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
266
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.
