Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Infiniti FX45 FX35 2003-2005 Approved FX45_35-S50-2004.0 tf

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TRANSFER


D DRIVELINE/AXLE

                                                                                                                                                             A




                                                                                                     SECTION                   TF
                                                                                                                        TRANSFER
                                                                                                                                                             B



                                                                                                                                                             C


                                                                                                                                                             TF


                                                                                                                                                             E
                                                                 CONTENTS
PRECAUTIONS ......................................................... 3 .           AWD CONTROL UNIT INSPECTION TABLE .... 19                       .         F
 Precautions for Supplemental Restraint System                                    CONSULT-II Function (ALL MODE AWD/4WD) .... 21                    .
 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-                                            FUNCTION ......................................................... 21
                                                                                                                                                    .
 SIONER" ................................................................. 3
                                                                        .           CONSULT-II SETTING PROCEDURE ............... 21                 .        G
 Precautions ............................................................. 3
                                                                        .           SELF-DIAG RESULT MODE .............................. 21         .
 Service Notice ......................................................... 4
                                                                        .           DATA MONITOR MODE ..................................... 23      .
 Wiring Diagrams and Trouble Diagnosis ................. 4              .           ACTIVE TEST MODE ........................................ 24    .
                                                                                                                                                             H
PREPARATION .......................................................... 5.           AWD CONTROL UNIT PART NUMBER ............ 24                    .
 Special Service Tools .............................................. 5 .        TROUBLE DIAGNOSIS FOR SYSTEM ................... 25                .
 Commercial Service Tools ....................................... 6     .         Power Supply Circuit For AWD Control Unit .......... 25           .
NOISE, VIBRATION AND HARSHNESS (NVH)                                                CONSULT-II REFERENCE VALUE IN DATA                                        I
TROUBLESHOOTING ............................................... 7       .           MONITOR MODE ............................................... 25 .
 NVH Troubleshooting Chart .................................... 7       .           DIAGNOSTIC PROCEDURE ............................. 25           .
TRANSFER FLUID .................................................... 8   .         AWD Control Unit .................................................. 26
                                                                                                                                                    .         J
 Replacement ........................................................... 8
                                                                        .           DIAGNOSTIC PROCEDURE ............................. 26           .
   DRAINING ............................................................ 8
                                                                        .         ABS System .......................................................... 26
                                                                                                                                                    .
   FILLING ................................................................ 8
                                                                        .           DIAGNOSTIC PROCEDURE ............................. 26           .
                                                                                                                                                             K
 Inspection ................................................................ 8
                                                                        .         AWD Solenoid ....................................................... 27
                                                                                                                                                    .
   FLUID LEAKAGE AND FLUID LEVEL ................. 8                    .           CONSULT-II REFERENCE VALUE IN DATA
AWD SYSTEM ........................................................... 9.           MONITOR MODE ............................................... 27 .
 Power Transfer Diagram ......................................... 9     .           DIAGNOSTIC PROCEDURE ............................. 27           .         L
 System Description ................................................. 9 .           COMPONENT INSPECTION ............................. 29           .
   DESCRIPTION ..................................................... 9  .         AWD Actuator Relay .............................................. 30
                                                                                                                                                    .
   ELECTRIC CONTROLLED COUPLING ............ 10                         .           CONSULT-II REFERENCE VALUE IN DATA                                       M
   AWD CONTROL UNIT ....................................... 10          .           MONITOR MODE ............................................... 30 .
   AWD WARNING LAMP .......................................11           .           DIAGNOSTIC PROCEDURE ............................. 30           .
 System Diagram .....................................................11 .         Engine Control Signal ............................................ 31
                                                                                                                                                    .
   COMPONENTS FUNCTION DESCRIPTION .... 12                              .           DIAGNOSTIC PROCEDURE ............................. 31           .
 CAN Communication ............................................. 12     .         CAN Communication Line ..................................... 31   .
   SYSTEM DESCRIPTION ................................... 12            .           DIAGNOSTIC PROCEDURE ............................. 31           .
TROUBLE DIAGNOSIS ........................................... 13        .        TROUBLE DIAGNOSIS FOR SYMPTOMS ............. 32                    .
 Fail-Safe Function ................................................. 13.         AWD Warning Lamp Does Not Turn ON When The
 How to Perform Trouble Diagnosis ....................... 13            .         Ignition Switch Is Turned To ON ............................ 32   .
   BASIC CONCEPT .............................................. 13      .           DIAGNOSTIC PROCEDURE ............................. 32           .
 Location of Electrical Parts .................................... 14   .         AWD Warning Lamp Does Not Turn OFF Several
 Circuit Diagram ..................................................... 15
                                                                        .         Seconds After Engine Started ............................... 32   .
 Wiring Diagram -- AWD -- ................................... 16        .           DIAGNOSTIC PROCEDURE ............................. 32           .
 Trouble Diagnosis Chart for Symptoms ................ 19               .         Heavy Tight-corner Braking Symptom Occurs
 AWD Control Unit Input/Output Signal Reference                                   When The Vehicle Is Driven And The Steering
 Values ................................................................... 19
                                                                        .         Wheel Is Turned Fully To Either Side After The


Revision: 2004 November                                                     TF-1                                                   2004 FX35/FX45
 Engine Is Started ................................................... 34
                                                                       .        REAR OIL SEAL ......................................................40
                                                                                                                                                    .
   DIAGNOSTIC PROCEDURE ............................. 34               .         Removal and Installation ........................................40.
 Vehicle Does Not Enter AWD Mode Even Though                                       REMOVAL ...........................................................40
                                                                                                                                                    .
 AWD Warning Lamp Turned To OFF ..................... 35               .           INSTALLATION ...................................................41
                                                                                                                                                    .
   DIAGNOSTIC PROCEDURE ............................. 35               .        AIR BREATHER HOSE ............................................42    .
 While Driving, AWD Warning Lamp Flashes Rapidly                                 Removal and Installation ........................................42.
 (When Flashing In Approx. 1 Minute And Then Turn-                              TRANSFER ASSEMBLY ..........................................43      .
 ing OFF) ................................................................ 36
                                                                       .         Removal and Installation ........................................43.
 While Driving, AWD Warning Lamp Flashes Slowly                                    REMOVAL ...........................................................43
                                                                                                                                                    .
 (When Continuing To Flash Until Turning Ignition                                  INSTALLATION ...................................................43
                                                                                                                                                    .
 Switch OFF) ........................................................... 36
                                                                       .         Components ...........................................................44
                                                                                                                                                    .
   DIAGNOSTIC PROCEDURE ............................. 36               .         Disassembly and Assembly ...................................45     .
AWD CONTROL UNIT ............................................. 38      .           DISASSEMBLY ...................................................45.
 Removal and Installation ....................................... 38   .           INSPECTION ......................................................49
                                                                                                                                                    .
   REMOVAL .......................................................... 38
                                                                       .           ASSEMBLY .........................................................49
                                                                                                                                                    .
   INSTALLATION ................................................... 38 .        SERVICE DATA AND SPECIFICATIONS (SDS) .....55                       .
FRONT OIL SEAL .................................................... 39 .         General Specifications ...........................................55
                                                                                                                                                    .
 Removal and Installation ....................................... 39   .
   REMOVAL .......................................................... 39
                                                                       .
   INSTALLATION ................................................... 39 .




Revision: 2004 November                                                    TF-2                                                    2004 FX35/FX45
                                             PRECAUTIONS

PRECAUTIONS                                                         PFP:00001
                                                                                                                        A
Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT
BELT PRE-TENSIONER"                                                                                         ADS000RH


The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along B
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front C
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING:                                                                                                             TF
q    To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
     in the event of a collision which would result in air bag inflation, all maintenance must be per-
     formed by an authorized NISSAN/INFINITI dealer.                                                                  E
q    Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
     sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
     Bag Module, see the SRS section.                                                                                 F
q    Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
     Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
     harness connectors.
                                                                                                                      G
Precautions                                                                                                  ADS000RI


q   Before connecting or disconnecting the AWD control unit
    harness connector, turn ignition switch "OFF" and discon-                                                           H
    nect negative battery cable. Because battery voltage is
    applied to AWD control unit even if ignition switch is turned
    "OFF".                                                                                                              I


                                                                                                                        J


                                                                                                          SEF289H
                                                                                                                        K
q   When connecting or disconnecting pin connectors into or
    from AWD control unit, take care not to damage pin termi-
    nals (bend or break).                                                                                               L
    When connecting pin connectors, make sure that there are
    no bends or breaks on AWD control unit pin terminal.
                                                                                                                        M




                                                                                                          SEF291H



q   Before replacing AWD control unit, perform AWD control
    unit input/output signal inspection and make sure whether
    AWD control unit functions properly or not. Refer to TF-19,
    "AWD Control Unit Input/Output Signal Reference Values" .




                                                                                                          SDIA1848E




Revision: 2004 November                              TF-3                                       2004 FX35/FX45
                                            PRECAUTIONS

Service Notice                                                                                            ADS000RJ


q   After overhaul refill the transfer with new transfer fluid.
q   Check the fluid level or replace the fluid only with the vehicle parked on level ground.
q   During removal or installation, keep inside of transfer clear of dust or dirt.
q   Replace all tires at the same time. Always use tires of the proper size and the same brand and pattern.
    Fitting improper size and unusual wear tires applies excessive force to vehicle mechanism and can cause
    longitudinal vibration.
q   Disassembly should be done in a clean work area.
q   Before proceeding with disassembly, thoroughly clean the transfer. It is important to prevent the internal
    parts from becoming contaminated by dirt or other foreign matter.
q   Check for the correct installation status prior to removal or disassembly. If matching marks are required,
    be certain they do not interfere with the function of the parts when applied.
q   All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
    reassembly.
q   Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
    with a new ones if necessary.
q   Gaskets, seals and O-rings should be replaced any time when the transfer is disassembled.
q   In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
    tightening sequence is specified, use it.
q   Observe the specified torque when assembling.
q   Clean and flush the parts sufficiently and blow-dry them.
q   Be careful not to damage sliding surfaces and mating surfaces.
q   Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere
    with the operation of the transfer.
Wiring Diagrams and Trouble Diagnosis                                                                     ADS000RK


When you read wiring diagrams, refer to the following:
q  GI-15, "How to Read Wiring Diagrams".
q  PG-3, "POWER SUPPLY ROUTING CIRCUIT".
When you perform trouble diagnosis, refer to the following:
q  GI-11, "How to Follow Trouble Diagnoses".
q  GI-27, "How to Perform Efficient Diagnosis for an Electrical Incident".




Revision: 2004 November                             TF-4                                       2004 FX35/FX45
                                                       PREPARATION

PREPARATION                                                                                                                        PFP:00002
                                                                                                                                                    A
Special Service Tools                                                                                                                    ADS000RL

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
  Tool number                                                                                                                                       B
  (Kent-Moore No.)                                                                       Description
  Tool name

  ST27862000                                                                             q   Installing front oil seal into front case
                                                                                                                                                    C
  (       --      )
  Drift
  a: 62.5 mm (2.461 in) dia.
  b: 42 mm (1.654 in) dia.                                                                                                                          TF

                                                                        ZZA0194D


  KV38108300                                                                             q   Removing and installing companion flange
                                                                                                                                                    E
  (J44195)                                                                                   lock nut
  Flange wrench
                                                                                                                                                     F


                                                                        NT771
                                                                                                                                                    G
  KV381054S0                                                                             q   Removing rear oil seal
  (J34286)
  Puller
                                                                                                                                                    H



                                                                                                                                                     I
                                                                        ZZA0601D


  ST30720000                                                                             q   Installing rear oil seal
  (J25405)
  Drift                                                                                                                                              J
  a: 77 mm (3.03 in) dia.
  b: 55.5 mm (2.185 in) dia.
                                                                                                                                                    K
                                                                        ZZA0811D


  KV40104830                                                                             q   Installing rear oil seal
  (       --      )                                                                                                                                  L
  Drift
  a: 76.3 mm (3.004 in) dia.
  b: 67.9 mm (2.673 in) dia.
                                                                                                                                                    M

                                                                        ZZA1003D


  ST33061000                                                                             q   Removing front drive shaft front bearing
  (J8107-2)
  Drift
  a: 38 mm (1.50 in) dia.
  b: 28.5 mm (1.122 in) dia.


                                                                        ZZA0810D


  ST35322000                                                                             q   Removing front drive shaft rear bearing
  (      --       )
  Drift
  a: 39 mm (1.54 in) dia.
  b: 31 mm (1.22 in) dia.


                                                                        ZZA1000D




Revision: 2004 November                                         TF-5                                                     2004 FX35/FX45
                            PREPARATION

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

 ST30022000                                       q   Installing front drive shaft front bearing
 (      --       )                                q   Installing main shaft into rear case
 Drift
 a: 110 mm (4.33 in) dia.
 b: 56 mm (2.20 in) dia.
 c: 46 mm (1.81 in) dia.

                                      ZZA0978D


 ST30914000                                       q   Installing front drive shaft rear bearing
 (      --       )
 Drift
 a: 98 mm (3.86 in) dia.
 b: 51 mm (2.01 in) dia.
 c: 40 mm (1.57 in) dia.

                                      ZZA0978D


 ST30613000                                       q   Installing main shaft oil seal into front case
 (      --       )
 Drift
 a: 72 mm (2.83 in) dia.
 b: 48 mm (1.89 in) dia.


                                      ZZA1000D



Commercial Service Tools                                                                           ADS000SA



  Tool name                                       Description

  Power tool                                      q   Loosening nuts and bolts




                                      PBIC0190E




Revision: 2004 November        TF-6                                              2004 FX35/FX45
        NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING                                                                                                                                                                         PFP:00003
                                                                                                                                                                                                                                                            A
NVH Troubleshooting Chart                                                                                                                                                                                                       ADS000RM


Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.                                                                                                                                                                                                          B




                                                                                                                                           TF-44



                                                                                                                                                                     TF-44



                                                                                                                                                                                                    TF-49



                                                                                                                                                                                                                                TF-49
                                                                                TF-8
 Reference page

                                                                                                                                                                                                                                                            C




                                                                                                         TRANSFER FLUID (Level too high)
                                                   TRANSFER FLUID (Level low)




                                                                                                                                                                                                                                BEARING (Worn or damaged)
                                                                                                                                                                     OIL SEAL (Worn or damaged)
                                                                                                                                           LIQUID GASKET (Damaged)
                                                                                TRANSFER FLUID (Wrong)
                                                                                                                                                                                                                                                            TF




                                                                                                                                                                                                    GEAR (Worn or damaged)
 SUSPECTED PARTS
 (Possible cause)
                                                                                                                                                                                                                                                            E



                                                                                                                                                                                                                                                             F

                          Noise                              1                          2                                                                                                                    3                            3
 Symptom                                                                                                                                                                                                                                                    G
                          Transfer fluid leakage                                        3                            1                              2                          2



                                                                                                                                                                                                                                                            H



                                                                                                                                                                                                                                                             I


                                                                                                                                                                                                                                                             J



                                                                                                                                                                                                                                                            K


                                                                                                                                                                                                                                                             L



                                                                                                                                                                                                                                                            M




Revision: 2004 November                            TF-7                                                                                                                                           2004 FX35/FX45
                                             TRANSFER FLUID

TRANSFER FLUID                                                                    PFP:31001

Replacement                                                                           ADS000RN

DRAINING
1.   Run the vehicle to warm up the transfer unit sufficiently.
2.   Stop the engine, and remove the drain plug to drain the transfer
     fluid.
3.   Apply sealant to drain plug. Install drain plug on transfer and
     tighten to the specified torque. Refer to TF-44, "Components" .
     q Use Genuine Silicone RTV or equivalent. Refer to GI-48,
        "Recommended Chemical Products and Sealants" .




                                                                                   SDIA2087E


FILLING
1.   Remove filler plug and add transfer fluid until fluid level reaches
     the specified limit near filler plug mounting hole.
        Fluid capacity
          : Approx. 1.25     (2-5/8 US pt, 2-1/4 lmp pt)
     CAUTION:
     Carefully fill the fluid. (Fill up for approx. 3 minutes.)
2.   Leave the vehicle for 3 minutes, and check the fluid level again.
3.   Set a new seal washer onto filler plug and install it on transfer
     and tighten to the specified torque. Refer to TF-44, "Compo-
                                                                                   SDIA2028E
     nents" .
     CAUTION:
     Do not reuse seal washer.
Inspection                                                                            ADS000RO

FLUID LEAKAGE AND FLUID LEVEL
1.   Check fluid level from filler plug mounting hole as shown in the
     figure.
2.   Before installing filler plug, set a new seal washer. Install filler
     plug on transfer and tighten to the specified torque. Refer to TF-
     44, "Components" .
     CAUTION:
     Do not reuse seal washer.



                                                                                   SDIA2028E




Revision: 2004 November                                TF-8                 2004 FX35/FX45
                                             AWD SYSTEM

AWD SYSTEM                                                                                            PFP:41650
                                                                                                                      A
Power Transfer Diagram                                                                                     ADS000RV




                                                                                                                      B



                                                                                                                      C


                                                                                                                      TF


                                                                                                                      E



                                                                                                                       F


                                                                                                                      G
                                                                                                     SDIA1611E


System Description                                                                                         ADS000RW

DESCRIPTION                                                                                                           H
q  Electronic control allows optimal distribution of torque to front/rear wheels to match road conditions.
q  Makes possible stable driving, with no wheel spin, on snowy roads or other slippery surfaces.
q  On roads which do not require AWD, it contributes to improved fuel economy by driving in conditions close           I
   to rear-wheel drive.
q  Sensor inputs determine the vehicle's turning condition, and in response tight cornering/braking are con-
   trolled by distributing optimum torque to front wheels.                                                             J
NOTE:
q  When driving, if there is a large difference between front and rear wheel speed which continues for a long
   time, fluid temperature of drive system parts becomes too high and AWD warning lamp flashes rapidly.               K
   (When AWD warning lamp flashes, vehicle changes to rear-wheel drive conditions.) Also, optional distri-
   bution of torque sometimes becomes rigid before lamp flashes rapidly, but it is not malfunction.
q  If AWD warning lamp is flashing rapidly, stop vehicle and allow it to idle for some time. Flashing will stop        L
   and AWD system will be restored.
q  When driving, AWD warning lamp may flash slowly if there is a significant difference in diameter of the
   tires. At this time, vehicle performance is not fully available and cautious driving is required. (Continues
                                                                                                                      M
   until engine is turned OFF.)
q  If the warning lamp flashes slowly during driving but remains OFF after engine is restarted, the system is
   normal. If it again flashes slowly after driving for some time, vehicle must be inspected.
q  When the difference of revolution speed between the front and rear wheel with AUTO mode the shift occa-
   sionally changes to direct 4-wheel driving conditions automatically. This is not malfunction.




Revision: 2004 November                             TF-9                                      2004 FX35/FX45
                                             AWD SYSTEM

ELECTRIC CONTROLLED COUPLING
Operation principle




                                                                                                  SDIA2270E

1.   AWD control unit supplies command current to electric controlled coupling (AWD solenoid).
2.   Control clutch is engaged by electromagnet and torque is detected in control clutch.
3.   The cam operates in response to control clutch torque and applies pressure to main clutch.
4.   Main clutch transmits torque to front wheels according to pressing power.
     q Transmission torque to front wheels is determined according
       to command current.




                                                                                                     SDIA1844E


AWD CONTROL UNIT
q    Controls distribution of drive power between rear-wheel drive
     (0:100) and AWD (50:50) conditions according to signals from
     sensors.
q    Self-diagnosis can be done with CONSULT-II.




                                                                                                     SDIA2273E




Revision: 2004 November                            TF-10                                     2004 FX35/FX45
                                                     AWD SYSTEM

AWD WARNING LAMP
Turns ON when there is a malfunction in AWD system. It indicates that fail-safe mode is engaged and vehicle                             A
change to rear-wheel drive or shifting driving force-AWD (Front-wheels still have some driving torque).
Also turns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately for 1
seconds after the engine starts if system is normal.                                                                                    B
AWD Warning Lamp Indication
                                Condition                                                AWD warning lamp
                                                                                                                                        C
                                                                       Turns ON when ignition switch is turned ON. Turns OFF
 Lamp check
                                                                                approx. 1 second after engine start.
 AWD system malfunction                                                                          ON
                                                                                                                                        TF
 Protection function is activated due to heavy load to electric con-
                                                                                   Rapid flashing: 2 times/second
 trolled coupling. (AWD system is not malfunctioning and AWD system
                                                                        (Flashing in approx. 1 minute and then turning OFF.)
 changes to 2WD mode.)
                                                                                                                                        E
                                                                                  Slow flashing: 1 time/2 seconds
 Large difference in diameter of front/rear tires
                                                                        (Continuing to flash until turning ignition switch OFF)
 Other than above (system normal)                                                                OFF
                                                                                                                                         F
System Diagram                                                                                                               ADS000RX




                                                                                                                                        G


                                                                                                                                        H



                                                                                                                                         I


                                                                                                                                         J



                                                                                                                                        K


                                                                                                                                         L



                                                                                                                                        M




                                                                                                                       SDIA2160E




Revision: 2004 November                                     TF-11                                              2004 FX35/FX45
                                                         AWD SYSTEM

COMPONENTS FUNCTION DESCRIPTION
        Component parts                                                             Function
                                  q   Controls driving force distribution by signals from each sensor and switch from rear wheel driving
 AWD control unit                     mode (0:100) to AWD mode (50:50).
                                  q   2WD mode is available by fail-safe function if malfunction is detected in AWD system.
 Wheel sensors                    Detects wheel speed.
 AWD solenoid                     Controls electric controlled coupling by command current from AWD control unit.
 Electric controlled coupling     Transmits driving force to front final drive.
                                  q   Illuminates if malfunction is detected in electrical system of AWD system.
 AWD warning lamp                 q   There is 1 blink in 2 seconds if rotation difference of front wheels and rear wheels is large.
                                  q   There are 2 blinks in 1 second if load is still applied to driving parts.
                                  Transmits the following signals via CAN communication to AWD control unit.
 ABS actuator and electric unit
                                  q   Vehicle speed signal
 (control unit)
                                  q   Stop lamp switch signal (brake signal)
                                  Transmits the following signals via CAN communication to AWD control unit.
 ECM                              q   Accelerator pedal position signal
                                  q   Engine speed signal
 Unified meter and A/C amp.       Transmits conditions of parking brake switch via CAN communication to AWD control unit.

CAN Communication                                                                                                                      ADS000RY

SYSTEM DESCRIPTION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
tiplex communication line with high data communication speed and excellent error detection ability. Many elec-
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.
For details, refer to LAN-6, "CAN Communication Unit" .




Revision: 2004 November                                          TF-12                                                 2004 FX35/FX45
                                      TROUBLE DIAGNOSIS

TROUBLE DIAGNOSIS                                                                                 PFP:00004
                                                                                                                 A
Fail-Safe Function                                                                                    ADS000S1


q   If any malfunction occurs in AWD electrical system, and control unit detects the malfunction, AWD warn-
    ing lamp on combination meter turns ON to indicate system malfunction.                                       B
q   When AWD warning lamp is ON, vehicle changes to rear-wheel drive or shifting driving force-AWD (Front-
    wheels still have some driving torque).
How to Perform Trouble Diagnosis                                                                      ADS000S2
                                                                                                                 C
BASIC CONCEPT
q   To perform trouble diagnosis, it is the most important to have understanding about vehicle systems (con-
    trol and mechanism) thoroughly.                                                                          TF
q   It is also important to clarify customer complaints before inspec-
    tion.
    First of all, reproduce symptoms, and understand them fully.                                              E
    Ask customer about his/her complaints carefully. In some cases,
    it will be necessary to check symptoms by driving vehicle with
    customer.
                                                                                                              F
    CAUTION:
    Customers are not professional. It is dangerous to make an
    easy guess like "maybe the customer means that...," or
    "maybe the customer mentions this symptom".                                                               G
                                                                                                   SEF233G



                                                                                                                 H
q   It is essential to check symptoms right from the beginning in
    order to repair malfunctions completely.
    For intermittent malfunctions, reproduce symptoms based on
    interview with customer and past examples. Do not perform                                                    I
    inspection on ad hoc basis. Most intermittent malfunctions are
    caused by poor contacts. In this case, it will be effective to shake
    suspected harness or connector by hand. When repairing with-                                                 J
    out any symptom diagnosis, you cannot judge if malfunctions
    have actually been eliminated.
q   After completing diagnosis, always erase diagnostic memory.
    Refer to TF-22, "How to Erase Self-diagnostic Results" .                                                     K
                                                                                                   SEF234G

q   For intermittent malfunctions, move harness or harness connec-
    tor by hand. Then check for poor contact or reproduced open circuit.
                                                                                                                 L



                                                                                                                 M




Revision: 2004 November                           TF-13                                   2004 FX35/FX45
                               TROUBLE DIAGNOSIS

Location of Electrical Parts                                   ADS000ST




                                                        SDIA2272E




Revision: 2004 November              TF-14         2004 FX35/FX45
                          TROUBLE DIAGNOSIS

Circuit Diagram                                          ADS000RZ

                                                                    A


                                                                    B



                                                                    C


                                                                    TF


                                                                    E



                                                                     F


                                                                    G


                                                                    H



                                                                     I


                                                                     J



                                                                    K


                                                                     L



                                                                    M




                                                   TDWM0015E




Revision: 2004 November         TF-15         2004 FX35/FX45
                           TROUBLE DIAGNOSIS

Wiring Diagram -- AWD --                                  ADS000S0




                                                    TDWM0012E




Revision: 2004 November          TF-16         2004 FX35/FX45
                          TROUBLE DIAGNOSIS


                                                               A


                                                               B



                                                               C


                                                               TF


                                                               E



                                                                F


                                                               G


                                                               H



                                                                I


                                                                J



                                                               K


                                                                L



                                                               M




                                                   TDWM0016E




Revision: 2004 November         TF-17         2004 FX35/FX45
                          TROUBLE DIAGNOSIS




                                                   TDWM0017E




Revision: 2004 November         TF-18         2004 FX35/FX45
                                                  TROUBLE DIAGNOSIS

Trouble Diagnosis Chart for Symptoms                                                                                                           ADS000S3

If AWD warning lamp turns ON, perform self-diagnosis. Refer to TF-21, "SELF-DIAG RESULT MODE" .                                                           A
                 Symptom                              Condition                     Check items                                    Reference page
                                                                                    CAN communication line
 AWD warning lamp does not turn ON when                                                                                                                   B
 the ignition switch is turned to ON.             Ignition switch: ON               Unified meter and A/C amp.                         TF-32
 (AWD warning lamp check)
                                                                                    Unified meter control unit
                                                                                    CAN communication line                                                C
                                                                                    Power supply and ground for AWD con-
                                                                                    trol unit
                                                                                    Unified meter and A/C amp.                                            TF
 AWD warning lamp does not turn OFF sev-
                                                  Engine running                    Unified meter control unit                         TF-32
 eral seconds after engine started.
                                                                                    AWD solenoid
                                                                                                                                                          E
                                                                                    AWD actuator relay (integrated in AWD
                                                                                    control unit)
                                                                                    Wheel sensor
                                                                                                                                                           F
                                                                                    CAN communication line
 Heavy tight-corner braking symptom occurs        q   While driving
                                                                                    Accelerator pedal position signal
 when the vehicle is driven and the steering      q   Steering wheel is
                                                                                    AWD solenoid                                       TF-34              G
 wheel is turned fully to either side after the       turned fully to either
 engine is started. (See NOTE.)                       sides                         Mechanical malfunction of electric con-
                                                                                    trolled coupling (clutch sticking etc.)
                                                                                    AWD solenoid                                                          H
 Vehicle does not enter AWD mode even                                               Mechanical malfunction of electric con-
                                                  While driving                                                                        TF-35
 though AWD warning lamp turned to OFF.                                             trolled coupling (Mechanical engage-
                                                                                    ment of clutch is not possible.)                                       I
                                                                                    Protection function is activated due to
 While driving, AWD warning lamp flashes                                            heavy load to electric controlled cou-
 rapidly. (When flashing in approx. 1 minute                                        pling. (AWD system is not malfunction-
                                                  While driving                                                                        TF-36               J
 and then turning OFF.)                                                             ing. Also, optional distribution of torque
 Rapid flashing: 2 times/second                                                     sometimes becomes rigid before lamp
                                                                                    flashes rapidly, but it is not malfunction.)
 While driving, AWD warning lamp flashes          q   While driving
                                                                                                                                                          K
 slowly. (When continuing to flash until turn-                                      Tire size is different between front and
                                                  q   Vehicle speed: 20 km/h                                                           TF-36
 ing ignition switch OFF)                                                           rear of vehicle.
 Slow flashing: 1 time/2 seconds                      (12 MPH) or more
                                                                                                                                                           L
NOTE:
Light tight-corner braking symptom may occur depending on driving conditions. This is not malfunction.

AWD Control Unit Input/Output Signal Reference Values                                                                                          ADS000S4   M
AWD CONTROL UNIT INSPECTION TABLE
Specifications with CONSULT-II
       Monitored item [Unit]                      Content                                   Condition                          Display value
                                                                               Vehicle stopped                          0.00 km/h (0.00 mph)

                                       Wheel speed (Front wheel                Vehicle running
 FR RH SENSOR [km/h] or [mph]                                                                                           Approximately equal to
                                       right)                                  CAUTION:                                 the indication on speed-
                                                                               Check air pressure of tire under         ometer (Inside of 



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