2004 Infiniti I35FACTORY OEM SERVICE PROCEDURE

Diagnostic Procedure

  1. CHECK FUEL FILLER CAP INSTALLATION 
    1. Turn ignition switch OFF
    2. Check for genuine NISSAN fuel filler cap design. Figure

    OK or NG 

    1. OK: GO TO 2.
    2. NG: Replace with genuine NISSAN fuel filler cap
  2. CHECK FUEL FILLER CAP INSTALLATION 

    Check that the cap is tightened properly by rotating the cap clockwise.

    OK or NG 

    1. OK: GO TO 3.
    2. NG:
      • Open fuel filler cap, ten clean cap and fuel filler neck threads using air blower.
      • Retighten until ratcheting sound is heard.
  3. CHECK FUEL FILLER CAP FUNCTION 

    Check for air releasing sound while opening the fuel filler cap.

    OK or NG 

    1. OK: GO TO 5.
    2. NG: GO TO 4.
  4. CHECK FUEL TANK VACUUM RELIEF VALVE 
    1. Wipe clean valve housing.
    2. Check valve opening pressure and vacuum. See Figure and Figure .

    Pressure: 

    15.3 - 20.0 kPa (0.156 - 0.204 kg/cm 2 , 2.22 - 2.90 psi) 

    Vacuum: 

    -6.0 to -3.3 kPa (-0.061 to -0.034 kg/cm 2 , -0.87 to -0.48 psi) 

    CAUTION: Use only a genuine fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the MIL may come on.

    OK or NG 

    1. OK: GO TO 5.
    2. NG: Replace fuel filler cap with a genuine one.
  5. INSTALL THE PRESSURE PUMP 

    To locate the EVAP leak, install EVAP service port adapter and pressure pump to EVAP service port securely. See Figure and Figure .

    NOTE: Improper installation of the EVAP service port adapter to the EVAP service port may cause leaking.
    1. Models with CONSULT-II: GO TO 6.
    2. Models with CONSULT-II: GO TO 7.
  6. CHECK FOR EVAP LEAK 

    With CONSULT-II 

    1. Turn ignition switch ON.
    2. Select EVAP SYSTEM CLOSE of WORK SUPPORT mode with CONSULT-II.
    3. Touch START and apply pressure into the EVAP line until the pressure indicator reaches the middle of the bar graph.
      NOTE:
      • Never use compressed air or a high pressure pump.
      • Do not exceed 4.12 kPa (0.042 kg/cm2 , 0.6 psi) of pressure in the system.
        Fig 1: Selecting EVAP SYSTEM CLOSE On WORK SUPPORT Mode (CONSULT-II)
        G00786951Courtesy of NISSAN MOTOR CO., U.S.A.
    4. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. See Figure . Refer to EVAPORATIVE EMISSION LINE DRAWING  .

    OK or NG 

    1. OK: GO TO 8.
    2. NG: Repair or replace.
  7. CHECK FOR EVAP LEAK 

    Without CONSULT-II 

    1. Turn ignition switch OFF.
    2. Apply 12 volts DC to EVAP canister vent control valve. The valve will close. (Continue to apply 12 volts until the end of test.)
    3. Apply 12 volts DC to vacuum cut valve bypass valve. The valve will open. (Continue to apply 12V until the end of test.)
      Fig 2: Apply 12 Volts DC To Vacuum Cut Valve Bypass Valve
      G00786953Courtesy of NISSAN MOTOR CO., U.S.A.
    4. Pressurize the EVAP line using pressure pump with 1.3 to 2.7 kPa (10 to 20 mmHg, 0.39 to 0.79 inHg), then remove pump and EVAP service port adapter.
      NOTE:
      • Never use compressed air or a high pressure pump.
      • Do not exceed 4.12 kPa (0.042 kg/cm2 , 0.6 psi) of pressure in the system.
    5. Using EVAP leak detector, locate the EVAP leak. For the leak detector, refer to the instruction manual for more details. See Figure . Refer to EVAPORATIVE EMISSION LINE DRAWING  .
      Fig 3: Identifying EVAP Leak Detector
      G00786954Courtesy of NISSAN MOTOR CO., U.S.A.

      OK or NG 

      1. OK: GO TO 8.
      2. NG: Repair or replace.
  8. CHECK WATER SEPARATOR 
    1. Check visually for insect nests in the water separator air inlet.
    2. Check visually for cracks or flaws in the appearance.
    3. Check visually for cracks or flaws in the hose.
    4. Check that A  and C  are not clogged by blowing air into B  with A  , and then C  plugged.
    5. Fig 4: Checking Water Separator
      G00786955Courtesy of NISSAN MOTOR CO., U.S.A.
    6. In case of NG in items 2 - 4, replace the parts.
      NOTE: Do not disassemble water separator.

      OK or NG 

      1. OK: GO TO 9.
      2. NG: GO TO Replace water separator.
  9. CHECK EVAP CANISTER VENT CONTROL VALVE, O-RING AND CIRCUIT 

    Refer to DTC P1448 EVAP CANISTER VENT CONTROL VALVE  .

    OK or NG 

    1. OK: GO TO 10.
    2. NG: Repair or replace EVAP canister vent control valve and O-ring or harness/connector.
  10. CHECK IF EVAP CANISTER SATURATED WITH WATER 
    1. Remove EVAP canister with EVAP canister vent control valve attached.
    2. Does water drain from the EVAP canister?
      Fig 5: Checking EVAP Canister Saturation
      G00786956Courtesy of NISSAN MOTOR CO., U.S.A.

    Yes or No 

    1. Yes: GO TO 11.
    2. No (With CONSULT-II): GO TO 13.
    3. No (Without CONSULT-II): GO TO 14.
  11. CHECK EVAP CANISTER 

    Weigh the EVAP canister with the EVAP canister vent control valve attached.

    The weight should be less than 1.8 kg (4.0 lb). 

    OK or NG 

    1. OK (With CONSULT-II): GO TO 13.
    2. OK (Without CONSULT-II): GO TO 14.
    3. NG: GO TO 12.
  12. DETECT MALFUNCTIONING PART 

    Check the following.

    • EVAP canister for damage
    • EVAP hose between EVAP canister and water separator for clogging or poor connection
    1. : Repair hose or replace EVAP canister.
  13. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION 

    With CONSULT-II 

    1. Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port.
    2. Start engine.
    3. Perform PURG VOL CONT/V in ACTIVE TEST mode.
    4. Touch Qu on CONSULT-II screen to increase PURG VOL CONT/V opening to 100.0%.
    5. Check vacuum hose for vacuum when revving engine up to 2,000 rpm. See Figure .

    Vacuum should exist. 

    OK or NG 

    1. OK: GO TO 16.
    2. NG: GO TO 15.
  14. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION 

    Without CONSULT-II 

    1. Start engine and warm it up to normal operating temperature.
    2. Stop engine.
    3. Disconnect vacuum hose to EVAP canister purge volume control solenoid valve at EVAP service port.
    4. Start engine and let it idle for at least 80 seconds.
    5. Check vacuum hose for vacuum when revving engine up to 2,000 rpm.

    Vacuum should exist. 

    OK or NG 

    1. OK: GO TO 17.
    2. NG: GO TO 15.
  15. CHECK VACUUM HOSE 

    Check vacuum hoses for clogging or disconnection. Refer to VACUUM HOSE DRAWING  .

    OK or NG 

    1. OK (With CONSULT-II): GO TO 16.
    2. OK (Without CONSULT-II): GO TO 17.
    3. NG: Repair or reconnect the hose.
  16. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE 

    With CONSULT-II 

    1. Start engine.
    2. Perform PURG VOL CONT/V in ACTIVE TEST mode with CONSULT-II. Check that engine speed varies according to the valve opening. See Figure .

    OK or NG 

    1. OK: GO TO 18.
    2. NG: GO TO 17.
  17. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE 

    With CONSULT-II 

    Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. See Figure and Figure .

    Without CONSULT-II 

    Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. See Figure and Figure .

    OK or NG 

    1. OK: GO TO 18.
    2. NG: Replace EVAP canister purge volume control solenoid valve.
  18. CHECK FUEL TANK TEMPERATURE SENSOR 
    1. Remove fuel level sensor unit.
    2. Check resistance between fuel level sensor unit and fuel pump terminals 4 and 5 by heating with hot water or heat gun as shown in Figure .

    OK or NG 

    1. OK: GO TO 19.
    2. NG: Replace fuel level sensor unit.
  19. CHECK EVAP CONTROL SYSTEM PRESSURE SENSOR 
    1. Remove EVAP control system pressure sensor with its harness connector connected.
      CAUTION: Never apply force to the air hole protector of the sensor if equipped.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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