Recall - Fuel Filler Hose Replacement

1-800-424-9153), or go to http://www.safercar.gov. Infiniti G35x Sedan AWD V6-3.5L (VQ35DE) Technical Service Bulletin # 06-006B Date: 060404

Recall - Fuel Filler Hose Replacement

RECALL CAMPAIGN BULLETIN

Reference:

ITB06-006b

Date:

April 4, 2006

VOLUNTARY RECALL CAMPAIGN FUEL HOSES

This bulletin has been amended. The Re-Assembly procedure for FX and G35 has been expanded. Please discard all previous versions of this

bulletin.

CAMPAIGN I.D. # / NHTSA # :

R0508 / 05V-555

APPLIED VEHICLES:

2003-04 G35 Coupe (CV35)

2003-04 G35 Sedan (V35)

2003-04 FX35 (S50)

2003-06 FX45 (S50)

APPLIED VINS:

NOTE:

Use Service Comm to confirm campaign eligibility.

INTRODUCTION

Infiniti has determined that some 2003-2004 model year Infiniti G35 sedan/coupe vehicles and 2003-2006 model year Infiniti FX35/45 vehicles may

have a defect which relates to motor vehicle safety. There is the possibility that the fuel filler hose may crack and result in fuel leakage from the hose

while refueling. If an ignition source is present a fire could occur. In addition fuel vapor hoses may crack and cause the malfunction indicator lamp

to come on. To prevent this condition from occurring Infiniti is conducting a Voluntary Safety Recall Campaign to replace the fuel filler and vapor

hoses with new ones.

IDENTIFICATION NUMBER

Nissan has assigned identification number R0508 to this campaign. This number must appear on all communications and documentation of any

nature dealing with this campaign.

NUMBER OF VEHICLES POTENTIALLY AFFECTED

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The number of vehicles potentially affected is approximately 138,800.

DEALER RESPONSIBILITY

It is the retailers responsibility to check Infiniti Net for the campaign status on each vehicle falling within the range of this voluntary safety recall

which for any reason enters the service department. This includes vehicles purchased from private parties or presented by transient (tourist) owners

and vehicles in a dealer's inventory.

Federal law requires that new vehicles in dealer inventory which are the subject of a safety recall must be corrected prior to delivery under a sale or

lease. Failure to do so can result in civil penalties by the National Highway Traffic Safety Administration. While federal law applies only to new

vehicles Infiniti strongly encourages dealers to correct any used vehicles in their inventory before they are retailed.

Repair Overview

Required Parts for G35 Coupe and G35 Sedan

(Refer to the Parts Information section for the part numbers.)

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^ Fuel hose kit (see Figure 1a)

Propeller shaft bolt kit (see Figure 1b)

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^ Exhaust tube gasket (see Figure 1c)

Required Parts for FX35 and FX45

(Refer to the Parts Information section for the part numbers.)

^ Fuel hose kit (see Figure 1d)

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^ Propeller shaft bolt kit (see Figure 1e)

NOTE:

There are two bolt kits available for the FX. Refer to the Parts Information section for ordering details.

^ Propeller shaft center bearing nuts (see Figure 1f)

^ Exhaust tube nuts (see Figure 1f)

^ Exhaust tube gasket (see Figure 1f)

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Required Special Tool for All Models (sent to each dealer)

The essential Jack Adapter Tool J-47441-A will be needed to perform these procedures.

^ If you are using an OTC 16-1728 high lift transmission jack use adapter block J-47002-4 between the jack and the jack adapter tool J-47441-A.

^ The adapter block is part of essential tool J-47002 transmission jack adapter kit.

NOTE:

Replacement tools can be ordered from Nissan TECH-MATE.

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PARTS INFORMATION

CLAIMS INFORMATION

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Submit a Campaign (CM) line claim using the claims coding shown.

"CM" I.D.: R0508

Service Procedure (G35 Coupe and G35 Sedan)

NOTE:

Refer to the FX35 and FX45 service procedure.

Remove the rear suspension member assembly and replace four fuel hoses (from the kit) as follows.

Preliminary Steps

1. Record all radio station presets.

2. Disconnect the negative battery cable.

3. Raise the vehicle on a hoist.

NOTE:

Make sure you release the parking brake.

Remove Rear Wheels/Brake Calipers

4. Remove both rear wheels/tires.

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5. Remove both brake calipers and hang them from the brake line supports with wire (see Figure 2).

Remove Center Exhaust Tube/Rear Muffler

G35 Coupe Procedure ONLY (steps 6 through 17)

NOTE:

For the G35 Sedan procedure, perform steps 18 through 22.

6. Remove the exhaust system ground strap from the muffler stud/nut (see Figure 3).

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7. On the passenger (RH) side: remove two bolts and one clip and remove the rear plastic under cover (see Figure 4).

8. Below the plastic cover you just removed:

remove three bolts and remove the passenger (RH) side rear metal cover (see Figure 5).

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9. On the driver's (LH) side: remove two nuts and one clip and remove the rear plastic under cover (see Figure 6).

10. Below the plastic cover you just removed: remove two bolts and one clip and remove the driver's (LH) side rear metal cover (see Figure 7).

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11. Remove nuts and bolts and remove the tunnel stay side covers and the tunnel stay bracket (see Figure 8).

12. Remove the nut that holds the center muffler mount bracket (see Figure 9).

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13. Remove the bolt that holds the passenger (RH) side rear muffler mount bracket (see Figure 10).

14. Remove the exhaust system center tube front nuts (see Figure 11).

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15. Support the rear muffler with a support jack (see Figure 12).

16. Remove the rear muffler bracket bolts (see Figure 13a and 13b).

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17. Carefully remove the exhaust center tube/rear muffler and place it in a safe location (see Figure 14).

NOTE:

Continue with step 23 (Reposition Propeller Shaft) for the G35 Coupe and G35 Sedan.

G35 Sedan Procedure ONLY (steps 18 through 22) for removing center exhaust tube / rear muffler

NOTE:

For the G35 Coupe procedure, go back to steps 6 through 17.

18. Place a support jack under the rear muffler.

19. Remove the three bolts that hold the rear muffler hanger bracket to the vehicle body (see Figure 15).

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20. Remove the nuts that hold the center muffler mount brackets to the vehicle body (see Figure 16).

21. Remove the exhaust system center tube front nuts (see Figure 17).

22. Carefully remove the exhaust center tube/rear muffler and place it in a safe location.

NOTE:

Continue with step 23 for the G35 Coupe and G35 Sedan Reposition Propeller Shaft procedure.

Re-position Propeller Shaft

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23. If applicable remove four nuts and remove the tunnel brace (see Figure 18).

24. Apply an index (line up) mark across the propeller shaft and differential pinion flange for correct re-assembly (see Figure 19a).

25. Remove four nuts and bolts and carefully re-position the propeller shaft down and to one side. Use a piece of wire to support the propeller

shaft to avoid excessive tension on the propeller shaft center bearing (see Figure 19b).

Disconnect Parking Brake Cables

26. Disconnect the parking brake cables as follows:

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a. Remove the nuts that hold the parking brake cable brackets to the rear suspension member (see Figure 20).

b. Remove the cables from the metal support brackets (see Figure 21).

c. Remove the nuts that hold the parking brake cables to the vehicle body (see Figure 22).

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d. Disconnect the cables from the front equalizer (see Figure 22).

Disconnect ABS Harness Connector/Remove Tie Wrap

27. Disconnect the ABS harness connector (see Figure 23a). Then remove the tie wrap from the suspension member using a pair of needle-nose

pliers (see Figure 23b).

^ If you accidentally break the tie wrap install a new one at re-assembly. The tie wrap part number is 24225-89960.

Disconnect Shock Absorber From Knuckle

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28. Place a support jack under the rear lower link. Then remove the bolt that holds the shock absorber to the knuckle (see Figure 24).

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NOTE:

Do NOT disconnect the shock absorber from the body at the top of the wheel well.

29. Place an index mark across the bushing and cross bar for proper re-assembly (see Figure 26).

Install Jack Adapter Tool # J-47441-A to Differential

NOTE:

For G35 Sedan only the four main suspension member nuts must be lowered before installing the Jack adaptor. This will allow the jack adaptor

to clear the spare tire wheel-well.

Rear Suspension Member Nuts

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a. Support the suspension member with a jack stand near the left rear nut.

b. Lower the nut until only 1 or 2 threads are showing below the nut (see Figure 26a).

c. Lower the jack stand.

d. Perform a, b, and c above for the right rear nut.

CAUTION:

Do not completely remove the nuts.

Front Suspension Member Nuts

a. Support the suspension member with a jack stand near the left front nut.

b. Lower the nut to about the middle of its travel (see Figure 26b).

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c. Lower the jack stand.

d. Perform a, b, and c above for the right front nut.

CAUTION:

Do not completely remove the nuts.

30. Install the jack adapter tool # J-47441-A to the differential pinion flange and suspension member as follows:

a. Install part "A" of the adapter tool onto the pinion flange. Make sure both pins on the tool are inserted into the pinion flange bolt holes

(see Figure 27).

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b. Slide part "B" of the adapter tool over the rear of part "A". Then insert the locator pins at the upper corners of the tool into the rear

suspension member (see Figure 28).

Remove Rear Suspension Member

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31. Use bolts to attach a transmission jack to the adapter tool (see Figure 29).

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32. Place an additional support jack under the front suspension member to help stabilize the vehicle on the lift (see Figure 30).

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33. Place an index mark across the coil spring and upper spring seat for proper re-installation (see Figure 31).

34. Place a support jack under the rear suspension member.

^ Then remove the bolts and nuts that hold the suspension member stay brackets (both passenger and driver's side brackets). See Figure 32.

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^ Slowly lower the support jack and remove the stay brackets.

NOTE:

The larger nuts hold the suspension member.

35. Remove the bolts and nuts and remove the rear stay bracket (see Figure 33).

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36. Carefully lower the suspension member (see Figure 34) and place it in a safe location away from "traffic".

Install Fuel Hoses

CAUTION:

Make sure the fuel tank is less than 114 full before you perform this procedure.

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37. Remove three nuts and remove the evaporative canister shield (see Figure 35).

38. Remove and replace the four fuel hoses (provided in the kit). See Figure 36.

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^ Replace hoses one at a time making sure they are correctly positioned and secured.

^ Tighten the fuel filler hose clamps so that the distance between the bolt head and metal plate is set to the proper dimension (see Figure 36).

33. Re-install all components in the reverse order of removal making sure of the following:

A. Make sure the additional support jack under the center of the front suspension member is in place and contacting the front suspension member.

(see Figure 36A)

B. Raise the rear suspension assembly on the studs until approximately 1.0 inch/ 25.4 mm of the rear stud and approximately 1.25 inch /31.7 mm

of the front stud is sticking through the mount.

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C. Use a single nut on each side to hold the front suspension stay bracket in place.

D. Use a single nut on each side to hold the rear suspension bracket in place.

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E. Use a support jack to raise one corner of the rear suspension assembly until the bushing assembly is flush to the body. Tighten the nut until the

nut contacts the bushing inner sleeve.

F. Repeat the same procedure on the other side.

G. Use a support jack to raise one corner of the front suspension assembly until the assembly is flush to the body. Tighten the nut until the nut

contacts the bushing inner sleeve.

H. Repeat the same procedure on the other side.

I. Torque the front and rear suspension mounting nuts to 110 Nm (11 kg-m 81 ft.lb.)

NOTE:

For removing the jack adaptor on a G35 sedan reverse the order of installation.

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^ All highlighted suspension fasteners are tightened to the proper torque specification (see Figures 37 and 38).

^ All index marks that you made earlier are lined up.

^ Use new nuts/bolts (provided in the kit) for securing the propeller shaft to the differential pinion flange. Tighten the nuts to: 73.5 Nm (7.5

kg-m 54 ft-lb).

^ Use a new gasket (see Parts Information) between the front and center exhaust tubes.

40. Re-connect the negative battery cable.

41. Re-program all radio station pre-sets.

Service Procedure (FX35 and FX45)

Remove the rear suspension member assembly and replace four fuel hoses (from the kit) as follows.

Preliminary Steps

1. Record all radio station presets.

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2. Disconnect the negative battery cable.

3. Raise the vehicle on a hoist.

NOTE:

Make sure the parking brake is released.

Remove Rear Wheels/Brake Calipers

4. Remove both rear wheels/tires.

5. Remove both brake calipers and hang them from the brake line supports with wire (see Figure 39).

Remove Center Exhaust Tube/Rear Muffler

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6. Remove the exhaust system ground strap from the vehicle under body (see Figure 40).

7. On the passenger (RH) side: release clips and remove the rear plastic under cover (see Figure 41).

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8. Below the plastic cover you just removed: release clips and remove the driver's (LH) side rear plastic under cover (see Figure 42).

9. Remove the nut that holds the center muffler mount bracket (see Figure 43).

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10. Remove nuts and bolts and remove the tunnel stay side covers and the tunnel stay (see Figure 44).

11. Remove and discard the exhaust system center tube front nuts (see Figure 45).

^ You will install new nuts at re-assembly. See Parts Information for the nut part number.

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12. Support the exhaust system (see Figure 46).

13. Remove the rear muffler bracket bolts (see Figure 47a and 47b).

NOTE:

If the vehicle is equipped with a factory installed tow hitch you must:

^ Remove the passenger side muffler bracket

^ Slide the driver's side rubber muffler hanger off of the muffler hanger pin

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14. Remove the rear muffler rubber support bolt (see Figure 48).

15. Carefully remove the exhaust system and place it in a safe location (see Figure 49).

Disconnect Parking Brake Cables

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16. Remove four nuts and remove the propeller shaft heat insulator (see Figure 50).

17. Apply an index (line up) mark across the propeller shaft and differential pinion flange for correct re-assembly (see Figure 51).

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18. Remove the front and rear parking brake brackets (see Figure 52a and 52b).

19. Remove the parking brake cables from the front equalizer (see Figure 53).

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20. Remove the parking brake cables from the support clips (see Figure 54).

Re-Position Propeller Shaft

21. Remove and discard the propeller shaft nuts and bolts (see Figure 55).

^ You will install new nuts and bolts at reassembly. See Parts Information for the bolt kit part number.

22. Position a support jack about six inches below the propeller shaft (see Figure 56). Then remove and discard the propeller shaft center bearing

nuts and carefully lower the shaft onto the support jack.

^ You will install new nuts at re-assembly. See Parts Information for the nut part number.

CAUTION:

Make sure to properly support the propeller shaft as it's being lowered.

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^ When you remove the center bearing nuts the propeller shaft rear flange will drop away from the differential pinion flange.

23. Use a piece of wire to hang the propeller shaft from one of the heat shield brackets (see Figure 57). Make sure the shaft is positioned to one

side of the differential pinion flange.

Disconnect ABS Harness Connector/Remove Tie Wrap

24. Disconnect the ABS harness connector (see Figure 58a). Then remove the tie wrap from the suspension member using a pair of needle-nose

pliers (see Figure 58b).

^ If you accidentally break the tie wrap install a new one at re-assembly. The tie wrap part number is 24225-89960.

Disconnect Shock Absorber From Lower Link

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25. Now place a support jack under the front lower link. Then disconnect the shock absorber from the link (see Figure 59).

IMPORTANT:

DO NOT disconnect the shock absorber from the studs at the top of the wheel well housing (see Figure 60).

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26. Place an index mark across the bushing and cross bar for proper re-assembly (see Figure 61).

Install Jack Adapter Tool # J-47441-A To Differential

27. Install the jack adapter tool # J-47441-A to the differential pinion flange and suspension member as follows:

a. Install part "A" of the adapter tool onto the pinion flange. Make sure both pins on the tool are inserted into the pinion flange bolt holes

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(see Figure 62).

b. Slide part "B" of the adapter tool over the rear of part "A". Then insert the locator pins at the upper corners of the tool into the rear

suspension member (see Figure 63).

c. Install and tighten the bolt that holds part "C" to part B as shown in Figure 63.

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d. Install jack adapter part C as shown in Figure 64.

e. Install and tighten the bolt that holds "part C" to "part A" as shown in Figure 64.

Remove Rear Suspension Member

28. Use bolts to install a transmission jack to the jack adapter as shown in Figure 65.

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29. Place an additional support jack under the front suspension member to help stabilize the vehicle on the lift (see Figure 66).

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30. Remove the bolts and nuts that hold the suspension member stay brackets (both passenger and driver's side brackets). See Figure 67. Then

remove the stay brackets.

NOTE:

The larger nuts hold the suspension member.

31. Remove the rear stay bracket and suspension member rear nuts (see Figure 68).

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32. Carefully lower the suspension member out of the vehicle (see Figure 69) and place it in a safe location.

Install Fuel Hoses

CAUTION:

Make sure the fuel tank is less than 1/4 full before you perform this procedure.

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33. Remove three nuts and remove the evaporative canister shield (see Figure 70).

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34. Remove and replace the four fuel hoses (provided in the kit). See Figure 71.

^ Replace hoses one at a time making sure they are correctly positioned and secured.

^ Tighten the fuel filler hose clamps so that the distance between the bolt head and metal plate is set to the proper dimension (see Figure 71).

Re-Assembly

33. Re-install all components in the reverse order of removal making sure of the following:

A. Make sure the additional support jack under the center of the front suspension member is in place and contacting the front suspension

member. (see Figure 36A)

B. Raise the rear suspension assembly on the studs until approximately 1.0 inch/ 25.4 mm of the rear stud and approximately 1.25 inch /31

.7 mm of the front stud is sticking through the mount.

C. Use a single nut on each side to hold the front suspension stay bracket in place.

D. Use a single nut on each side to hold the rear suspension bracket in place.

E. Use a support jack to raise one corner of the rear suspension assembly until the bushing assembly is flush to the body. Tighten the nut

until the nut contacts the bushing inner sleeve.

F. Repeat the same procedure on the other side.

G. Use a support jack to raise one corner of the front suspension assembly until the assembly is flush to the body. Tighten the nut until the

nut contacts the bushing inner sleeve.

H. Repeat the same procedure on the other side.

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I. Torque the front and rear suspension mounting nuts to 89 Nm (9.1 kg-m 66 ft.lb.)

^ All highlighted suspension fasteners are tightened to the proper torque specification (see Figure 72). All index marks that you made

earlier are lined up.

^ Use new nuts/bolts (provided in the kit) for securing the propeller shaft to the differential pinion flange. Tighten the nuts to: 56.9

Nm (5.8 kg-m 42 ft-lb).

^ Use new nuts (see Parts Information) for mounting the propeller shaft center bearing assembly. Tighten these nuts/bolts to: 44 Nm

(4.5 kg-m 70 ft-lb).

^ Use a new gasket (see Parts Information) between the front and center exhaust tubes. Also use new nuts (see Parts Information) for

securing these tubes together.

36. Re-connect the negative battery cable.

37. Re-program all radio station pre-sets.

Computers/Controls - Reprogramming Utilizing CONSULT(R)

Infiniti G35x Sedan AWD V6-3.5L (VQ35DE) Technical Service Bulletin # 11-049A Date: 110818

Computers/Controls - Reprogramming Utilizing CONSULT(R)

Classification: EC11-022A

Reference: ITB11-049A

Date: August 18, 2011

REPROGRAMMING WITH CONSULT

This bulletin has been amended. The statements below have changed. No other changes have been made. Please discard any previous copies.

APPLIED VEHICLES: All Infiniti vehicles with a reprogrammable ECU

SERVICE INFORMATION

If you have a reprogram that requires the use of CONSULT-II (C-II) and C-II is not available:

^ Refer to the chart below to determine CONSULT applicability.

CURRENT REPROGRAMMING APPLICABILITY CHART

Reprogramming C-II Loaner Program

(Available ONLY for reprogramming use)

^ Contact TECH LINE and they will determine if a C-II Loaner is needed. If so they will make arrangements for the loaner to be shipped.

^ Dealerships must return the C-II Loaner immediately after the reprogramming is completed.

^ If the Loaner is not returned within one week of delivery your FOM will be contacted to collect the unit.

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Disclaimer Infiniti G35x Sedan AWD V6-3.5L (VQ35DE) Technical Service Bulletin # 04-028 Date: 040609

170

Instruments - Low Tire Pressure Warning System

Classification:

WT04-008

Reference:

ITB04-028

Date:

June 9, 2004

LOW TIRE PRESSURE WARNING SYSTEM (LTPWS)

TECHNICAL INFORMATION

APPLIED VEHICLES:

All with LTPWS

SERVICE INFORMATION

LTPWS and TPMS are the same Systems. Only the name has changed.

^ Old name: TPMS (Tire Pressure Monitor System)

^ New name: LTPWS (Low Tire Pressure Warning System)

This bulletin provides important information for the LTPWS. Use this information:

^ For correctly setting the tire air pressure.

^ When inspecting an incident vehicle or when performing a PDI.

^ When speaking to customers.

^ To help avoid LTPWS incidents and customer concerns.

Setting The Correct Tire Pressure During PDI:

^ During the PDI process set the tire pressure to the specification shown on the Tire and Loading Information Label (placard).

^ Refer to the vehicle Owner's Manual for the placard location. For example on the 2004 QX56 the placard is located in the middle of the drivers

side B-pillar.

^ Tire pressures should be set with the tires cold (see NOTE).

^ Once the tires are set to the correct pressure confirm the following during the PDI drive check:

> The LTPWS properly operates.

> The correct tire pressure is displayed (by LTPWS).

Factors That Affect Tire Pressure: Temperature and Altitude

NOTE:

The tire pressures should be checked when the tires are COLD. The tires are considered COLD after the vehicle has been parked for 3 or more

hours, or driven less than 1 mile (1.6 km) at moderate speeds.

Cold Ambient Temperatures:

^ The LTPWS measures the pressure inside the tire.

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^ Cold ambient temperature conditions may cause the tire pressure to drop and the LTPWS to illuminate the Low Tire Pressure Warning Light.

Example (vehicle with a tire pressure specification of 32 p.s.i.):

^ If the temperature is 70锟斤拷F and the tire pressure is 30 psi., the LTPWS warning light will stay OFF.

^ However, if the temperature drops to 30锟斤拷 F, the tire pressure will drop to 27 p.s.i. and the LTPWS light will come ON.

If you think the LPTWS light is coming on because of temperature-related pressure changes:

^ First, check the tire pressure using the LTPWS display before replacing any parts.

^ Set the tire pressure to the correct specification. It's shown on the vehicle's Tire and Loading Information Label.

NOTE:

LTPWS does not adjust air pressure for a temperature change.

^ Please inform the customer that tire pressure can change due to temperature.

^ Cold ambient temperature conditions may effect the tire pressure more at high altitudes. See High Altitude.

High Altitude:

^ The LTPWS measures the pressure inside the tire.

^ The LTPWS does not adjust air pressure for extreme altitude conditions.

^ In extreme altitude conditions a standard tire pressure gauge may show a different pressure than the LTPWS display.

^ The tire pressure should be set using the LTPWS display.

Example:

^ When the vehicle is at 0 ft altitude, the LTPWS display and the standard tire gauge will show the same p.s.i. reading: In this case 30 p.s.i.

^ When the vehicle is at 5,427 ft altitude (same temperature) the LTPWS display will still show 30 p.s.i. and the standard tire gauge will show 33

p.s.i.

LTPWS Sensor Reading Times:

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The tire pressure signals from the wheel sensors are updated by the control unit as follows:

^ With the vehicle stopped and ignition ON: The sensors will transmit a signal 1 time per hour.

^ Over 20 MPH: The sensors will transmit a signal 1 time per minute.

^ On command using the transponder and the Consult "Data Monitor Screen".

Low Tire Pressure Warning Light:

^ This is a separate light that warns of low tire pressure. Complete information can be found in the vehicle Owner's Manual & Service Manual.

A/T, CVT - Terminology Update To SAE JJ1930 and J2012

Disclaimer Infiniti G35x Sedan AWD V6-3.5L (VQ35DE) Technical Service Bulletin # 09-027 Date: 090602

A/T, CVT - Terminology Update To SAE JJ1930 and J2012

Classification AT09-008

Reference ITB09-027

Date June 2, 2009

UPDATE TO AT/CVT TERMINOLOGY IN SERVICE MANUALS

APPLIED SERVICE MANUALS: 1994-2009

SERVICE INFORMATION

The terminology for Automatic Transmission ("AT") and Continuously Variable Transmission ("CVT") in the Infiniti Service Manuals is being

updated to reflect the terminology in SAE J1930 and J2012.

368

369

370

371

372

373

374

375

When using 1994-2009 Service Manuals, please refer to the updated AT/CVT terminology as shown above.

NOTE:

Later versions of 2008 and 2009 Electronic Service Manuals will have updated AT/CVT terminology applied.

Fuel System - Fuel Tank Difficult To Fill More Than Half

Infiniti G35x Sedan AWD V6-3.5L (VQ35DE) Technical Service Bulletin # 08-041A Date: 081028

Fuel System - Fuel Tank Difficult To Fill More Than Half

Classification: FE08-004A

Reference: ITB08-041A

Date: October 28, 2008

HARD TO FILL FUEL TANK

Applied Vehicles has been amended and the Classification was changed to FE. No other content has changed. Please discard all earlier versions.

APPLIED VEHICLES:

2003 - 2006 G35 Sedan (V35)

2007 - 2008 G35 Sedan (V36)

2003 - 2007 G35 Coupe (CV35)

2008 G37 Coupe (CV36)

2006 - 2008 M (Y50)

IF YOU CONFIRM

The fuel tank is difficult to fill more than 1/2

NOTE:

Filling nozzle continues to click OFF when the fuel tank is more than 1/2 full.

ACTIONS

Install the Cut Bracket (cover) onto the Fill Limit Vent Valve (FLVV) inside the fuel tank (see Service Procedure).

NOTE:

All fuel must be removed from the tank for this procedure.

IMPORTANT:

The purpose of "ACTIONS" (above) is to give you a quick idea of the work you will be performing. You MUST closely follow the entire Service

Procedure as it contains information that is essential to successfully completing this repair.

PARTS INFORMATION

109

CLAIMS INFORMATION

SERVICE PROCEDURE

NOTE:

The procedure in this bulletin will require placing your entire arm into the fuel tank. The fuel tank must be empty for this procedure.

1. Remove the fuel pump from the fuel tank.

^ Refer to Section FL in the Service Manual for fuel pump removal information.

^ CAUTION:

The fuel tank is required to be less than 7/8 full before removing the fuel pump in order to prevent fuel spillage from the fuel pump opening.

2. Cut / split the side of a piece of rubber tube (vacuum line) and place it on the edge of the fuel pump opening.

^ This will protect your hands and arms from the sharp edge of the fuel tank.

Before continuing with this procedure:

^ Make sure the fuel tank is empty.

110

^ Read through all of the steps and understand the procedure.

3. Hold the Cut Bracket (cover) so the open side of the cover is towards the passenger side of the vehicle.

NOTE:

There is very little room inside the tank to maneuver the cover. You should hold it in the installation direction as you put it into the tank.

4. While holding the cover, reach into the tank.

5. Maneuver the cover to the FLV valve and snap the cover onto the valve.

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112

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^ The FLV valve is located in the middle upper area of the tank. Refer to Figures 4 through 8.

^ See Photos above (Figures 5 - 8).

6. Use a mirror to confirm the cover is installed correctly.

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7. Reinstall all parts removed in reverse order.

NOTE:

Make sure to use a new 0-ring (P/N 17342 - 01A00) on the fuel pump opening.

Antitheft System - No Start Using New Ignition Key

Disclaimer Infiniti G35x Sedan AWD V6-3.5L (VQ35DE) Technical Service Bulletin # 04-018A Date: 050913

Antitheft System - No Start Using New Ignition Key

Classification:

EL04-008a

Reference:

IB04-018a

Date:

September 13, 2005

137

G35 AND QX56; ENGINE WILL NOT START

IVIS / NATS SYSTEM DESCRIPTION / KEY REGISTRATION

IMPORTANT:

THIS BULLETIN HAS BEEN REVISED.

The Applied Vehicles section was updated. Also, the "If You Confirm" and "Action" statements were added.

Nothing else in the bulletin was changed.

Use this bulletin ITB04-018a for complete information.

Discard all previously distributed copies of ITB04-018.

APPLIED VEHICLES:

2004 and later G35 (V35)

2004 and later QX56 (JA60)

IF YOU CONFIRM:

A no-start condition when using a new ignition key.

ACTION:

Perform key registration NEW service procedure covered in this bulletin.

SERVICE INFORMATION

^ This bulletin covers a new version of the Infiniti Vehicle Immobilizer System/Nissan Anti-Theft System (IVIS/NATS). This system, referred to

as NATS", is standard equipment on the Applied Vehicles listed above.

^ This new version of NATS uses advanced anti-theft functions which are "password protected". This helps prevent "unauthorized access" into the

NATS registration procedure.

^ To obtain the password from ASIST, first use CONSULT-II to get the "BCM-specific" 5-digit number (PIN) code from the vehicle.

^ Unlike earlier NATS systems, this NATS system DOES NOT need to be Re-Initialized if the Electronic Control Unit (ECM) is replaced.

NOTE:

The ECM and Body Control Module (BCM) do work together, but the BCM in this new system controls the information necessary to "tell"

the ECM to start the vehicle.

IMPORTANT:

The NATS "Control Unit (C/U) Initialization and Key Registration" Procedure in this bulletin is for the Applied Vehicles only. Do not use this

procedure on other NATS-equipped vehicles.

System Components (see Figure 1)

^ NATS ignition key (with transponder chip).

138

^ NATS antenna amplifier located around the ignition key cylinder.

^ Body Control Module (BCM)

^ Engine Control Module (ECM)

^ Security indicator (Light Emitting Diode or LED) located on the dash.

System Operation

^ The NATS uses a digital radio frequency (RF) to transmit a key code between the NATS key ID chip (which is imbedded in the NATS ignition

key) and the BCM.

^ When a registered NATS key transmits a valid (good) key code the BCM will send a signal to the ECM that will allow the engine to start.

^ If the key doesn't "send" a good code the BCM will not transmit a valid code to the ECM and the ECM will not let the engine start.

Special Service Notes:

Key Registration Required

^ NATS will not allow the engine to start without the use of a registered ignition key.

^ Previous and current Infiniti models with NATS have a Key I.D. chip in the ignition key head (see Figure 2).

^ If a vehicle will not start and the Dash Security Lamp is ON solid it is possible that the ignition keys were not properly registered into the

vehicle's Body Control Module (BCM).

^ When a NATS ignition key is replaced a new key added or the BCM is replaced the Control Unit (C/U) Initialization and Key Registration

MUST BE PERFORMED or THE ENGINE WILL NOT START.

^ If a new ignition key(s) needs to be added or if any ignition key needs to be re-registered ALL other ignition keys must be re-registered at the

same time or they will no longer start the engine.

Other Important Information

^ When a NATS key is manufactured the NATS key code is permanently encoded to the NATS key ID chip. This code cannot be changed.

^ It is recommend to use only Infiniti service parts (key blanks).

^ NATS only allows the vehicle to start. It does not activate the vehicle theft warning system.

^ Each vehicle is supplied from the factory with three registered NATS ignition keys. A maximum of five ignition keys can be registered to the

NATS.

Transponders

If a NATS-equipped vehicle experiences an intermittent no-start condition another transponder could be causing interference (blocking the

signal).

Examples of transponder interference:

139

^ Other vehicle ignition keys that have transponders (key I.D. chips). Either from the same vehicle or another model.

^ Transponders such as the Mobil Speedpass(R) may be a source of interference (see Figure 3).

^ These items may be too close (3/4 to 1 inch) to the registered key that is being used to start the vehicle.

^ In cases of interference from other keys or transponders there will be a "DIFFERENCE OF KEY" code stored in the Engine Control Module

(ECM). The MIL will not turn "ON" for this code.

^ Once the vehicle is started transponder interference will not cause the engine to stall.

^ To avoid transponder interference, advise the customer to keep all other transponders on separate key rings.

SERVICE PROCEDURE

NATS C/U Initialization (using the 4-Digit PIN Code) and Key Registration

^ It is highly recommended that you read through the entire service procedure before doing it for the first time.

1st step; Prepare

1. Collect all existing ignition keys from the customer.

Note:

ANY KEYS THAT ARE NOT REGISTERED AT THIS TIME WILL NO LONGER START THE VEHICLE.

2. Separate all NATS ignition keys and other transponders away from each other.

^ Take them off the key ring.

^ You must keep them separate during the whole key registration process.

2nd step; Get the "BCM-specific" 5-Digit Number Code

1. Insert the NATS (purple) Program Card into slot A of the CONSULT-II (see Figure 4).

2. Connect CONSULT-II to the vehicles data link connector.

^ Use the CONSULT-II CAN converter and cable set to do this.

3. Insert a key into the ignition and turn the Ignition ON. Do Not start the engine.

140

4. Wait for the CONSULT-II system software to "load". Then select the following on the CONSULT-II screen:

[START] > [OTHER] > [OK] > [NATS BCM] Or [S/ENT] > [PIN READ] (CONSULT-II will display and print the BCM-Specific 5-digit

code.)

5. Take the printout and go to an ASIST terminal to "decode" the BCM-Specific 5-digit code.

3rd step; Decode the number

1. From the ASIST Main Menu screen click on Information Tool Box.

2. From the "Information Tool Box" screen click on NATS Decoder button (see Figure 5).

3. Follow the steps in Figure 6.

NOTE:

^ The letter "0" is not used in the 5-digit number code. Anything that looks like an "0" is really the number zero "0".

4th step; C/U Initialization Procedure

1. Select [BACK] twice on the CONSULT-II screen. It should return to the SELECT SYSTEM screen.

141

2. Select [NATS V 5.0].

3. Touch [C/U INITIALIZATION].

4. On the CONSULT-II IMMU INITIALIZATION touch screen:

^ Type in the 4-digit PIN.

^ You wrote it down from ASIST IVIS/NVIS (NATS) screen (step 3).

5. Touch [START] on CONSULT-II to perform C/U INITIALIZATION.

6. When C/U INITIALIZATION is complete:

a. INITIALIZATION COMPLETED will be displayed on the IMMU INITIALIZATION screen.

b. Turn ignition key to the "OFF/LOCK" position and pull it out.

c. WAIT AT LEAST 5 SECONDS.

d. Go to 5th step; Key Registration.

NOTE:

The key that you just used is NOT registered vet.

5th step; Key Registration

1. Insert a key into the ignition and turn it to the "ON" position.

Do not start the engine.

2. Wait at least 5 seconds (the Security Lamp will flash 5 times, then it will stop).

3. Turn the key to "OFF/LOCK" and remove it.

^ The key is now registered. Keep it separate from the other keys.

IMPORTANT:

Keep the first REGISTERED key separate from ALL the other keys for right now. DO NOT MIX UP KEYS!

NOTE:

^ The first registered key will be used later in step 4 (below). Keep it separate from all other keys.

^ Keep the "registered" keys and the "unregistered" keys in different piles during this process.

^ Accidentally inserting an already "registered" key into the ignition at this point will drop the system out of the registration mode.

^ If this happens you will have to start all over again. Go back to # 1 of 4th step (C/U Initialization); and restart from there.

4. Repeat steps 1, 2 and 3 for all remaining "unregistered" keys.

^ Remember a maximum of five keys can be registered into the system.

5. After registering and removing the last key;

^ Re-insert the first registered key and

^ turn the key to the ON position for 5 seconds.

^ This will take the system out of the key registration mode.

NOTE:

The Security Lamp will not flash during this 5-second period.

6. Turn the key to the "OFF" position.

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7. Wait for the Security Lamp to start blinking (approximately 5 seconds).

^ This indicates the completion of Key ID Registration and C/U Initialization.

^ Proceed to Key Confirmation (Step 6).

6th step; Key "Confirmation" (check)

1. Confirm that the Security Indicator Lamp on the dash is blinking.

This verifies the completion of the Key ID Registration procedure.

2. Confirm all keys operate (start the engine) as follows:

a. Start the engine.

b. Turn the ignition OFF and remove the key.

c. Watch and wait for the Security Indicator Lamp to begin blinking (approximately 5 seconds).

^ This indicates the system has reset.

^ You must wait for the system to reset between key checks or key operation will not be confirmed.

d. Start the engine using the next key.

e. Repeat steps a - c for all keys that were registered.

3. Press [BACK] on the CONSULT-II screen.

4. Press [BACK] on the CONSULT-II screen again.

5. Put any registered key into the ignition and turn it to the "ON" position.

6. Select [SELF-DIAGNOSIS RESULTS] to check for DTC's.

^ In rare cases "CHAIN OF ECM-IMMU" or other DTC's may be stored during the Key Registration process.

^ If DTC's are stored press [ERASE] to clear them.

7. Turn the ignition to "LOCK" and remove the key.

8. Turn CONSULT-II OFF and disconnect it from the vehicle.

298

Disclaimer Infiniti G35x Sedan AWD V6-3.5L (VQ35DE) Technical Service Bulletin # 04-027A Date: 060828

298

Engine Controls - MIL ON/DTC's P1031/P1051/P1148/P1168

Classification:

EC04-022a

Reference:

ITB04-027a

Date:

August 28, 2006

2004-2005 FX35 AND G35; MIL "ON" WITH DTC P1031, P1051, P1148, P1168

ITB04-027 has been amended and supersedes ITB04-023 Please discard all previous versions of these bulletins.

APPLIED VEHICLES:

2004-2005 FX35 (S50) and G35 (V35)

APPLIED VINS:

G35 Sedan 2WD After JNKCV51E(*)4M6000001

G35 Sedan 4WD After JNKCV51F(*)4M7000001

G35 Coupe After JNKCV54E(*)4M8000001

FX35 2WD After JNRAS08U(*)4X105001

FX35 4WD After JNRAS08W(*)4X210001

Vehicles built After October 2003.

APPLIED DATES:

IF YOU CONFIRM:

A MIL "ON" with the following DTC(s) stored:

On 2004 MY vehicles ONLY

^ P1031 / P1051 (A/F Sensor Heater), and/or

^ P1148 / P1168 (A/F Sensor Closed Loop Control),

On 2005 MY vehicles ONLY

^ P1148 / P1168 (A/F Sensor Closed Loop Control),

ACTIONS:

Step A: Use Consult II to confirm this bulletin applies:

^ Check the Current ECM Part Number.

^ Perform A/F Sensor test to confirm proper air fuel operation.

If the A/F sensor fails the test this bulletin does not apply. Go back to ASIST for further repair information.

^ Compare your Current ECM Part Number to Chart A.

If that part number does not match one in Chart A, this bulletin does not apply. Go back to ASIST for further diagnostic and repair

information.

Step B: If this bulletin applies, reprogram the ECM.

IMPORTANT:

The purpose of "ACTIONS" (above) is to give you a quick idea of the work you will be performing. You MUST closely follow the entire

Service Procedure as it contains information that is essential to successfully completing this repair.

CLAIMS INFORMATION

299

Submit a Primary Failed Part (PP) line claim using the claims coding shown.

SERVICE PROCEDURE

Step A: Confirm This Bulletin Applies

1. With CONSULT-II "ON" print the Freeze Frame data as shown.

2. Attach this printout to the Repair Order.

^ Figure 1 is an example of the F.F. Data printout.

^ The Freeze Frame data that you've printed contains the ECM Part Number (P/N).

^ The ECM part number will be used to see if this bulletin applies or not.

3. Use CONSULT-II DATA MONITOR to view;

^ Engine Speed and

^ A/F Sensor voltage (see Figure 2).

300

4. Hold the engine speed at about 2000 rpm no-load for 2 minutes.

^ This will create a stable condition for step 5 (below).

5. Observe A/F SEN1 (B1) and A/F SEN1 (B2) voltage for 30 seconds while holding 2000 rpm no-load.

a. During most of this test the A/F sensor voltages should remain between 1.37 and 1.57 volts.

NOTE:

If the engine rpm is held constant voltage will fluctuate (change) but should remain in this range.

^ If the A/F sensor voltages are out of this range for most of the test this bulletin does not apply. Go back to ASIST for further diagnostic

and repair information.

^ If the A/F sensor voltages are OK proceed to step 6.

6. Check the ECM Part Number on the printout you made in Step 1.

^ Compare your vehicle's ECM P/N to those shown under Current ECM P/N in Chart A below:

Chart A

A. If your vehicle's ECM P/N matches a P/N in the chart above:

^ Go to Step B: ECM Reprogramming.

B. If your vehicle's ECM P/N does not match a P/N in the chart above:

This bulletin does not apply. Go back to ASIST for further diagnostic and repair information.

Step B: ECM REPROGRAMMING

Vehicle ECM Reprogramming Overview

^ There are four basic steps (tasks) under Step B:

1. Download reprogramming data (transfer it) from ASIST into CONSULT-II.

2. Preparation steps before reprogramming.

3. Reprogram the vehicle ECM.

4. ECM Reprogramming Wrap-up..

NOTE:

^ For those familiar with ECM Reprogramming please review the following steps and use them as a Quick Reference for ECM

reprogramming.

301

Step One: Download (Transfer) Data From ASIST Into CONSULT-II

1. Select vehicle model and model year (Example: FX35 2004).

2. Select the correct reprogramming data:

a. Locate the specific Model Configuration (Example: VQ35 A/i 2WD).

NOTE:

Model Configuration may include items such as engine type transmission type and vehicle options such as ASCD TCS and ABS etc.

b. Select (click on) the "To" number.

NOTE:

The "To" number will read: 23710-XXXXX.

3. Click on the Add button.

This will add the data you selected to the File(s) Selected list.

4. Write the To number on the Repair Order.

5. Click on Continue and follow directions to perform data transfer (download) from ASIST into CONSULT-II.

Step Two: Preparation for Reprogramming ECM

1. Connect a battery charger to the vehicle's battery. Set the charger to a low charge rate (trickle charge).

302

CAUTION:

For number 2 below and number 3, DO NOT connect the CONSULT-II A/C Power Supply.

2. Press [SUB MODE] (see Figure C) then:

a. From the listed items find and select [BATTERY CHARGE].

3. Check the CONSULT-II's Charger Input reading (see Figure D).

NOTE:

^ "Battery Voltage" is the voltage level of CONSULT-II's battery.

^ "Charger Input" is the voltage level of the vehicle's battery. (It must be above 12 volts.)

303

CAUTION:

If the "Charger Input" is below 12 volts:

^ A list of items to check when "Charger Input" voltage is below 1 2V is contained in the "ECM Reprogramming For Infiniti Vehicles" general

procedure.

Step Three: Reprogram the ECM

^ General procedure called "ECM Reprogramming For Infiniti Vehicles"

Step Four: "Wrap-up" After Reprogramming is finished

1. Turn the ignition switch "OFF" and CONSULT-II OFF".

2. Wait more than 10 seconds then;

a. Turn the ignition switch "ON" for 2 second then

b. Turn the ignition switch "OFF" again for 10 seconds (see Figure E). This will reset ECM "self learned Data.

3. Start the engine and check the idle speed.

^ If idle speed is too low perform Idle Air Volume Learning (IAVL). See the appropriate Service Manual (ESM) for this procedure.

NOTE:

If the engine will not idle hold the engine RPM at about 2000 then slowly bring it down to an idle. IAVL can now be performed.

4. Confirm the engine is operating normally.

5. Make sure the MIL is OFF.

^ If the MIL comes ON use CONSULT-II with the Diagnostic (red/white) Card to erase any DTCs that may have stored during the

reprogramming procedure.

Body - Removing Foreign Material From The Windshield

Disclaimer Infiniti G35x Sedan AWD V6-3.5L (VQ35DE) Technical Service Bulletin # 13-007 Date: 130322

Body - Removing Foreign Material From The Windshield

Classification: BT13-007

Reference: ITB13-007

Date: March 22, 2013

REMOVING FOREIGN MATERIAL FROM THE WINDSHIELD

APPLIED VEHICLES: All Infiniti

SERVICE INFORMATION

Windshield "foreign material" that is on the surface of the glass in some cases can be cleaned off with a very particular type and grade of steel wool.

^ Most any foreign material on the surface of the Windshield can be cleaned off by using #0000 super fine steel wool.

> The #0000 grade super fine steel wool can be found in most hardware stores.

^ In most cases the glass cannot be damaged by manually rubbing (no power tools) too hard or too much and it is recommended not to use any

cleaners with the steel wool.

Use new steel wool from an un-opened bag and store unused portion in a re-sealable container to prevent contamination.

455

^ Do not use dirty or contaminated steel wool. Dirty or contaminated steel wool will scratch the glass. If the steel wool is dropped on the floor get a

new piece of steel wool to clean the windshield.

^ Clean (then dry) windshield first with soap and water to remove any abrasive dirt or grit that may be present before using steel wool.

NOTE:

Always try and clean any windshield surface issue first with #0000 grade super fine steel wool before glass replacement is considered.

CLAIMS INFORMATION

Foreign material on the windshield surface is not a warrantable condition.

Materials used to clean the windshield, such as the steel wool mentioned above, are considered a shop supply.

Audio System - Satellite Radio Antenna Installation

Disclaimer Infiniti G35x Sedan AWD V6-3.5L (VQ35DE) Technical Service Bulletin # 06-019 Date: 061011

Audio System - Satellite Radio Antenna Installation

Classification:

EL06-013

Reference:

ITB06-019

Date:

October 11, 2006

2003-2007 G35; SATELLITE RADIO ANTENNA INSTALLATION TIPS

307

APPLIED VEHICLES:

2003 - 2007 G35 Sedan and Coupe

SERVICE INFORMATION

The service information provided here only clarifies the most critical areas in the Satellite Radio antenna installation instructions for accessory

(dealer installed) Satellite Radio.

Carefully follow the complete antenna installation instructions provided with the antenna kit or the installation instructions available in the NNA

Dealer Portal.

Critical Steps for Antenna Installation

^ Ambient temperature must be above 20锟斤拷C (68锟斤拷 F). If not, tape and mating surface must be heated to at least 20锟斤拷C (68锟斤拷 F).

^ Make sure technician hands, gloves, or anything that comes into contact with the feeder cover or mating surface is clean and free from

contaminants.

^ Mating surface must be free of contaminants and cleaned with 50/50 isopropyl alcohol / water solution.

^ Apply adhesion promoter to the glass surface per the installation instructions.

^ Do not contaminate the tape surface or mating surface prior to installation.

^ Be aware the feeder cover will stick instantly to the prepared and primed surface and CANNOT be repositioned. Feeder cover alignment and

positioning must be DONE prior to attachment.

^ Apply smooth and even pressure on the feeder cover to ensure 100% wet-out.

^ Keep the vehicle inside in a warm area (above 20锟斤拷C or 68锟斤拷 F) for at least an hour after installation to help promote initial curing of the tape.

^ Advise the customer to avoid any activity which would impose pressure on the feeder cover (such as a car wash) within the first 48 hours.

Computers/Controls - CONSULT III PLUS(R) Saved Data List

Infiniti G35x Sedan AWD V6-3.5L (VQ35DE) Technical Service Bulletin # 12-057 Date: 120912

Computers/Controls - CONSULT III PLUS(R) Saved Data List

Classification: EC12-022

Reference: ITB12-057

Date: September 12, 2012

24

SAVED DATA LIST REPROGRAMMING WITH CONSULT III PLUS

SERVICE INFORMATION

^ When performing a "Reprogramming" operation with C-III plus, the screen in Figure 1 may display.

^ This screen displays "Saved Data" from previous C-III plus operations.

^

During the initial "Reprogramming Confirmation" set-up, if you get this screen:

1. Select Delete, then

2. Select Other Operation, then

3. Continue with the reprogramming procedure.

NOTE:

If reprogramming does not complete, this screen can display for reprogramming recovery. Do not select Delete if this screen displays

during reprogram recovery.

359

Infiniti G35x Sedan AWD V6-3.5L (VQ35DE) Technical Service Bulletin # 08-014 Date: 080310

359

Tire Monitor System - TPMS Sensor Seal Leak

Classification: WT08-006

Reference: ITB08-014

Date: March 10, 2008

TPMS SENSOR SEAL LEAK

APPLIED VEHICLES:

2004 - 2006 G35 Sedan (V35) with TPMS

2004 - 2007 G35 Coupe (CV35) with TPMS

2004 - 2008 FX (S50) with TPMS

2004 M45 (Y34) with TPMS

2006 - 2008 M (Y50) with TPMS

2004 - 2006 Q45 (F50) with TPMS

2004 - 2008 QX56 (JA60) with TPMS

SERVICE INFORMATION

When repairing an air leak at a TPMS (Tire Pressure Monitor System) sensor seal a seal is now available separately.

DO NOT replace the entire sensor when only a seal is needed.

PARTS INFORMATION

CLAIMS INFORMATION

Reference the current Infiniti Warranty Flat Rate Manual for claims coding information.

Lighting - Exterior Lamp Fogging

Infiniti G35x Sedan AWD V6-3.5L (VQ35DE) Technical Service Bulletin # 03-051F Date: 120221

Lighting - Exterior Lamp Fogging

Classification: EL03-031F

Reference: ITB03-051F

Date: February 21, 2012

EXTERIOR LAMP FOGGING

This bulletin has been amended. The Applied Vehicles section and the first paragraph of the Service Information section have been revised. Please

discard all previous versions. This bulletin supercedes ITB08-019A.

APPLIED VEHICLES: 2001-2012 Infiniti, All Models

SERVICE INFORMATION

Occasionally customers may notice water vapor or fog in the exterior lamps. This is generally NOT due to a defect.

The following information illustrations and flow chart are provided to help you in determining if an incident for water/condensation in lamps is

normal or not.

All current exterior lamp assemblies are vented to the atmosphere (not sealed).

97

^ This is necessary to allow for expansion and contraction of air from temperature "variations" (warmer or colder) without damage to the lamp.

^ Moisture in the air sometimes "travels" into and out of the lamp assembly through these vents.

^ Certain environmental conditions may cause moisture to condense.

^ The fogging/cloudiness should disappear over time when the lamp is in a dry environment.

Fog may temporarily form inside the lens of the exterior lamp assemblies based on environmental conditions or sudden temperature changes (such as

in a car wash or parked on a cold sunny day). This is normal. See Figure 1.

NOTE:

This condensation can appear anywhere on the outer lens typically at its coldest location.

If the moisture trickles, drips, or pools it may not be considered normal and the headlamp assembly may have a water leak path. See Figure 2 for an

example.

98

If large drops of water collect inside the lens refer to the flow chart above to find the next step to take.

SERVICE PROCEDURE

Should a customer note water in a lamp assembly please use the following flow chart to determine if the condition is normal or requires lamp

Emissions - EVAP Canister Vent Control Valve Replacement

Infiniti G35x Sedan AWD V6-3.5L (VQ35DE) Technical Service Bulletin # 09-062 Date: 091117

Emissions - EVAP Canister Vent Control Valve Replacement

Classification: EC09-026

Reference: ITB09-062

Date: November 17, 2009

VENT CONTROL VALVE REPLACEMENT

APPLIED VEHICLES:

All Infiniti models using Vent Control Valve P/Ns 14935-AM60A / AM60B

SERVICE INFORMATION

When replacing the EVAP canister vent control valve for any reason:

417

^ Use the one listed in the PARTS INFORMATION section of this bulletin.

^ For vent control valve replacement procedure, refer to the appropriate section of the Electronic Service Manual (ESM) if needed.

^ When installing the new valve, do not add any lube to its o-ring.

^ Make sure to use the "new style" valve listed in PARTS INFORMATION.

Fuel System - Fuel Tank Difficult to Refuel

Disclaimer Infiniti G35x Sedan AWD V6-3.5L (VQ35DE) Technical Service Bulletin # 05-031 Date: 050614

Fuel System - Fuel Tank Difficult to Refuel

Classification:

FE05-003

Reference:

ITB05-031

Date:

June 14, 2005

2003-2005 G35 AND FX; FUEL TANK DIFFICULT TO FILL AT TIMES

APPLIED VEHICLE(S):

2003-2005 G35 (V35) and (CV35)

2003-2005 FX (S50)

IF YOU CONFIRM

The fuel tank is intermittently difficult to fill.

283

ACTION

Replace the shutter valve inside of the fuel tank. (see fuel tank cut-away view, Figure 1)

IMPORTANT:

The purpose of ACTIONS (above) is to give you a quick idea of the work you will be performing. You MUST closely follow the entire Service

Procedure as it contains information that is essential to successfully completing this repair.

PARTS INFORMATION

CLAIMS INFORMATION

Submit a Primary Failed Part (PP) line claim using the claims coding shown.

284

SERVICE PROCEDURE

1. Release the fuel pressure from the fuel system using CONSULT-II (or other suitable method). Follow the procedure in the "EC" section of the

ESM.

2. Use a suitable device to remove as much fuel as possible from the fuel tank.

WARNING:

Follow all CAUTIONS and WARNINGS provided in the Service Manual.

3. Remove the fuel level sensor. Refer to the FE section of the ESM.

WARNING:

The fuel level sensor opening and internal baffle have edges that are sharp.

4. You'll be working inside the fuel tank. To prevent injury place a split piece of rubber vacuum hose electrical harness cover tape or other

suitable covering

^ Apply tape onto the edge of the fuel level sensor opening. (see Figure 2)

285

^ Apply an electrical harness cover to the edge of the vented baffle inside the tank. (see Figure 3 cut-away view from bottom of tank)

5. Reach inside the tank and gently bend the baffle away from you so you can reach under it. However don't overdo it. If you bend it too far you

won't be able to reach the shutter valve on the end of the tank inlet.

6. Remove the shutter valve with a twisting motion while pulling it straight off. (see Figure 4 cut-away view from bottom of tank)

7. Install the shutter valve listed in the Parts Information section of this bulletin.

^ Push it on the end of the tube with a twisting motion

^ Turn it until a "snap" is heard and felt

^ Confirming the tab locks to the hole. (shown in Figure 4)

286

^ The hole is on the end of the fuel inlet tube. (see Figure 5)

8. Gently bend the baffle back to it's original position.

9. Remove the protectors you installed to the tank in step 4. (opening and baffle)

10. Install the new fuel level sensor 0-ring in the groove on the fuel tank.

11. Re-install the fuel level sensor on the fuel tank. Refer to the FE section of the ESM.

12. Add the removed quantity of fuel to the tank.

Engine Controls - ECM Replacement Procedures

Disclaimer Infiniti G35x Sedan AWD V6-3.5L (VQ35DE) Technical Service Bulletin # 00-038C Date: 040416

Engine Controls - ECM Replacement Procedures

Classification:

155

EC00-008c

Reference:

ITB00-038c

Date:

April 16, 2004

ECM REPLACEMENT PROCEDURES

ATTENTION:

THIS BULLETIN HAS BEEN REVISED.

^ The Service Procedures for replacing an ECM on an Applied vehicle were revised.

^ Please use this bulletin ITB00-038c for complete information.

^ Discard all previously distributed copies of ITB00-038.

APPLIED VEHICLES:

All 2000 and later

1999 Q45 (FY33)

1999 QX4 (JR5O) from VIN JNRAR07**XW060101

IF YOU CONFIRM:

The Electronic Control Module (ECM) needs to be replaced on a 2000 MY and later vehicle, or an Applied 1999 MY vehicle (see above).

ACTIONS:

^ Re-register all customer keys if the vehicle has ECM based NATS (see step 1).

^ Check ASIST for any new updates for the new ECM you're installing (see steps 2 - 4).

^ Perform the "ACCELERATOR PEDAL & THROTTLE VALVE CLOSED POSITION LEARNING" procedure (see step 5).

^ After installing the new ECM, perform the "IDLE AIR VOL LEARNING" procedure (when applicable) using CONSULT-II. See step 6.

^ For 2005 and later vehicles, enter the vehicle VIN into the new ECM (see step 7).

CAUTION:

Failure to perform all the work steps in the specified order can cause poor engine running, MIL "ON", or vehicle emission test rejection.

IMPORTANT:

The purpose of "ACTIONS" (above) is to give you a quick idea of the work you will be performing. You MUST closely follow the entire

Service Procedure as it contains information that is essential to successfully completing this repair.

156

CLAIMS INFORMATION

Disclaimer

Service Procedure

Check NATS On The Vehicle

157

1. Check to see if the vehicle you're working on has ECM based NATS V2.0 or V5.0.

a. If the vehicle has ECM based NATS V2.0 or V5.0 it will NOT start after you install a service replacement ECM. So you'll have to

re-register all ignition keys including spare keys with CONSULT-II and the purple NATS card. After you do this proceed with step 2.

^ If you do not know how to re-register the keys refer to the ESM for the NATS key re-registration procedure.

b. If the vehicle has BCM based NATS (instead of ECM based NATS V2.0 or V5.0) you do NOT have to re-register the ignition or spare

keys. Proceed with step 2.

Check For ECM Data Updates in ASIST

2. In ASIST select [CONSULT Utilities] >> [ECM/TCM Data]. Then choose Model and Model Year (see Figure 1).

3. Look for ECM Data Updates (listed by ECM P/Ns and vehicle configuration) in the top center display panel of the ASIST screen (see Figure

1).

a. If there is no updates listed for your vehicle configuration you do NOT have to reprogram the service replacement ECM. Proceed with

step 5.

b. If there is updates listed for your vehicle configuration see if they apply to the service replacement ECM you're going to install. Do this

by performing step 4.

4. Select the configuration on the screen for the vehicle you're working on. Then confirm that your ECM is listed in the "Replaces

23710-XXXXX, -XXXXX etc" section in the lower center Details panel of the ASIST screen (see Figure 1).

a. If your ECM is listed in the Details panel you must reprogram the ECM with the latest data update. After you do this proceed with step

5.

CAUTION:

The 1999-2000 Q45 and 1999-2000 QX4 have a gray CONSULT connector AND a white GST connector. Do NOT attempt to

perform the ECM Reprogramming procedure with CONSULT-II connected to the gray CONSULT connector. See the appropriate

ESM for further details if necessary.

b. If your ECM is NOT listed in the Details panel you do NOT have to reprogram the ECM. Proceed with step 5.

Accelerator Pedal & Throttle Valve Closed Position Learning

5. Perform the Accelerator Pedal & Throttle Valve Closed Position Learning as follows:

a. Make sure the accelerator pedal is fully released.

b. Turn the ignition switch "ON" for 2 seconds.

c. Turn the ignition switch OFF for 10 seconds.

d. Turn the ignition switch "ON" for 2 seconds then

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e. Turn the ignition switch "OFF" again for 10 seconds (see Figure 2).

f. Proceed with step 6.

Perform Idle Air Volume Learning (IAVL)

NOTE:

Make sure all electrical loads are turned OFF, including A/C, defroster, radio, lights, etc. while performing the following procedures. Also, make

sure the engine cooling fans are NOT operating during the following procedures.

6. Perform the Idle Air Volume Learning procedure as follows:

a. Connect CONSULT-II to the vehicle.

b. Warm up engine and transmission to operating temperature.

c. In the [CONSULT WORK SUPPORT] mode, select [IDLE AIR VOL LEARN]. See Figure 3.

NOTE:

^ If IDLE AIR VOL LEARN is not shown as a SELECT WORK ITEM on CONSULT, the vehicle does not need the procedure.

^ In this case only, this bulletin is complete, no further action is needed.

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d. Press [START] on the "IDLE AIR VOL LEARN" screen. See Figure 4.

e. Press [START] on the "WORK SUPPORT" screen to begin the Idle Air Volume Learning (IAVL) procedure. See Figure 5.

^ The IAVL procedure will take several minutes to complete.

^ CONSULT will display "Please Wait" in the center of the screen while the IAVL procedure is in process. See Figure 6.

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^ CONSULT will display "CMPLT" in the top right corner of the screen when the IAVL procedure is finished. See Figure 7.

f. Once the IAVL procedure is finished proceed with step 7.

For 2005 and Later MY Vehicles ONLY: Enter VIN Into New Service Replacement ECM

7. Enter the VIN into the new service replacement ECM as follows:

a. Select [ENGINE] on the select System screen. See Figure 8.

b. Select [WORK SUPPORT] on the select Diag Mode screen. See Figure 9.

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c. Scroll down and select [VIN REGISTRATION] on the select Work Item screen. See Figure 10.

d. Press [START] on the "VIN Registration" screen. See Figure 11.

e. Select [INPUT] on the "VIN Registration" screen. See Figure 12.

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f. Enter the entire VIN using the keyboard. See Figure 13.

^ Use [CHNG] to switch between the letters and numbers keyboard screens.

g. Once the entire VIN is entered select [ENTER] on the Keyboard screen. See Figure 14.

h. Select [INPUT] on the VIN Registration screen and enter the entire VIN again. See Figure 15.

^ You MUST enter the VIN a second time for confirmation purposes.

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i. Once the entire VIN is entered (a second time) select [ENTER] on the Keyboard screen. See Figure 16.

j. Select [START] on the "VIN Registration" screen to complete the VIN registration process. See Figure 17.

Restraints - DTC's B1129 Or B1134 Set

Infiniti G35x Sedan AWD V6-3.5L (VQ35DE) Technical Service Bulletin # 12-034B Date: 120828

Restraints - DTC's B1129 Or B1134 Set

Classification: RS12-004B

Reference: ITB12-034B

Date: August 28, 2012

2003 - 2005 G35 SEDAN AND COUPE

DTC B1129 OR B1134 SIDE MODULE OPEN

This bulletin has been amended to correct the model years in the Claims Information. No other changes have been made to the body of this bulletin.

APPLIED VEHICLES: 2003 - 2005 G35 Sedan (V35) with power seats

2003 - 2005 G35 Coupe (CV35)

IF YOU CONFIRM

25

DTC B1129 or B1134 (SIDE MODULE RH or LH [OPEN]) is stored in Self Diagnosis Current or Self Diagnosis Past.

NOTE:

This service bulletin provides updated procedures specifically for vehicles that have been repaired using the methods described in ITB10-034 or

ITB10-036 as determined by the following actions:

ACTIONS

NOTE:

^ A portion of the Service Procedure in campaigns R1019 and P0339 was updated.

^ The updated portion involves replacement of the Side Air Bag Connector.

^ This bulletin provides the information needed to perform the updated portion of the procedure on vehicles with DTC B1129 or B1134 that

were previously campaigned.

IMPORTANT:

The purpose of ACTION (above) is to give you a quick idea of the work you will be performing. You MUST closely follow the entire SERVICE

PROCEDURE as it contains information that is essential to successfully completing this repair.

PARTS INFORMATION

26

CLAIMS INFORMATION

27

Preparation For Side Air Bag Connector Replacement Kit

SERVICE PROCEDURE

NOTE:

^ This procedure applies to front power seats only.

^ Some 2003 G35 Sedans have a manual front passenger seat that is not included in this bulletin.

Preparation for Side Air Bag Connector Replacement Kit Installation (Sedan and Coupe)

1. Write down all radio station presets.

2. If equipped, write down / record the following customer settings for the ATC (Automatic Temperature Control) system. (Refer to the Service

Manual as needed):

^ Temperature Setting Trimmer

^ Foot Position Setting Trimmer

^ Inlet Port Memory Function

3. Move front seat(s) forward and remove the rear mounting bolts.

4. Move front seat(s) to the full rear position.

5. Adjust the seatback (recline) on front seat(s) to the full forward position.

6. Remove the front mounting bolts for the front seat(s).

NOTE:

^ For most vehicles, both front seats should have the above steps performed before disconnecting the battery cable.

^ Some 2003 G35 Sedans have a manual front passenger seat that is not included in this bulletin.

7. Make sure the ignition is OFF and disconnect both battery cables (negative cable first).

8. Wait at least 3 minutes after the battery cables are disconnected.

IMPORTANT:

Follow all cautions, warnings, and notes in the Electronic Service Manual (ESM) when working on or near a Supplemental Restraint

System (SRS), such as an airbag.

28

9. Tip the seat(s) backward as far as possible without harness overstretching the seat wiring harness.

^ Driver seat shown, passenger seat is similar.

NOTE:

Use covers as needed to protect seats and other interior surfaces.

Sedan - Front Seat Side Air Bag Connector Replace Kit(Power Only)

SEDAN: Front Seat (Driver and Passenger Power) Side Air Bag (SAB) Connector Replacement Kit

IMPORTANT:

Follow all cautions, warnings, and notes in the Electronic Service Manual (ESM) when working on or near a Supplemental Restraint

System (SRS), such as an airbag.

NOTE:

^ Some 2003 G35 Sedans have a manual front passenger seat that is not included in this bulletin.

^ Make sure to perform this procedure on the driver seat and the front passenger power seat.

^ Figures 1a through 5a are used for both the driver seat and the front passenger power seat.

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^ Preparation steps should already have been done (Refer to Preparation for Side Air Bag Connector Replacement kit Sedan and Coupe).

1. Look under the seat and locate the SAB connector (see Figure 1a).

2. Remove / disconnect the SAB connector from the mounting bracket.

^ Disconnect / snap loose the connector mounting clip.

^ Cut / remove the mounting clip type tie-wraps.

3. Remove the mounting clip from the SAB connector.

4. Replace the SAB connector with new connector ends.

^ Refer to Side Air Bag (SAB) Connector Replacement.

^ Use Connector Replacement Kit P/N 24009-CM71A.

5. Reinstall the connector mounting clip onto the new SAB connector (see Figure 3a).

6. Install 2 new "mounting clip type" tie-wraps as shown in Figure 3a.

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^ Pull the tie-wraps tight against the harness.

NOTE

7. Mount the new SAB connector on the bracket as shown in Figure 5a.

NOTE:

Make sure to perform this procedure on the driver seat and the front passenger power seat.

8. After kit installation, reinstall the seat(s) in reverse order.

^ Torque for seat mounting bolts: 49 N-m (5.0 kg-m, 36 ft-lb)

9. Go to "Final Steps After Installation of Side Air Bag Connector Kits".

Coupe (2003-2005)-Driver Seat Side Air Bag Connector Replace Kit

31

COUPE (2003-2005): Driver Seat Side Air Bag (SAB) Connector Replacement Kit Installation

IMPORTANT:

Follow all cautions, warnings, and notes in the Electronic Service Manual (ESM) when working on or near a Supplemental Restraint

System (SRS), such as an airbag.

NOTE:

Preparation steps should already have been done.

1. Look under the seat and locate the SAB connector (taped to harness). See Figure 1b.

2. Remove the tape to expose the SAB connector.

3. Cut and remove the 3 tie-wraps shown in Figure 2b.

4. Replace the SAB connector with new connector ends.

^ Refer to Side Air Bag (SAB) Connector Replacement.

32

^ Use Connector Replacement Kit P/N 24009-CM71A.

5. Reattach the SAB connector to the seat main harness as follows:

a. First, use tie-wraps to secure the SAB connector to the main harness (see Figures 3b, 4b and 5b).

^ Make sure the connector is secured to the side of the harness as shown in Figure 4b.

^ One tie-wrap (P/N 24216-S5800) - Harness to connector - as shown in Figure 5b.

^ Two tie-wraps (P/N 24216-S5800) - harness to harness - 15 mm (9/16 inch) from the connector as shown in Figure 5b.

33

b. Completely tape the SAB connector to the main harness as shown in Figure 6b.

IMPORTANT:

Use ONLY specified tape (P/N 24828 - AM00A).

6. Go to:

^ COUPE (2003-2004): Front Passenger Seat Side Air Bag Connector Replacement Kit Installation.

Or

^ COUPE (2005): Front Passenger Seat Side Air Bag Connector Replacement Kit Installation.

Coupe (2003-2004)-Front Passenger Seat Side Air Bag Connector Replace Kit

COUPE (2003-2004): Front Passenger Seat Side Air Bag Connector Replacement Kit Installation.

34

IMPORTANT:

Follow all cautions, warnings, and notes in the Electronic Service Manual (ESM) when working on or near a Supplemental Restraint

System (SRS), such as an airbag.

NOTE:

Preparation steps should already have been done.

1. Look under the seat and locate the SAB connector (taped to harness). See Figure 1c.

2. Cut / remove the tie-wrap shown in Figure 1c.

3. Remove the tape to expose the SAB connector.

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4. Cut and remove the 3 tie-wraps shown in Figure 2c.

NOTE:

Leave the metal rod taped to the harness.

5. Replace the SAB connector with new connector ends.

^ Refer to Side Air Bag (SAB) Connector Replacement.

^ Use Connector Replacement Kit P/N 24009-CM71A.

36

6. Attach the new SAB connector to the seat harness and metal rod as shown in Figure 3c and 4c.

^ Make sure the connector is secured to the bottom of the harness as shown in Figure 3c.

^ Use 2 tie-wraps (P/N 24216-S5800) - harness to harness - as shown in Figure 4c.

^ Cut excess tie-wrap flush so there are no sharp edges.

37

7. Completely tape the SAB connector to the seat harness as shown in Figure 5c.

IMPORTANT:

Use ONLY specified tape (P/N 24828 - AM00A).

8. Attach tie-wrap (P/N 24216 - S5800) around harnesses and S-spring as shown in Figure 5c.

^ Cut excess tie-wrap flush so there are no sharp edges.

NOTE:

Make sure SAB connector replacement kits are installed on both front seats.

9. After installation of kits on both front seats, reinstall the seats in reverse order.

^ Torque for seat mounting bolts: 49 N-m (5.0 kg-m, 36 ft-lb)

10. Go to Final Steps After Installation of Side Air Bag Connector Replacement Kits.

Coupe (2005) - Front Passenger Seat Side Air Bag Connector Replace Kit

COUPE (2005): Front Passenger Seat Side Air Bag Connector Replacement Kit Installation

IMPORTANT:

Follow all cautions, warnings, and notes in the Electronic Service Manual (ESM) when working on or near a Supplemental Restraint

System (SRS), such as an airbag.

NOTE:

Preparation steps should already have been done.

38

1. Look under the seat and locate the SAB connector (see Figure 1d).

2. Remove / disconnect the SAB connector from the mounting bracket.

^ Cut the mounting clip type tie-wraps.

^ Disconnect / snap loose the connector mounting clip.

3. Remove the mounting clip from the side air bag connector.

4. Replace the SAB connector with new connector ends.

^ Refer to Side Air Bag (SAB) Connector Replacement.

^ Use Connector Replacement Kit P/N 24009-CM71A.

39

5. Reinstall the connector mounting clip onto the new SAB connector (see Figure 3d).

6. Install 2 new "mounting clip type" tie-wraps as shown in Figure 3d.

7. Mount the new SAB connector on the bracket as shown.

NOTE:

Make sure SAB connector replacement kits are installed on both front seats.

8. After installation of kits on both front seats, reinstall the seats in reverse order.

^ Torque for seat mounting bolts: 49 N-m (5.0 kg-m, 36 ft-lb).

9. Go to Final Steps After Installation of Side Air Bag Connector Replacement Kits.

40

Final Steps After Install of Side Air Bag Connector Replacement Kit

Final Steps After Installation of Side Air Bag Connector Kits

1. Connect the battery cables, positive cable first.

2. Reset the clock and the radio station presets.

3. Reset / Re-initialize power windows, power sunroof, ATC, etc. as needed.

^ Refer to Additional Service When Removing Battery Negative Terminal in the GI section of the appropriate Service Manual for details.

4. Connect C-III plus to the vehicle and check air bag codes.

^ Erase any side module "open circuit" codes (SIDE MODULE RH or LH [OPEN]: B1129 or B1134) stored in Self Diagnosis Current or

Self Diagnosis Past.

^ Codes other than the above are not covered by this bulletin. If any codes other than the above are stored; diagnose and repair as needed

using usual diagnostic and repair procedures.

5. Disconnect CONSULT from the vehicle.

6. Turn the ignition OFF and then ON. Make sure the air bag warning lamp (on the instrument panel) turns ON and then goes OFF after about 7

seconds.

Side Air Bag (SAB) Connector Replacement

Side Air Bag (SAB) Connector Replacement

NOTE:

Use connector replacement kit -- P/N 24009-CM71A (one kit per connector/seat).

1. Attach a personal ground strap to your wrist and a ground point on the vehicle.

^ Keep the ground strap attached during the entire connector replacement process.

NOTE:

Personal ground straps are available at local electronic supply stores.

41

2. Position the SAB connector and harness so you have ample working room.

3. Disconnect the SAB connector.

NOTE:

The SAB harness side (seat side) end will be replaced first.

42

4. Remove / pull off the corrugated cover end (see Figures CR4 and CR5).

5. Cut / split the side of the corrugated cover and remove it to expose the SAB wires.

^ Cut enough to expose 165 mm (6-1/2 inches) of the SAB wires.

CAUTION:

Do not damage the SAB wires.

6. Measure 150 mm (6 inches) from the back side of the SAB connector.

43

7. Install the shorting pin at the 150 mm (6 inch) point (see Figure CR7 to CR10).

NOTE:

The shorting pin is included in the connector replacement kit.

WARNING:

Make sure the shorting pin is securely installed before cutting the harness wires. The shorting pin will prevent unintended air bag

deployment from static electricity.

a. Align the harness wires with the slits in the shorting pin as shown in Figure CR8 and CR9.

CAUTION:

Damage to the harness may occur if the wires are not aligned with the slits.

Align the harness wires with the slits in the shorting pin as shown.

44

b. Use pliers to securely attach the shorting pin to the harness.

8. Cut the SAB harness wires 60 mm (2-3/8 inches) from the back side of the SAB connector (see Figure CR11).

9. Strip about 10 mm of insulation from the ends of the SAB harness wires.

10. Slide solder sleeve connector onto the SAB harness wires as shown in Figure CR13.

NOTE:

^ Solder sleeve connectors are included in the connector replacement kit.

^ When the shorting pin is removed these solder sleeve connectors will be used to cover the pierced insulation.

45

11. Cut the wires on the new SAB connector 60 mm (2-3/8 inches) from the back side of the connector (see Figure CR14).

NOTE:

^ Make sure you are prepping the SAB side (seat side) of the SAB connector (male end).

^ The wire length of the new connector must match the cut of wire length of the old connector.

12. Strip about 10 mm of insulation from the wire ends of the new connector.

13. Slide solder sleeve connectors onto the connector wires as show in Figure CR15.

NOTE:

Solder sleeve connectors are included in the connector replacement kit.

14. Twist the wires of the new SAB connector together with the wires of the SAB harness as shown in Figure CR16.

NOTE:

46

There is no need to match wires. It does not matter which wire from the harness is connected to which wire from the connector.

15. Slide the solder sleeve connectors from the connector side over the twisted wires (see Figure CR16).

16. Attach the new connector using the solder sleeve connectors (refer to Instructions for Using Solder Sleeve Connectors shown below).

NOTE:

It is recommended that you read all of the instructions for using solder sleeve connectors shown below before starting.

Instructions for Using Solder Sleeve Connectors

A. Securely twist together the wires that will be connected / soldered.

B. Position the Solder Sleeve Connector so that the solder ring (in the connector) is centered around the exposed twisted wire area.

WARNING:

Do not use an electric type soldering tool. An electric type soldering tool may generate a current that may activate the SAB.

47

C. Use the special Flameless Heat Gun - J-46538 to heat the solder sleeve connector.

This operation will:

^ Melt the solder (silver ring inside the solder sleeve connector) into the exposed twisted wire area.

^ Melt the sealant (red rings inside solder sleeve connector) onto the wires.

^ Shrink the plastic sleeve onto the wires.

Important Soldering Tips:

^ Position the solder sleeve connector in the middle of the heat shield of the Heat Gun.

^ Start heating the connector from the center and move back and forth (side to side) and around to allow even distribution of the heat

to the entire connector.

^ Make sure the solder completely flows into the exposed twisted wires and the adhesive properly seals the wire insulation to the

connector sleeve. Stop applying the heat immediately after this happens.

WARNING:

^ The Flameless Heat Gun and the solder sleeve connectors become HOT during the soldering process.

^ Allow the gun and connectors to cool before handling them.

CAUTION:

Be careful not to damage the connector or wires with the heat gun:

^ Do not apply heat for more than about 40 seconds.

^ Do not overheat the connector or wires (i.e., severe darkening of connector sleeve or wire insulation).

17. Once the wires are attached with the solder sleeve connectors, remove the shorting pin.

NOTE:

48

When the shorting pin is removed there will be exposed wires at the point of the pierced insulation. The additional solder sleeve

connectors will be used to cover these exposed wires.

18. Slide the additional solder sleeve connectors over the exposed wires (see Figures CR21 and CR22).

19. Apply the solder sleeve connectors.

^ Position the solder part of the connector over the exposed wires.

^ Use the special Flameless Heat Gun-J-46538 to heat the solder sleeve connector.

^ Refer to Important Soldering Tips below.

Important Soldering Tips:

^ Position the solder connector in the middle of the heat shield of the Heat Gun.

^ Start heating the connector from the center and move back and forth (side to side) and around to allow even distribution of the heat to the

entire connector.

^ Make sure the adhesive properly seals the wire insulation to the connector sleeve. Stop applying the heat immediately after this happens.

WARNING:

^ The Flameless Heat Gun and the Solder Connectors become HOT during the soldering process.

^ Allow the Gun and connectors to cool down before handling them.

CAUTION:

Be careful not to damage the connector or wires with the heat gun:

^ Do NOT apply heat for more than about 40 seconds.

^ Do NOT overheat the connector or wires (i.e., severe darkening of connector sleeve or wire insulation).

49

20. Install a new corrugate cover over the SAB wires.

NOTE:

New corrugated cover is supplied with the connector replacement kit.

21. Apply electrical tape to the corrugated cover and wires as shown.

^ As you wrap, keep the tape tight to the harness.

^ Over-lap the tape 50% as you wrap.

Replacement of the body side connector end

22. Cut / remove the plastic covering from the body side harness wires.

50

^ Cut enough to expose 75 mm (3 inches) of the wires.

23. Cut the wires 60 mm (2-3/8 inches) from the back side of the connector as shown in Figure CR26.

24. Strip about 10 mm of insulation from the ends of the body side harness wires.

25. Cut the wires on the new body side connector end 60 mm (2-3/8 inches) from the back side of the connector as shown in Figure CR28.

NOTE:

^ Make sure you are prepping the body side connector (female end).

^ The wire length of the new connector must match the cut of wire length of the old connector.

26. Strip about 10 mm of insulation from the wire ends.

51

27. Install solder sleeve connectors on the wires as show in Figure CR29.

NOTE:

Solder sleeve connectors are included in the connector replacement kit.

28. Twist the wires of the new connector together with the wires of the harness.

NOTE:

There is no need to match wires. It does not matter which wire from the harness is connected to which wire from the connector.

29. Slide the solder sleeve connectors over the connectors twisted wires (see Figure CR30).

30. Attach the new connector using the solder sleeve connectors (refer to Instructions for Using Solder Sleeve Connectors.

31. Cover the wires with a corrugated cover.

52

^ Cut the corrugated cover to the correct length.

NOTE:

Corrugated cover is included in the connector replacement kit.

32. Apply electrical tape to the corrugated cover and wires as shown.

^ As you wrap, keep the tape tight to the harness.

^ Over-lap the tape 50% as you wrap.

33. Re-connect the SAB connector.