Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Infiniti M45 Y34 2003-2004 Approved M45-Y34-2004 em
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ENGINE MECHANICAL
B ENGINE
A
SECTION
ENGINE MECHANICAL
EM EM
C
D
E
CONTENTS
PRECAUTIONS ......................................................... 3 . INTAKE MANIFOLD ................................................ 18 . F
Precautions for Draining Coolant ............................ 3 . Removal and Installation ....................................... 18 .
Precautions for Disconnecting Fuel Piping ............. 3 . REMOVAL .......................................................... 18 .
Precautions for Removal and Disassembly ............ 3 . INSPECTION AFTER REMOVAL ...................... 20 . G
Precautions for Inspection, Repair and Replace- INSTALLATION .................................................. 20 .
ment ........................................................................ 3
. INSPECTION AFTER INSTALLATION ............... 20 .
Precautions for Assembly and Installation .............. 3 . EXHAUST MANIFOLD AND THREE WAY CATA-
H
Parts Requiring Angle Tightening ............................ 3 . LYST ......................................................................... 22
.
Precautions for Liquid Gasket ................................. 4 . Removal and Installation ....................................... 22 .
REMOVAL OF LIQUID GASKET SEALING ......... 4 . REMOVAL .......................................................... 22 .
LIQUID GASKET APPLICATION PROCEDURE 4 ..... INSPECTION AFTER REMOVAL ...................... 23 . I
PREPARATION .......................................................... 5 . INSTALLATION .................................................. 24 .
Special Service Tools .............................................. 5 . OIL PAN AND OIL STRAINER ................................ 25 .
Commercial Service Tools ....................................... 7 . Removal and Installation ....................................... 25 . J
NOISE, VIBRATION AND HARSHNESS (NVH) REMOVAL .......................................................... 25 .
TROUBLESHOOTING ............................................. 10 . INSPECTION AFTER REMOVAL ...................... 26 .
NVH Troubleshooting --Engine Noise .................. 10 . INSTALLATION .................................................. 26 .
K
Use the Chart Below to Help You Find the Cause INSPECTION AFTER INSTALLATION ............... 27 .
of the Symptom. .....................................................11 . IGNITION COIL ........................................................ 28 .
ENGINE ROOM COVER ......................................... 12 . Removal and Installation ....................................... 28 .
Removal and Installation ....................................... 12 . REMOVAL .......................................................... 28 . L
REMOVAL .......................................................... 12 . INSTALLATION .................................................. 28 .
INSTALLATION .................................................. 12 . SPARK PLUG (PLATINUM-TIPPED TYPE) ............ 29 .
DRIVE BELTS .......................................................... 13. Removal and Installation ....................................... 29 . M
Checking Drive Belts ............................................. 13 . REMOVAL .......................................................... 29 .
Tension Adjustment ............................................... 13 . INSPECTION AFTER REMOVAL ...................... 29 .
Removal and Installation ....................................... 13 . INSTALLATION .................................................. 30 .
REMOVAL .......................................................... 13 . FUEL INJECTOR AND FUEL TUBE ....................... 31 .
INSTALLATION .................................................. 14 . Removal and Installation ....................................... 31 .
Drive Belt Auto Tensioner and Idler Pulley ............ 15 . REMOVAL .......................................................... 31 .
REMOVAL .......................................................... 15 . INSTALLATION .................................................. 33 .
INSTALLATION .................................................. 15 . INSPECTION AFTER INSTALLATION ............... 35 .
AIR CLEANER AND AIR DUCT .............................. 16 . ROCKER COVER .................................................... 36 .
Removal and Installation ....................................... 16 . Removal and Installation ....................................... 36 .
REMOVAL .......................................................... 16 . REMOVAL .......................................................... 36 .
INSTALLATION .................................................. 16 . INSTALLATION .................................................. 37 .
CHANGING AIR CLEANER FILTER .................. 17 .
Revision: 2004 October EM-1 2004 M45
TIMING CHAIN ......................................................... 38
. Disassembly and Assembly ...................................80 .
Removal and Installation ....................................... 38 . DISASSEMBLY ...................................................81 .
REMOVAL .......................................................... 39
. ASSEMBLY .........................................................85 .
INSPECTION AFTER REMOVAL ....................... 42 . How to Select Piston and Bearing .........................90 .
INSTALLATION ................................................... 43. DESCRIPTION ...................................................90 .
INSPECTION AFTER INSTALLATION ............... 48 . HOW TO SELECT PISTON ................................90 .
CAMSHAFT .............................................................. 49
. HOW TO SELECT CONNECTING ROD BEAR-
Removal and Installation ....................................... 49 . ING ......................................................................91
.
REMOVAL .......................................................... 50
. HOW TO SELECT MAIN BEARING ...................92 .
INSPECTION AFTER REMOVAL ....................... 50 . Inspection After Disassembly .................................96 .
INSTALLATION ................................................... 53. CRANKSHAFT END PLAY .................................96 .
Valve Clearance ..................................................... 55
. CONNECTING ROD SIDE CLEARANCE ..........96 .
INSPECTION ...................................................... 55
. PISTON AND PISTON PIN CLEARANCE ..........96 .
ADJUSTMENT ................................................... 58 . PISTON RING SIDE CLEARANCE ....................97 .
OIL SEAL ................................................................. 61
. PISTON RING END GAP ...................................97 .
Removal and Installation of Valve Oil Seal ............ 61 . CONNECTING ROD BEND AND TORSION ......98 .
REMOVAL .......................................................... 61
. CONNECTING ROD BIG END DIAMETER .......98 .
INSTALLATION ................................................... 61. CONNECTING ROD BUSHING OIL CLEAR-
Removal and Installation of Front Oil Seal ............ 62 . ANCE ..................................................................98
.
REMOVAL .......................................................... 62
. CYLINDER BLOCK DISTORTION .....................99 .
INSTALLATION ................................................... 62. INNER DIAMETER OF MAIN BEARING HOUS-
Removal and Installation of Rear Oil Seal ............. 64 . ING .................................................................... 100
.
REMOVAL .......................................................... 64
. PISTON TO CYLINDER BORE CLEARANCE . 100
INSTALLATION ................................................... 64. CRANKSHAFT MAIN JOURNAL DIAMETER .. 102 .
CYLINDER HEAD .................................................... 65 . CRANKSHAFT PIN JOURNAL DIAMETER ..... 102 .
On-Vehicle Service ................................................ 65
. OUT-OF-ROUND AND TAPER OF CRANK-
CHECKING COMPRESSION PRESSURE ........ 65 . SHAFT .............................................................. 102
.
Removal and Installation ....................................... 66 . CRANKSHAFT RUNOUT ................................. 102 .
REMOVAL .......................................................... 66
. OIL CLEARANCE OF CONNECTING ROD
INSPECTION AFTER REMOVAL ....................... 67 . BEARING .......................................................... 103 .
CYLINDER HEAD DISTORTION ....................... 67 . OIL CLEARANCE OF MAIN BEARING ............ 103 .
INSTALLATION ................................................... 67. CRUSH HEIGHT OF MAIN BEARING ............. 104 .
Disassembly and Assembly ................................... 68 . CRUSH HEIGHT OF CONNECTING ROD
DISASSEMBLY .................................................. 69 . BEARING .......................................................... 104 .
ASSEMBLY ........................................................ 69
. SERVICE DATA AND SPECIFICATIONS (SDS) ... 105 .
Inspection After Disassembly ................................ 71 . Standard and Limit ............................................... 105 .
VALVE DIMENSIONS ......................................... 71 . GENERAL SPECIFICATIONS .......................... 105 .
VALVE GUIDE CLEARANCE ............................. 71 . INTAKE MANIFOLD AND EXHAUST MANI-
VALVE GUIDE REPLACEMENT ........................ 71 . FOLD ................................................................ 105
.
VALVE SEAT CONTACT .................................... 73 . DRIVE BELTS ................................................... 105 .
VALVE SEAT REPLACEMENT .......................... 73 . CAMSHAFT AND CAMSHAFT BEARING ........ 106 .
VALVE SPRING SQUARENESS ........................ 74 . CYLINDER HEAD ............................................. 108 .
VALVE SPRING DIMENSIONS AND VALVE CYLINDER BLOCK ........................................... 111 .
SPRING PRESSURE LOAD .............................. 75 . PISTON, PISTON RING AND PISTON PIN ..... 112 .
ENGINE ASSEMBLY ............................................... 76 . CONNECTING ROD ......................................... 113 .
Removal and Installation ....................................... 76 . CRANKSHAFT .................................................. 113 .
REMOVAL .......................................................... 76
. MAIN BEARING ................................................ 114 .
INSTALLATION ................................................... 78. CONNECTING ROD BEARING ........................ 115 .
INSPECTION AFTER INSTALLATION ............... 79 . Tightening Torque ................................................ 116 .
CYLINDER BLOCK .................................................. 80 .
Revision: 2004 October EM-2 2004 M45
PRECAUTIONS
PRECAUTIONS PFP:00001
A
Precautions for Draining Coolant ABS000OV
q Drain coolant when engine is cooled.
EM
Precautions for Disconnecting Fuel Piping ABS000OW
q Before starting work, make sure no fire or spark producing items are in the work area.
q Release fuel pressure before disconnecting and disassembly. C
q After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly ABS000OX
D
q When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
q Exercise maximum care to avoid damage to mating or sliding surfaces. E
q Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
q Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly.
q When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally F
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be
used where noted in the step.
Precautions for Inspection, Repair and Replacement ABS000OY G
q Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way,
and replace if necessary.
H
Precautions for Assembly and Installation ABS000OZ
q Use torque wrench to tighten bolts or nuts to specification.
q When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the I
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.
q Replace with new gasket, packing, oil seal or O-ring. J
q Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
q Guide pins are used for several parts alignment. When replacing and reassembling parts with guide pins, K
make sure that guide pins are installed in the original portion.
q Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well. L
q Release air within route when refilling after draining coolant.
q After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems
for leakage. M
Parts Requiring Angle Tightening ABS000P0
q Use the angle wrench [SST: KV10112100 (BT8653-A)] for the final tightening of the following engine parts:
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