Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Infiniti FX45 FX35 2003-2005 Approved FX45_35-S50-2003 em
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ENGINE MECHANICAL
B ENGINE
A
SECTION
ENGINE MECHANICAL
EM EM
C
D
E
CONTENTS
VQ35DE INTAKE MANIFOLD COLLECTOR ......................... 19 . F
Removal and Installation ....................................... 19 .
PRECAUTIONS ......................................................... 5 . REMOVAL .......................................................... 19 .
Precautions Necessary for Steering Wheel Rotation INSPECTION AFTER REMOVAL ...................... 21 . G
After Battery Disconnect ......................................... 5 . INSTALLATION .................................................. 21 .
OPERATION PROCEDURE ................................ 5 . INTAKE MANIFOLD ................................................ 23 .
Precautions for Drain Engine Coolant ..................... 5 . Removal and Installation ....................................... 23 .
Precautions for Disconnecting Fuel Piping ............. 5 . H
REMOVAL .......................................................... 23 .
Precautions for Removal and Disassembly ............ 5 . INSPECTION AFTER REMOVAL ...................... 23 .
Precautions for Inspection, Repair and Replace- INSTALLATION .................................................. 24 .
ment ........................................................................ 5
. EXHAUST MANIFOLD AND THREE WAY CATA- I
Precautions for Assembly and Installation .............. 5 . LYST ......................................................................... 25
.
Parts Requiring Angle Tightening ............................ 6 . Removal and Installation ....................................... 25 .
Precautions for Liquid Gasket ................................. 6 . REMOVAL .......................................................... 25 . J
REMOVAL OF LIQUID GASKET SEALING ......... 6 . INSPECTION AFTER REMOVAL ...................... 26 .
LIQUID GASKET APPLICATION PROCEDURE 6 ..... INSTALLATION .................................................. 26 .
PREPARATION .......................................................... 8 . OIL PAN AND OIL STRAINER ................................ 28 .
Special Service Tools .............................................. 8 . K
Removal and Installation ....................................... 28 .
Commercial Service Tools ..................................... 10 . 2WD MODEL ...................................................... 28 .
NOISE, VIBRATION AND HARSHNESS (NVH) REMOVAL .......................................................... 28 .
TROUBLESHOOTING ............................................. 13 . INSPECTION AFTER REMOVAL ...................... 30 . L
NVH Troubleshooting --Engine Noise .................. 13 . INSTALLATION .................................................. 30 .
Use the Chart Below to Help You Find the Cause INSPECTION AFTER INSTALLATION ............... 32 .
of the Symptom. .................................................... 14 . AWD MODEL ..................................................... 33 . M
DRIVE BELTS .......................................................... 15. REMOVAL .......................................................... 34 .
Checking Drive Belts ............................................. 15 . INSPECTION AFTER REMOVAL ...................... 36 .
Tension Adjustment ............................................... 15 . INSTALLATION .................................................. 36 .
ALTERNATOR AND POWER STEERING OIL INSPECTION AFTER INSTALLATION ............... 38 .
PUMP BELT ....................................................... 16 . IGNITION COIL ........................................................ 40 .
AIR CONDITIONER COMPRESSOR BELT ...... 16 . Removal and Installation ....................................... 40 .
Removal and Installation ....................................... 16 . REMOVAL .......................................................... 40 .
REMOVAL .......................................................... 16 . INSTALLATION .................................................. 40 .
INSTALLATION .................................................. 16 . SPARK PLUG (PLATINUM-TIPPED TYPE) ............ 41 .
AIR CLEANER AND AIR DUCT .............................. 17 . Removal and Installation ....................................... 41 .
Removal and Installation ....................................... 17 . REMOVAL .......................................................... 41 .
REMOVAL .......................................................... 17 . INSPECTION AFTER REMOVAL ...................... 41 .
INSTALLATION .................................................. 17 . INSTALLATION .................................................. 42 .
Changing Air Cleaner Filter ................................... 18 .
INSPECTION ..................................................... 18 .
REMOVAL .......................................................... 18 .
INSTALLATION .................................................. 18 .
Revision; 2004 April EM-1 2003 FX
FUEL INJECTOR AND FUEL TUBE ....................... 43 . ENGINE ASSEMBLY .............................................. 108 .
Removal and Installation ....................................... 43 . Removal and Installation ...................................... 108 .
REMOVAL .......................................................... 44
. 2WD MODEL .................................................... 108 .
INSTALLATION ................................................... 45. REMOVAL ......................................................... 109 .
INSPECTION AFTER INSTALLATION ............... 47 . INSTALLATION ................................................. 111 .
ROCKER COVER .................................................... 49 . INSPECTION AFTER INSTALLATION ............. 112 .
Removal and Installation ....................................... 49 . AWD MODEL .................................................... 113 .
REMOVAL .......................................................... 49
. REMOVAL ......................................................... 113 .
INSTALLATION ................................................... 50. INSTALLATION ................................................. 116 .
FRONT TIMING CHAIN CASE ................................ 52 . INSPECTION AFTER INSTALLATION ............. 116 .
Removal and Installation ....................................... 52 . CYLINDER BLOCK ................................................ 118 .
REMOVAL .......................................................... 52
. Disassembly and Assembly ................................. 118 .
INSTALLATION ................................................... 56. DISASSEMBLY ................................................. 119 .
INSPECTION AFTER INSTALLATION ............... 60 . ASSEMBLY ....................................................... 124 .
TIMING CHAIN ......................................................... 61
. How to Select Piston and Bearing ....................... 129 .
Removal and Installation ....................................... 61 . DESCRIPTION ................................................. 129 .
REMOVAL .......................................................... 62
. HOW TO SELECT PISTON .............................. 129 .
INSPECTION AFTER REMOVAL ....................... 69 . HOW TO SELECT CONNECTING ROD BEAR-
INSTALLATION ................................................... 69. ING .................................................................... 130
.
INSPECTION AFTER INSTALLATION ............... 78 . HOW TO SELECT MAIN BEARING ................. 131 .
CAMSHAFT .............................................................. 80
. Inspection After Disassembly ............................... 134 .
Removal and Installation ....................................... 80 . CRANKSHAFT END PLAY ............................... 134 .
REMOVAL .......................................................... 80
. CONNECTING ROD SIDE CLEARANCE ........ 134 .
INSPECTION AFTER REMOVAL ....................... 82 . PISTON AND PISTON PIN OIL CLEARANCE . 134
INSTALLATION ................................................... 85. PISTON RING SIDE CLEARANCE .................. 135 .
Valve Clearance ..................................................... 87
. PISTON RING END GAP ................................. 135 .
INSPECTION ...................................................... 87
. CONNECTING ROD BEND AND TORSION .... 135 .
ADJUSTMENT ................................................... 90 . CONNECTING ROD BEARING HOUSING
OIL SEAL ................................................................. 92
. DIAMETER (BIG END) ..................................... 136 .
Removal and Installation of Valve Oil Seal ............ 92 . CONNECTING ROD BUSHING OIL CLEAR-
REMOVAL .......................................................... 92
. ANCE (SMALL END) ........................................ 136 .
INSTALLATION ................................................... 92. CYLINDER BLOCK DISTORTION ................... 137 .
Removal and Installation of Front Oil Seal ............ 93 . INNER DIAMETER OF MAIN BEARING HOUS-
REMOVAL .......................................................... 93
. ING .................................................................... 137
.
INSTALLATION ................................................... 94. PISTON TO CYLINDER BORE CLEARANCE . 138
Removal and Installation of Rear Oil Seal ............. 94 . OUTER DIAMETER OF CRANKSHAFT JOUR-
REMOVAL .......................................................... 94
. NAL ................................................................... 139
.
INSTALLATION ................................................... 94. OUTER DIAMETER OF CRANKSHAFT PIN ... 139 .
CYLINDER HEAD .................................................... 96 . OUT-OF-ROUND AND TAPER OF CRANK-
On-Vehicle Service ................................................ 96
. SHAFT .............................................................. 139
.
CHECKING COMPRESSION PRESSURE ........ 96 . CRANKSHAFT RUNOUT ................................. 140 .
Removal and Installation ....................................... 97 . CONNECTING ROD BEARING OIL CLEAR-
REMOVAL .......................................................... 97
. ANCE ................................................................ 140
.
INSPECTION AFTER REMOVAL ....................... 98 . MAIN BEARING OIL CLEARANCE .................. 141 .
INSTALLATION ................................................... 99. CRUSH HEIGHT OF MAIN BEARING ............. 141 .
Disassembly and Assembly ................................. 100 . CRUSH HEIGHT OF CONNECTING ROD
DISASSEMBLY ................................................ 101 . BEARING .......................................................... 141 .
Inspection After Disassembly .............................. 101 . OUTER DIAMETER OF MAIN BEARING CAP
CYLINDER HEAD DISTORTION ..................... 101 . BOLT ................................................................. 142
.
VALVE DIMENSIONS ....................................... 102 . OUTER DIAMETER OF CONNECTING ROD
VALVE GUIDE CLEARANCE ........................... 103 . BOLT ................................................................. 142
.
VALVE GUIDE REPLACEMENT ...................... 103 . DRIVE PLATE ................................................... 142 .
VALVE SEAT CONTACT .................................. 104 . OIL JET ............................................................. 142
.
VALVE SEAT REPLACEMENT ........................ 105 . OIL JET RELIEF VALVE ...................................142 .
VALVE SPRING SQUARENESS ...................... 106 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 143 .
VALVE SPRING DIMENSIONS AND VALVE Standard and Limit ............................................... 143 .
SPRING PRESSURE LOAD ............................ 106 . GENERAL SPECIFICATIONS .......................... 143 .
ASSEMBLY ...................................................... 106. DRIVE BELT ..................................................... 144 .
INTAKE MANIFOLD COLLECTOR, INTAKE
Revision; 2004 April EM-2 2003 FX
MANIFOLD AND EXHAUST MANIFOLD ........ 144 . LYST ....................................................................... 177
.
SPARK PLUG .................................................. 144 . Removal and Installation ..................................... 177 . A
CYLINDER HEAD ............................................ 145 . REMOVAL ........................................................ 177 .
VALVE .............................................................. 145
. INSPECTION AFTER REMOVAL .................... 178 .
CAMSHAFT AND CAMSHAFT BEARING ....... 150 . INSTALLATION ................................................ 179 . EM
CYLINDER BLOCK .......................................... 151 . OIL PAN AND OIL STRAINER .............................. 180 .
PISTON, PISTON RING AND PISTON PIN ..... 152 . Removal and Installation ..................................... 180 .
CONNECTING ROD ........................................ 153 . REMOVAL ........................................................ 180 .
CRANKSHAFT ................................................. 154 . INSPECTION AFTER REMOVAL .................... 181 . C
AVAILABLE MAIN BEARING ........................... 155 . INSTALLATION ................................................ 181 .
CONNECTING ROD BEARING ....................... 156 . INSPECTION AFTER INSTALLATION ............. 182 .
BEARING OIL CLEARANCE ........................... 156 . IGNITION COIL ...................................................... 183 . D
Removal and Installation ..................................... 183 .
VK45DE REMOVAL ........................................................ 183 .
INSTALLATION ................................................ 183 . E
PRECAUTIONS ..................................................... 157 . SPARK PLUG (PLATINUM-TIPPED TYPE) .......... 184 .
Precautions for Drain Engine Coolant ................. 157 . Removal and Installation ..................................... 184 .
Precautions for Disconnecting Fuel Piping ......... 157 . REMOVAL ........................................................ 184 .
Precautions for Removal and Disassembly ........ 157 . INSPECTION AFTER REMOVAL .................... 184 . F
Precautions for Inspection, Repair and Replace- INSTALLATION ................................................ 185 .
ment .................................................................... 157
. FUEL INJECTOR AND FUEL TUBE ..................... 186 .
Precautions for Assembly and Installation .......... 157 . Removal and Installation ..................................... 186 . G
Parts Requiring Angular Tightening .................... 157 . REMOVAL ........................................................ 186 .
Precautions for Liquid Gasket ............................. 158 . INSTALLATION ................................................ 187 .
REMOVAL OF LIQUID GASKET SEALING ..... 158 . INSPECTION AFTER INSTALLATION ............. 188 . H
LIQUID GASKET APPLICATION PROCEDURE 158 . ROCKER COVER .................................................. 189 .
PREPARATION ...................................................... 159 . Removal and Installation ..................................... 189 .
Special Service Tools .......................................... 159 . REMOVAL ........................................................ 189 .
Commercial Service Tools ................................... 161 . I
INSTALLATION ................................................ 190 .
NOISE, VIBRATION AND HARSHNESS (NVH) TIMING CHAIN ....................................................... 192 .
TROUBLESHOOTING ........................................... 164 . Removal and Installation ..................................... 192 .
NVH Troubleshooting --Engine Noise ................ 164 . REMOVAL ........................................................ 193 . J
Use the Chart Below to Help You Find the Cause INSPECTION AFTER REMOVAL .................... 195 .
of the Symptom. .................................................. 165 . INSTALLATION ................................................ 196 .
ENGINE ROOM COVER ....................................... 166 . CAMSHAFT ........................................................... 202 . K
Removal and Installation ..................................... 166 . Removal and Installation ..................................... 202 .
REMOVAL ........................................................ 166 . REMOVAL ........................................................ 202 .
INSTALLATION ................................................ 166 . INSTALLATION ................................................ 203 . L
DRIVE BELTS ........................................................ 167 . INSPECTION AFTER REMOVAL .................... 205 .
Checking Drive Belts ........................................... 167 . Valve Clearance .................................................. 208 .
Tension Adjustment ............................................. 167 . INSPECTION ................................................... 208 .
Removal and Installation ..................................... 167 . ADJUSTMENT ................................................. 209 . M
REMOVAL ........................................................ 167 . OIL SEAL ............................................................... 213
.
INSTALLATION ................................................ 168 . Removal and Installation of Valve Oil Seal .......... 213 .
Drive Belt Auto Tensioner and Idler Pulley .......... 169 . REMOVAL ........................................................ 213 .
REMOVAL ........................................................ 169 . INSTALLATION ................................................ 213 .
INSTALLATION ................................................ 169 . Removal and Installation of Front Oil Seal .......... 214 .
AIR CLEANER AND AIR DUCT ............................ 170 . REMOVAL ........................................................ 214 .
Removal and Installation ..................................... 170 . INSTALLATION ................................................ 214 .
REMOVAL ........................................................ 170 . Removal and Installation of Rear Oil Seal ........... 215 .
INSTALLATION ................................................ 170 . REMOVAL ........................................................ 215 .
CHANGING AIR CLEANER FILTER ................ 171 . INSTALLATION ................................................ 215 .
INTAKE MANIFOLD .............................................. 172 . CYLINDER HEAD .................................................. 217 .
Removal and Installation ..................................... 172 . On-Vehicle Service .............................................. 217 .
REMOVAL ........................................................ 173 . CHECKING COMPRESSION PRESSURE ...... 217 .
INSPECTION AFTER REMOVAL .................... 174 . Removal and Installation ..................................... 218 .
INSTALLATION ................................................ 174 . REMOVAL ........................................................ 218 .
INSPECTION AFTER INSTALLATION ............ 176 . INSPECTION AFTER REMOVAL .................... 219 .
EXHAUST MANIFOLD AND THREE WAY CATA- INSTALLATION ................................................ 219 .
Revision; 2004 April EM-3 2003 FX
Disassembly and Assembly ................................. 220 . ANCE (SMALL END) ........................................ 248 .
DISASSEMBLY ................................................ 220 . CYLINDER BLOCK DISTORTION ................... 249 .
ASSEMBLY ...................................................... 221 . INNER DIAMETER OF MAIN BEARING HOUS-
Inspection After Disassembly .............................. 222 . ING .................................................................... 250
.
CYLINDER HEAD DISTORTION ..................... 222 . PISTON TO CYLINDER BORE CLEARANCE . 250
VALVE DIMENSIONS ....................................... 222 . OUTER DIAMETER OF CRANKSHAFT JOUR-
VALVE GUIDE CLEARANCE ........................... 222 . NAL ................................................................... 252
.
VALVE GUIDE REPLACEMENT ...................... 223 . OUTER DIAMETER OF CRANKSHAFT PIN ... 252 .
VALVE SEAT CONTACT .................................. 224 . OUT-OF-ROUND AND TAPER OF CRANK-
VALVE SEAT REPLACEMENT ........................ 225 . SHAFT .............................................................. 252
.
VALVE SPRING SQUARENESS ...................... 226 . CRANKSHAFT RUNOUT ................................. 252 .
VALVE SPRING DIMENSIONS AND VALVE CONNECTING ROD BEARING OIL CLEAR-
SPRING PRESSURE LOAD ............................ 226 . ANCE ................................................................ 253
.
ENGINE ASSEMBLY ............................................. 227 . MAIN BEARING OIL CLEARANCE .................. 253 .
Removal and Installation ..................................... 227 . CRUSH HEIGHT OF MAIN BEARING ............. 254 .
REMOVAL ........................................................ 227 . CRUSH HEIGHT OF CONNECTING ROD
INSTALLATION ................................................. 229 . BEARING .......................................................... 254 .
INSPECTION AFTER INSTALLATION ............. 229 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 255 .
CYLINDER BLOCK ................................................ 231 . Standard and Limit ............................................... 255 .
Disassembly and Assembly ................................. 231 . GENERAL SPECIFICATIONS .......................... 255 .
DISASSEMBLY ................................................ 232 . INTAKE MANIFOLD AND EXHAUST MANI-
ASSEMBLY ...................................................... 235 . FOLD ................................................................ 255
.
How to Select Piston and Bearing ....................... 240 . DRIVE BELTS ................................................... 255 .
DESCRIPTION ................................................. 240 . CYLINDER HEAD ............................................. 256 .
HOW TO SELECT PISTON .............................. 240 . VALVE ............................................................... 256
.
HOW TO SELECT CONNECTING ROD BEAR- CAMSHAFT AND CAMSHAFT BEARING ........ 260 .
ING ................................................................... 241
. CYLINDER BLOCK ........................................... 261 .
HOW TO SELECT MAIN BEARING ................. 242 . PISTON, PISTON RING AND PISTON PIN ..... 262 .
Inspection After Disassembly .............................. 245 . CONNECTING ROD ......................................... 263 .
CRANKSHAFT END PLAY ............................... 245 . CRANKSHAFT .................................................. 263 .
CONNECTING ROD SIDE CLEARANCE ........ 246 . MAIN BEARING ................................................ 264 .
PISTON AND PISTON PIN CLEARANCE ....... 246 . CONNECTING ROD BEARING ........................ 265 .
PISTON RING SIDE CLEARANCE .................. 247 .
PISTON RING END GAP ................................. 247 .
CONNECTING ROD BEND AND TORSION .... 248 .
CONNECTING ROD BEARING (BIG END) ..... 248 .
CONNECTING ROD BUSHING OIL CLEAR-
Revision; 2004 April EM-4 2003 FX
PRECAUTIONS
[VQ35DE]
PRECAUTIONS
[VQ35DE] PFP:00001
A
Precautions Necessary for Steering Wheel Rotation After Battery Disconnect
ABS00B3H
NOTE:
q This Procedure is applied only to models with Intelligent Key system and NVIS/IVIS (NISSAN/INFINITI EM
VEHICLE IMMOBILIZER SYSTEM - NATS).
q Remove and install all control units after disconnecting both battery cables with the ignition knob in the
LOCK position. C
q Always use CONSULT-II to perform self-diagnosis as a part of each function inspection after finishing
work. If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NVIS/IVIS, an electrically controlled steering lock D
mechanism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible. E
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.
OPERATION PROCEDURE F
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged. G
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ACC position. At this time, the
steering lock will be released.
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be H
rotated.
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the LOCK position before connecting I
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT-II.
J
Precautions for Drain Engine Coolant ABS005ZK
Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel Piping ABS005ZL K
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. L
q After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly ABS005ZM
M
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.
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 re-assembly.
q When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
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 ABS005ZN
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and Installation ABS005ZO
q Use torque wrench to tighten bolts or nuts to specification.
Revision; 2004 April EM-5 2003 FX
PRECAUTIONS
[VQ35DE]
q When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
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 liquid gasket, packing, oil seal or O-ring.
q Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.
q Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
q Release air within route when refilling after draining engine coolant.
q Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine
stopped). Then make sure that there are no leaks at fuel line connections.
q After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil and
exhaust systems for leakage.
Parts Requiring Angle Tightening ABS005ZP
q Use an angle wrench [SST: KV10112100 (BT8653-A)] for the final tightening of the following engine parts:
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