Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Infiniti G35 2003-2005 Coupe Sedan Approved Infiniti G35 Coupe 2003 em
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ENGINE MECHANICAL
B ENGINE
A
SECTION
ENGINE MECHANICAL
EM EM
C
D
E
CONTENTS
PRECAUTIONS ......................................................... 3 . INTAKE MANIFOLD COLLECTOR ......................... 16 . F
Precautions for Battery Service ............................... 3 . Removal and Installation ....................................... 16 .
Precautions for Draining Engine Coolant ................ 3 . REMOVAL .......................................................... 16 .
Precautions for Disconnecting Fuel Piping ............. 3 . INSPECTION AFTER REMOVAL ...................... 18 . G
Precautions for Removal and Disassembly ............ 3 . INSTALLATION .................................................. 18 .
Precautions for Inspection, Repair and Replace- INTAKE MANIFOLD ................................................ 20 .
ment ........................................................................ 3
. Removal and Installation ....................................... 20 .
H
Precautions for Assembly and Installation .............. 3 . REMOVAL .......................................................... 20 .
Parts Requiring Angular Tightening ........................ 3 . INSPECTION AFTER REMOVAL ...................... 20 .
Precautions for Liquid Gasket ................................. 4 . INSTALLATION .................................................. 21 .
REMOVAL OF LIQUID GASKET SEALING ......... 4 . EXHAUST MANIFOLD AND THREE WAY CATA- I
LIQUID GASKET APPLICATION PROCEDURE 4 ..... LYST ......................................................................... 22
.
PREPARATION .......................................................... 5 . Removal and Installation ....................................... 22 .
Special Service Tools .............................................. 5 . REMOVAL .......................................................... 22 . J
Commercial Service Tools ....................................... 7 . INSPECTION AFTER REMOVAL ...................... 23 .
NOISE, VIBRATION AND HARSHNESS (NVH) INSTALLATION .................................................. 24 .
TROUBLESHOOTING ............................................. 10 . OIL PAN AND OIL STRAINER ................................ 26 .
K
NVH Troubleshooting -- Engine Noise ................. 10 . Removal and Installation ....................................... 26 .
Use the Chart Below to Help You Find the Cause REMOVAL .......................................................... 26 .
of the Symptom. .....................................................11 . INSPECTION AFTER REMOVAL ...................... 28 .
DRIVE BELTS .......................................................... 12. INSTALLATION .................................................. 28 . L
Checking Drive Belts ............................................. 12 . INSPECTION AFTER INSTALLATION ............... 30 .
Tension Adjustment ............................................... 12 . IGNITION COIL ........................................................ 31 .
ALTERNATOR AND POWER STEERING OIL Removal and Installation ....................................... 31 . M
PUMP BELT ....................................................... 13 . REMOVAL .......................................................... 31 .
AIR CONDITIONER COMPRESSOR BELT ...... 13 . INSTALLATION .................................................. 31 .
Removal and Installation ....................................... 13 . SPARK PLUG (PLATINUM-TIPPED TYPE) ............ 32 .
REMOVAL .......................................................... 13 . Removal and Installation ....................................... 32 .
INSTALLATION .................................................. 13 . REMOVAL .......................................................... 32 .
AIR CLEANER AND AIR DUCT .............................. 14 . INSPECTION AFTER REMOVAL ...................... 32 .
Removal and Installation ....................................... 14 . INSTALLATION .................................................. 33 .
REMOVAL .......................................................... 14 . FUEL INJECTOR AND FUEL TUBE ....................... 34 .
INSTALLATION .................................................. 14 . Removal and Installation ....................................... 34 .
Changing Air Cleaner Filter ................................... 15 . REMOVAL .......................................................... 35 .
INSPECTION ..................................................... 15 . INSTALLATION .................................................. 36 .
REMOVAL .......................................................... 15 . INSPECTION AFTER INSTALLATION ............... 38 .
INSTALLATION .................................................. 15 . ROCKER COVER .................................................... 39 .
Removal and Installation ....................................... 39 .
REMOVAL .......................................................... 39 .
INSTALLATION .................................................. 40 .
Revision; 2004 April EM-1 2003 G35 Coupe
FRONT TIMING CHAIN CASE ................................ 42 . HOW TO SELECT CONNECTING ROD BEAR-
Removal and Installation ....................................... 42 . ING .................................................................... 111
.
REMOVAL .......................................................... 42
. HOW TO SELECT MAIN BEARING ................. 112 .
INSTALLATION ................................................... 45. Inspection After Disassembly ............................... 115 .
TIMING CHAIN ......................................................... 50
. CRANKSHAFT SIDE CLEARANCE ................. 115 .
Removal and Installation ....................................... 50 . CONNECTING ROD SIDE CLEARANCE ........ 115 .
REMOVAL .......................................................... 51
. PISTON AND PISTON PIN CLEARANCE ........ 115 .
INSPECTION AFTER REMOVAL ....................... 56 . PISTON RING SIDE CLEARANCE .................. 116 .
INSTALLATION ................................................... 57. PISTON RING END GAP ................................. 116 .
CAMSHAFT .............................................................. 66
. CONNECTING ROD BEND AND TORSION .... 117 .
Removal and Installation ....................................... 66 . CONNECTING ROD BEARING HOUSING
REMOVAL .......................................................... 67
. DIAMETER (BIG END) ..................................... 117 .
INSPECTION AFTER REMOVAL ....................... 68 . CONNECTING ROD BUSHING OIL CLEAR-
INSTALLATION ................................................... 71. ANCE (SMALL END) ........................................ 117 .
Valve Clearance ..................................................... 73
. CYLINDER BLOCK DISTORTION ................... 118 .
INSPECTION ...................................................... 73
. INNER DIAMETER OF MAIN BEARING HOUS-
ADJUSTMENT ................................................... 76 . ING .................................................................... 119
.
OIL SEAL ................................................................. 78
. PISTON TO CYLINDER BORE CLEARANCE . 119
Removal and Installation of Valve Oil Seal ............ 78 . OUTER DIAMETER OF CRANKSHAFT JOUR-
REMOVAL .......................................................... 78
. NAL ................................................................... 120
.
INSTALLATION ................................................... 78. OUTER DIAMETER OF CRANKSHAFT PIN ... 120 .
Removal and Installation of Front Oil Seal ............ 79 . OUT-OF-ROUND AND TAPER OF CRANK-
REMOVAL .......................................................... 79
. SHAFT .............................................................. 120
.
INSTALLATION ................................................... 80. CRANKSHAFT RUNOUT ................................. 121 .
Removal and Installation of Rear Oil Seal ............. 80 . OIL CLEARANCE OF CONNECTING ROD
REMOVAL .......................................................... 80
. BEARING .......................................................... 121 .
INSTALLATION ................................................... 80. OIL CLEARANCE OF MAIN BEARING ............ 122 .
CYLINDER HEAD .................................................... 81 . CRUSH HEIGHT OF MAIN BEARING ............. 122 .
On-Vehicle Service ................................................ 81
. CRUSH HEIGHT OF CONNECTING ROD
CHECKING COMPRESSION PRESSURE ........ 81 . BEARING .......................................................... 122 .
Removal and Installation ....................................... 82 . OUTER DIAMETER OF MAIN BEARING CAP
REMOVAL .......................................................... 82
. BOLT ................................................................. 123
.
INSPECTION AFTER REMOVAL ....................... 83 . OUTER DIAMETER OF CONNECTING ROD
INSTALLATION ................................................... 84. BOLT ................................................................. 123
.
Disassembly and Assembly ................................... 86 . FLYWHEEL DEFLECTION (M/T MODELS) ..... 123 .
DISASSEMBLY .................................................. 86 . MOVEMENT AMOUNT OF FLYWHEEL (M/T
Inspection After Disassembly ................................ 87 . MODELS) .......................................................... 123 .
VALVE DIMENSIONS ......................................... 87 . DRIVE PLATE (A/T MODELS) .......................... 124 .
VALVE GUIDE CLEARANCE ............................. 87 . OIL JET ............................................................. 124
.
VALVE GUIDE REPLACEMENT ........................ 88 . OIL JET RELIEF VALVE ...................................124 .
VALVE SEAT CONTACT .................................... 89 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 125 .
VALVE SEAT REPLACEMENT .......................... 89 . Standard and Limit ............................................... 125 .
VALVE SPRING SQUARENESS ........................ 90 . GENERAL SPECIFICATIONS .......................... 125 .
VALVE SPRING DIMENSIONS AND VALVE INTAKE MANIFOLD COLLECTOR, INTAKE
SPRING PRESSURE LOAD .............................. 91 . MANIFOLD AND EXHAUST MANIFOLD ......... 125 .
ASSEMBLY ........................................................ 91
. DRIVE BELT ..................................................... 126 .
ENGINE ASSEMBLY ............................................... 93 . SPARK PLUG ................................................... 126 .
Removal and Installation ....................................... 93 . CYLINDER HEAD ............................................. 126 .
REMOVAL .......................................................... 94
. VALVE ............................................................... 127
.
INSTALLATION ................................................... 96. CAMSHAFT AND CAMSHAFT BEARING ........ 131 .
INSPECTION AFTER INSTALLATION ............... 97 . CYLINDER BLOCK ........................................... 131 .
CYLINDER BLOCK .................................................. 98 . PISTON, PISTON RING AND PISTON PIN ..... 132 .
Disassembly and Assembly ................................... 98 . CONNECTING ROD ......................................... 133 .
DISASSEMBLY .................................................. 99 . CRANKSHAFT .................................................. 134 .
ASSEMBLY ...................................................... 103. AVAILABLE MAIN BEARING ............................ 135 .
How to Select Piston and Bearing ....................... 110 . CONNECTING ROD BEARING ........................ 136 .
DESCRIPTION ................................................. 110 . BEARING OIL CLEARANCE ............................ 136 .
HOW TO SELECT PISTON .............................. 110 . Tightening Torque ................................................ 137 .
Revision; 2004 April EM-2 2003 G35 Coupe
PRECAUTIONS
PRECAUTIONS PFP:00001
A
Precautions for Battery Service ABS00B4E
Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interfer-
ence between the window edge and the vehicle when the door is opened/closed. During normal operation, the EM
window slightly raises and lowers automatically to prevent any window to vehicle interference. The automatic
window function will not work with the battery disconnected.
Precautions for Draining Engine Coolant ABS0045H C
q Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel Piping ABS0045I D
q Before starting work, make sure no fire or spark producing items are in the work area.
q Release fuel pressure before disassembly.
q After disconnecting pipes, plug openings to stop fuel leakage. E
Precautions for Removal and Disassembly ABS0045J
q When instructed to use special service tools, use the specified tools. Always be careful to work safely, F
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. G
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
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be H
used where noted in the step.
Precautions for Inspection, Repair and Replacement ABS0045K
I
q Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way,
and replace if necessary.
Precautions for Assembly and Installation ABS0045L
J
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 K
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.
L
q Thoroughly wash, clean, and air-blow each part. Carefully check 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.
M
Before assembly, oil sliding surfaces well.
q Release air within route when refilling after draining engine coolant.
q After repairing, start engine and increase engine speed to check engine coolant, fuel, oil, and exhaust
systems for leakage.
Parts Requiring Angular Tightening ABS0045M
q Use an angle wrench for the final tightening of the following engine parts:
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