEHICLE MAINTENANCE > â&#x20AC;˘ If some cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole of the cylinder to re-check it for compression. - If the added engine oil improves the compression, piston rings may be worn out or damaged. Check piston rings and replace if necessary. - If the compression pressure remains at low level despite the addition of engine oil, valves may be malfunctioning. Check valves for damage. Replace valve or valve seat accordingly. â&#x20AC;˘ If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil, cylinder head gaskets are leaking. In such a case, replace cylinder head gaskets. 9. After inspection is completed, install removed parts. 10. Start the engine, and check that the engine runs smoothly. 11. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-125, "Description".

Revision: 2007 November

EM-24

2008 EX35

ENGINE COVER < ON-VEHICLE REPAIR >

ON-VEHICLE REPAIR

ENGINE COVER Exploded View

INFOID:0000000003470631

: Engine cover

JPBIA0256GB

Removal and Installation

INFOID:0000000003470632

REMOVAL Loosen mounting bolts and nuts in the reverse order as shown in the figure, and then remove engine cover. CAUTION: Never damage or scratch engine cover when installing or removing.

M JPBIA1823ZZ

INSTALLATION

Install engine cover, and then tighten mounting bolts and nuts in numerical order as shown in the figure. CAUTION: Never damage or scratch engine cover when installing or removing.

JPBIA1823ZZ

Revision: 2007 November

EM-25

2008 EX35

DRIVE BELT AUTO TENSIONER AND IDLER PULLEY < ON-VEHICLE REPAIR >

DRIVE BELT AUTO TENSIONER AND IDLER PULLEY Exploded View

INFOID:0000000003139094

JPBIA0004ZZ

Front timing chain case

Idler pulley

Drive belt auto-tensioner

Idler pulley

Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation

INFOID:0000000003139095

Removal 1. 2.

Remove drive belt. Refer to EM-13, "Exploded View". • Keep auto-tensioner pulley arm locked after drive belt is removed. Remove auto-tensioner and idler pulley. Refer to EM-13, "Exploded View". • Keep auto-tensioner pulley arm locked to install or remove auto-tensioner.

Installation Installation is the reverse order of removal. CAUTION: If there is damage greater than peeled paint, replace drive belt auto-tensioner.

Revision: 2007 November

EM-26

2008 EX35

AIR CLEANER AND AIR DUCT < ON-VEHICLE REPAIR >

AIR CLEANER AND AIR DUCT

Exploded View

INFOID:0000000003139096

J JPBIA1824GB

Mass air flow sensor (bank 1)

Air cleaner filter

Bracket

Resonator (RH)

Bracket

Grommet

Air cleaner case (RH)

10. Clamp

11. Air duct (RH)

12. PCV hose

13. Air duct (LH)

14. Mass air flow sensor (bank 2)

15. Air cleaner case (LH)

16. Bracket

17. Resonator (LH)

18. Bracket

19. Clamp

20. PCV hose

To electric throttle control actuator (bank 2)

Holder

To electric throttle control actuator (bank 1)

To rocker cover (bank 2)

Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation

INFOID:0000000003139097

REMOVAL 1. 2. 3. 4.

Disconnect mass air flow sensor harness connector. Disconnect PCV hose. Remove air cleaner case with mass air flow sensor and air duct, disconnecting each joints. • Add marks as necessary for easier installation. Remove mass air flow sensor from air cleaner case, as necessary. CAUTION: Handle mass air flow sensor with the following cares. • Never shock mass air flow sensor. • Never disassemble mass air flow sensor.

Revision: 2007 November

EM-27

2008 EX35

AIR CLEANER AND AIR DUCT < ON-VEHICLE REPAIR > • Never touch mass air flow sensor.

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

Inspection

INFOID:0000000003139098

INSPECTION AFTER REMOVAL Inspect air duct and resonator assembly for crack or tear. • If anything found, replace air duct and resonator assembly.

Revision: 2007 November

EM-28

2008 EX35

INTAKE MANIFOLD COLLECTOR < ON-VEHICLE REPAIR >

INTAKE MANIFOLD COLLECTOR

Exploded View

INFOID:0000000003139099

J JPBIA1900GB

EVAP canister purge control solenoid 2. valve

Clamp

EVAP hose

Clamp

Water hose

Electric throttle control actuator (bank1)

Gasket

10. Intake manifold collector

11. Gasket

12. Water hose

13. Water hose

Electric throttle control actuator 14. (bank2)

15. EVAP hose

16. Water hose

17. EVAP tube assembly

18. EVAP hose

To vacuum pipe

To water outlet (rear)

To brake booster

To heater pipe

Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation

INFOID:0000000003139100

REMOVAL WARNING: Never drain engine coolant when the engine is hot to avoid the danger of being scalded. 1. Remove engine cover with power tool. Refer to EM-25, "Exploded View". 2. Remove air cleaner case and air duct (RH and LH). Refer to EM-27, "Exploded View". 3. Remove electric throttle control actuator as follows: a. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leakage. Revision: 2007 November

EM-29

2008 EX35

INTAKE MANIFOLD COLLECTOR < ON-VEHICLE REPAIR > CAUTION: • Perform this step when engine is cold. • Never spill engine coolant on drive belt. b. Disconnect water hoses from electric throttle control actuator. When engine coolant is not drained from radiator, attach plug to water hoses to prevent engine coolant leakage. c. Disconnect harness connector. d. Loosen mounting bolts in reverse order as shown in the figure. NOTE: • When removing only intake manifold collector, move electric throttle control actuator without disconnecting the water hose. • The figure shows the electric throttle control actuator (bank 1) viewed from the air duct side. • Viewed from the air duct side, order of loosening mounting bolts of electric throttle control actuator (bank 2) is the same as that of the electric throttle control actuator (bank 1). CAUTION: Handle carefully to avoid any shock to electric throttle conJPBIA0011ZZ trol actuator. 4. 5. 6.

Disconnect vacuum hose, PCV hose and EVAP hose from intake manifold collector. Remove EVAP canister purge volume control solenoid valve and EVAP tube assembly from intake manifold collector. Loosen mounting bolts and nuts with power tool in the reverse order as shown in the figure to remove intake manifold collector. : Engine front

JPBIA0012ZZ

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

• If stud bolts were removed, install them and tighten to the specified torque below. : 10.8 N·m (1.1 kg-m, 8 ft-lb) • Tighten mounting bolts and nuts in numerical order as shown in the figure. : Engine front

JPBIA0012ZZ

WATER HOSE

• Insert hose by 27 to 32 mm (1.06 to 1.26 in) from connector end. • Clamp hose at location of 3 to 7 mm (0.12 to 0.28 in) from hose end. ELECTRIC THROTTLE CONTROL ACTUATOR (BANK 1 AND BANK 2)

Revision: 2007 November

EM-30

2008 EX35

INTAKE MANIFOLD COLLECTOR < ON-VEHICLE REPAIR > • Tighten in numerical order as shown in the figure. NOTE: A • The figure shows the electric throttle control actuator (bank 1) viewed from the air duct side. • Viewed from the air duct side, order of tightening mounting bolts EM of electric throttle control actuator (bank 2) is the same as that of the electric throttle control actuator (bank 1). • Perform the “Throttle Valve Closed Position Learning” when harness connector of electric throttle control actuator is disconnected. C Refer to EC-17, "THROTTLE VALVE CLOSED POSITION LEARNING : Description". JPBIA0011ZZ • Perform the “Idle Air Volume Learning” and “Throttle Valve Closed D Position Learning” when electric throttle control actuator is replaced. Refer to EC-17, "IDLE AIR VOLUME LEARNING : Description" and EC-17, "THROTTLE VALVE CLOSED POSITION LEARNING : Description". E

Revision: 2007 November

EM-31

2008 EX35

INTAKE MANIFOLD < ON-VEHICLE REPAIR >

INTAKE MANIFOLD Exploded View

INFOID:0000000003139101

PBIC5453E

Harness bracket

Refer to EM-32

Intake manifold

Gasket

Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation

INFOID:0000000003139102

REMOVAL 1. 2. 3. 4. 5.

Release fuel pressure. Refer to EC-538, "Inspection". Remove intake manifold collector. Refer to EM-29, "Exploded View". Remove fuel tube and fuel injector assembly. Refer to EM-37, "Exploded View". Remove harness bracket. Loosen mounting bolts and nuts in reverse order as shown in the figure to remove intake manifold with power tool. : Engine front

CAUTION: • Cover engine openings to avoid entry of foreign materials. • Put a mark on the intake manifold and the cylinder head with paint before removal because they need installed in the specified direction. Remove gaskets.

JPBIA0013ZZ

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. : 10.8 N·m (1.1 kg-m, 8 ft-lb)

Revision: 2007 November

EM-32

2008 EX35

INTAKE MANIFOLD < ON-VEHICLE REPAIR > • Tighten all mounting bolts and nuts to the specified torque in two or more steps in numerical order as shown in the figure.

: Engine front

CAUTION: Install intake manifold with the marks (put on the intake manifold and the cylinder head before removal) aligned.

1st step: : 7.4 N·m (0.75 kg-m, 5 ft-lb)

JPBIA0013ZZ

2nd step and after: : 25.5 N·m (2.6 kg-m, 19 ft-lb)

Inspection

INFOID:0000000003139103

INSPECTION AFTER REMOVAL

Surface Distortion • Check the surface distortion of the intake manifold mating surface with a straightedge (A) and a feeler gauge (B).

Limit

: Refer to EM-140, "Intake Manifold". H

• If it exceeds the limit, replace intake manifold.

I JPBIA0015ZZ

Revision: 2007 November

EM-33

2008 EX35

EXHAUST MANIFOLD < ON-VEHICLE REPAIR >

EXHAUST MANIFOLD Exploded View

INFOID:0000000003139104

JPBIA1909GB

Heated oxygen sensor 2 (bank 1)

Air fuel ratio sensor 1 (bank 1)

Exhaust manifold cover (upper)

Exhaust manifold (bank 1)

Exhaust manifold cover (lower)

Gasket

Ring gasket

Three way catalyst (bank 1)

Gasket

11. Gasket

12.

Three way catalyst (bank 2)

13. Ring gasket

14. Exhaust manifold (bank 2)

15.

Exhaust manifold cover (lower)

16. Gasket

17. Air fuel ratio sensor 1 (bank 2)

18.

Exhaust manifold cover (upper)

10. Heated oxygen sensor 2 (bank 2)

Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation

INFOID:0000000003139105

REMOVAL WARNING: Perform the work when the exhaust and cooling system have completely cooled down. NOTE: When removing bank 1 side parts only, step 2, 5 and 7 are unnecessary. 1. Remove engine undercover with power tool. 2. Drain engine coolant. Refer to CO-7, "Draining". 3. Remove engine cover with power tool. Refer to EM-25, "Exploded View". 4. Remove air cleaner case and air duct (RH and LH). Refer to EM-27, "Exploded View". 5. Remove heater pipe and water hose. Refer to CO-23, "Exploded View". 6. Remove exhaust front tube and three way catalysts (bank 1 and bank 2). Refer to EX-5, "Exploded View". 7. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Revision: 2007 November

EM-34

2008 EX35

EXHAUST MANIFOLD < ON-VEHICLE REPAIR > 8. Disconnect air fuel ratio sensor 1 harness connectors (bank 1 and bank 2) and remove harness clip. 9. Using the heated oxygen sensor wrench [SST: KV10114400 (J38365)] (C), remove air fuel ratio sensor 1 (bank 1 and bank 2).

EM A

: Bank 2

: Bank 1

CAUTION: • Be careful not to damage air fuel ratio sensor 1. • Discard any air fuel ratio sensor 1 which has been dropped onto a hard surface such as a concrete floor. Replace with a new sensor.

JPBIA0271ZZ

10. Remove exhaust manifold cover (upper) (bank 1 and bank 2). 11. Loosen mounting nuts in the reverse order as shown in the figure to remove exhaust manifold. A

: Bank 1

: Bank 2

: Engine front

NOTE: Disregard the numerical order No. 7 and 8 in removal.

K JPBIA0017ZZ

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

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

EXHAUST MANIFOLD GASKET

• Install exhaust manifold gasket in direction shown in the figure. (Follow same procedure for both banks.) O A

: Bank 1

: Triangle press

: Bank 2

: Engine front

JPBIA0019ZZ

EXHAUST MANIFOLD

Revision: 2007 November

EM-35

2008 EX35

EXHAUST MANIFOLD < ON-VEHICLE REPAIR > • If stud bolts were removed, install them and tighten to the specified torque below. Tightening torque

: Refer to EM-34, "Exploded View".

• Install exhaust manifold and tighten mounting nuts in numerical order as shown in the figure. A

: Bank 1

: Bank 2 : Engine front

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

JPBIA0017ZZ

AIR FUEL RATIO SENSOR 1 CAUTION: • Before installing a new air fuel ratio sensor 1, clean exhaust system threads using heated oxygen sensor thread cleaner tool (commercial service tool: J-43897-18 or J-43897-12) and apply anti-seize lubricant. • Never over torque air fuel ratio sensor 1. Doing so may cause damage to air fuel ratio sensor 1, resulting in the “MIL” coming on.

Inspection

INFOID:0000000003139106

INSPECTION AFTER REMOVAL Surface Distortion • Check the surface distortion of the exhaust manifold mating surface with a straightedge (A) and a feeler gauge (B).

Limit

: Refer to EM-140, "Exhaust Manifold".

• If it exceeds the limit, replace exhaust manifold.

JPBIA0018ZZ

Revision: 2007 November

EM-36

2008 EX35

FUEL INJECTOR AND FUEL TUBE < ON-VEHICLE REPAIR >

FUEL INJECTOR AND FUEL TUBE

Exploded View

INFOID:0000000003139107

J JPBIA1708GB

Quick connector cap

Fuel feed hose (with damper)

Fuel sub tube

O-ring

Fuel damper cap

Fuel damper

O-ring

Fuel tube

10. Clip

11. O-ring (black)

O-ring

12. Fuel injector

13. O-ring (green) A.

Refer to EM-37

Refer to GI-4, "Components" for symbols in the figure.

CAUTION: Never remove or disassemble parts unless instructed as shown in the figure.

Removal and Installation

N INFOID:0000000003139108

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. • Never smoke while servicing fuel system. Keep open flames and sparks away from the work area. • Never drain engine coolant when the engine is hot to avoid the danger of being scalded. 1. Release fuel pressure. Refer to EC-538, "Inspection". 2. Disconnect battery cable from the negative terminal. Refer to PG-103, "Exploded View". 3. Remove engine cover with power tool. Refer to EM-25, "Exploded View". 4. Remove air cleaner case and air duct (RH and LH). Refer to EM-27, "Exploded View". Revision: 2007 November

EM-37

2008 EX35

FUEL INJECTOR AND FUEL TUBE < ON-VEHICLE REPAIR > 5. Remove intake manifold collector. Refer to EM-29, "Exploded View". 6. Remove fuel feed hose (with damper) (1) from fuel sub-tube (2) and remove harness bracket (3). : Engine front

NOTE: There is no fuel return route. CAUTION: • While hoses are disconnected, plug them to prevent fuel from draining. • Never separate damper and hose. JPBIA0032ZZ

7. a. b.

When separating fuel feed hose (with damper) and centralized under-floor piping connection, disconnect quick connector as follows: Remove quick connector cap (2) from quick connector connection on right member side. Disconnect fuel feed hose (with damper) (1) from bracket hose clamp.

JPBIA0254ZZ

c. d.

Push in retainer tabs (2). Draw and pull out quick connector (1) straight from centralized under-floor piping (3). CAUTION: • Pull quick connector holding position (A) as shown in the figure. • Never 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. JPBIA1854ZZ • Keep parts away from heat source. Especially, be careful when welding is performed around them. • Never expose parts to battery electrolyte or other acids. • Never bend or twist connection between quick connector and fuel feed hose (with damper) during installation/removal. • To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags, etc. (A) or something similar.

JPBIA0135ZZ

8. 9.

Remove fuel sub tube mounting bolt. Disconnect harness connector from fuel injector.

Revision: 2007 November

EM-38

2008 EX35

FUEL INJECTOR AND FUEL TUBE < ON-VEHICLE REPAIR > 10. Loosen mounting bolts in reverse order as shown in the figure, and remove fuel tube and fuel injector assembly.

: Engine front

CAUTION: Never tilt fuel tube, or remaining fuel in pipes may flow out from pipes.

C JPBIA0034ZZ

11. Remove fuel injector (2) from fuel tube (4) as follows:

a. b.

: O-ring

: Installed condition

: Clip mounting groove

Open and remove clip (1). 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. • Never bump or drop fuel injector. • Never disassemble fuel injector.

G JPBIA0036ZZ

12. Remove fuel sub-tube and fuel damper, if necessary. I

INSTALLATION 1. a.

b. c.

Install fuel damper (4) as follows: Install new O-ring (2) to fuel tube (1) as shown. When handling new O-ring, be careful of the following caution: CAUTION: • Handle O-ring with bare hands. Never wear gloves. • Lubricate O-ring with new engine oil. • Never clean O-ring with solvent. • Check 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, never insert it quickly into fuel tube. • Insert new O-ring straight into fuel tube. Never twist it. Install spacer (3) to fuel damper. Insert fuel damper straight into fuel tube. CAUTION: • Insert straight, checking sure that the axis is lined up. • Never pressure-fit with excessive force. Reference value

d. 2.

: 130 N (13.3 kg, 29.2 lb)

• Insert fuel damper until (B) is touching (A) of fuel tube. Tighten bolts evenly in turn. • After tightening bolts, check that there is no gap between fuel damper cap (5) and fuel tube. Install fuel sub-tube. • When handling new O-rings, be careful of the following caution: CAUTION: • Handle O-ring with bare hands. Never wear gloves.

Revision: 2007 November

EM-39

JPBIA0316ZZ

2008 EX35

FUEL INJECTOR AND FUEL TUBE < ON-VEHICLE REPAIR > • Lubricate O-ring with new engine oil. • Never clean O-ring with solvent. • Check 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, never insert it quickly into fuel tube. • Insert new O-ring straight into fuel tube. Never decenter or twist it. • Insert fuel sub-tube straight into fuel tube. • Tighten mounting bolts evenly in turn. • After tightening mounting bolts, check that there is no gap between flange and fuel tube. 3. Install new O-rings to fuel injector, paying attention to the following. CAUTION: • Upper and lower O-ring are different. Be careful not to confuse them. Fuel tube side Nozzle side

: Black : Green

• • • • •

4. a.

Handle O-ring with bare hands. Never wear gloves. Lubricate O-ring with new engine oil. Never clean O-ring with solvent. Check 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, never insert it quickly into fuel tube. • Insert O-ring straight into fuel injector. Never decenter or twist it. Install fuel injector to fuel tube as follows: Insert clip (3) into clip mounting groove (D) on fuel injector (5). 2

: O-ring (Black)

: O-ring (Green)

CAUTION: • Never reuse clip. Replace it with a new one. • Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring. Insert fuel injector into fuel tube (1) with clip attached. • Insert it while matching it to the axial center. • Insert fuel injector so that protrusion (A) of fuel tube matches cutout (B) of clip. • Check that fuel tube flange (E) is securely fixed in flange fixing groove (C) on clip. Check that installation is complete by checking that fuel injector does not rotate or come off. • Check that protrusions of fuel injectors are aligned with cutouts of clips after installation.

JPBIA0037ZZ

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: 2007 November

EM-40

2008 EX35

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