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ENGINE MECHANICAL


B ENGINE

                                                                                                                                                                       A




                                                                                                   SECTION
                                                                                          ENGINE MECHANICAL
                                                                                                                               EM                                      EM



                                                                                                                                                                       C


                                                                                                                                                                       D


                                                                                                                                                                       E
                                                                   CONTENTS
PRECAUTIONS ......................................................... 3  .         INTAKE MANIFOLD COLLECTOR ......................... 17                     .        F
 Precautions for Battery Service ............................... 3       .           Removal and Installation ....................................... 17      .
 Precautions for Draining Engine Coolant ................ 3              .            REMOVAL .......................................................... 17   .
 Precautions for Disconnecting Fuel Piping ............. 3               .            INSPECTION AFTER REMOVAL ...................... 19                      .        G
 Precautions for Removal and Disassembly ............ 3                  .            INSTALLATION .................................................. 20      .
 Precautions for Inspection, Repair and Replace-                                   INTAKE MANIFOLD ................................................ 22        .
 ment ........................................................................ 3
                                                                         .           Removal and Installation ....................................... 22      .
                                                                                                                                                                       H
 Precautions for Assembly and Installation .............. 3              .            REMOVAL .......................................................... 22   .
 Parts Requiring Angle Tightening ............................ 4         .            INSPECTION AFTER REMOVAL ...................... 22                      .
 Precautions for Liquid Gasket ................................. 4       .            INSTALLATION .................................................. 23      .
   REMOVAL OF LIQUID GASKET SEALING ......... 4                          .         EXHAUST MANIFOLD AND THREE WAY CATA-                                                 I
   LIQUID GASKET APPLICATION PROCEDURE 4                                 .....     LYST ......................................................................... 24
                                                                                                                                                              .
PREPARATION .......................................................... 6 .           Removal and Installation ....................................... 24      .
 Special Service Tools (SST) .................................... 6      .            REMOVAL .......................................................... 24   .        J
 Commercial Service Tools ....................................... 8      .            INSPECTION AFTER REMOVAL ...................... 26                      .
NOISE, VIBRATION AND HARSHNESS (NVH)                                                  INSTALLATION .................................................. 26      .
TROUBLESHOOTING ..............................................11         .         OIL PAN AND OIL STRAINER ................................ 28               .
                                                                                                                                                                       K
 NVH Troubleshooting --Engine Noise ...................11                .           Removal and Installation ....................................... 28      .
 Use the Chart Below to Help You Find the Cause                                       REMOVAL .......................................................... 28   .
 of the Symptom. .................................................... 12 .            INSPECTION AFTER REMOVAL ...................... 30                      .
DRIVE BELTS .......................................................... 13.            INSTALLATION .................................................. 30      .        L
 Checking Drive Belts ............................................. 13   .            INSPECTION AFTER INSTALLATION ............... 33                        .
 Tension Adjustment ............................................... 13   .         IGNITION COIL ........................................................ 34  .
   ALTERNATOR AND POWER STEERING OIL                                                 Removal and Installation ....................................... 34      .        M
   PUMP BELT ....................................................... 14  .            REMOVAL .......................................................... 34   .
   A/C COMPRESSOR BELT ................................ 14               .            INSTALLATION .................................................. 34      .
 Removal and Installation ....................................... 14     .         SPARK PLUG (PLATINUM-TIPPED TYPE) ............ 35                          .
   REMOVAL .......................................................... 14 .           Removal and Installation ....................................... 35      .
   INSTALLATION .................................................. 14    .            REMOVAL .......................................................... 35   .
AIR CLEANER AND AIR DUCT .............................. 15               .            INSPECTION AFTER REMOVAL ...................... 35                      .
 Removal and Installation ....................................... 15     .            INSTALLATION .................................................. 36      .
   REMOVAL .......................................................... 15 .         FUEL INJECTOR AND FUEL TUBE ....................... 37                     .
   INSTALLATION .................................................. 15    .           Removal and Installation ....................................... 37      .
 Changing Air Cleaner Filter ................................... 16      .            REMOVAL .......................................................... 38   .
   INSPECTION ..................................................... 16   .            INSTALLATION .................................................. 39      .
   REMOVAL .......................................................... 16 .            INSPECTION AFTER INSTALLATION ............... 41                        .
   INSTALLATION .................................................. 16    .         ROCKER COVER .................................................... 43       .
                                                                                     Removal and Installation ....................................... 43      .
                                                                                      REMOVAL .......................................................... 43   .
                                                                                      INSTALLATION .................................................. 44      .


Edition: 2004 September                                                      EM-1                                                          2005 G35 Coupe
FRONT TIMING CHAIN CASE ................................ 46            .         Disassembly and Assembly ................................. 110           .
  Removal and Installation ....................................... 46  .           DISASSEMBLY ................................................. 111      .
    REMOVAL .......................................................... 46
                                                                       .           ASSEMBLY ....................................................... 116   .
    INSTALLATION ................................................... 49.         How to Select Piston and Bearing ....................... 123             .
    INSPECTION AFTER INSTALLATION ............... 54                   .           DESCRIPTION ................................................. 123      .
TIMING CHAIN ......................................................... 55
                                                                       .           HOW TO SELECT PISTON .............................. 123                .
  Removal and Installation ....................................... 55  .           HOW TO SELECT CONNECTING ROD BEAR-
    REMOVAL .......................................................... 56
                                                                       .           ING .................................................................... 124
                                                                                                                                                          .
    INSPECTION AFTER REMOVAL ....................... 63                .           HOW TO SELECT MAIN BEARING ................. 125                       .
    INSTALLATION ................................................... 64.         Inspection After Disassembly ............................... 128         .
    INSPECTION AFTER INSTALLATION ............... 74                   .           CRANKSHAFT END PLAY ............................... 128                .
CAMSHAFT .............................................................. 75
                                                                       .           CONNECTING ROD SIDE CLEARANCE ........ 128                             .
  Removal and Installation ....................................... 75  .           PISTON TO PISTON PIN OIL CLEARANCE .... 128                            .
    REMOVAL .......................................................... 76
                                                                       .           PISTON RING SIDE CLEARANCE .................. 129                      .
    INSPECTION AFTER REMOVAL ....................... 77                .           PISTON RING END GAP ................................. 129              .
    INSTALLATION ................................................... 80.           CONNECTING ROD BEND AND TORSION .... 130                               .
    INSPECTION AFTER INSTALLATION ............... 83                   .           CONNECTING ROD BIG END DIAMETER ..... 130                              .
  Valve Clearance ..................................................... 84
                                                                       .           CONNECTING ROD BUSHING OIL CLEAR-
    INSPECTION ...................................................... 84
                                                                       .           ANCE ................................................................ 130
                                                                                                                                                          .
    ADJUSTMENT ................................................... 87  .           CYLINDER BLOCK DISTORTION ................... 131                      .
OIL SEAL ................................................................. 88
                                                                       .           MAIN BEARING HOUSING INNER DIAMETER.132
  Removal and Installation of Valve Oil Seal ............ 88           .           PISTON TO CYLINDER BORE CLEARANCE . 132
    REMOVAL .......................................................... 88
                                                                       .           CRANKSHAFT MAIN JOURNAL DIAMETER .. 133                                .
    INSTALLATION ................................................... 88.           CRANKSHAFT PIN JOURNAL DIAMETER ..... 134                              .
  Removal and Installation of Front Oil Seal ............ 89           .           CRANKSHAFT OUT-OF-ROUND AND TAPER.134
    REMOVAL .......................................................... 89
                                                                       .           CRANKSHAFT RUNOUT ................................. 134                .
    INSTALLATION ................................................... 90.           CONNECTING ROD BEARING OIL CLEAR-
  Removal and Installation of Rear Oil Seal ............. 90           .           ANCE ................................................................ 134
                                                                                                                                                          .
    REMOVAL .......................................................... 90
                                                                       .           MAIN BEARING OIL CLEARANCE .................. 135                      .
    INSTALLATION ................................................... 90.           CRUSH HEIGHT OF MAIN BEARING ............. 136                         .
CYLINDER HEAD .................................................... 92  .           CRUSH HEIGHT OF CONNECTING ROD
  On-Vehicle Service ................................................ 92
                                                                       .           BEARING .......................................................... 136 .
    CHECKING COMPRESSION PRESSURE ........ 92                          .           MAIN BEARING CAP BOLT OUTER DIAMETER                                   .136
  Removal and Installation ....................................... 93  .           CONNECTING ROD BOLT OUTER DIAMETER.137
    REMOVAL .......................................................... 93
                                                                       .           FLYWHEEL DEFLECTION ............................... 137                .
    INSPECTION AFTER REMOVAL ....................... 94                .           MOVEMENT AMOUNT OF FLYWHEEL .......... 137                             .
    INSTALLATION ................................................... 95.           DRIVE PLATE (A/T MODELS) .......................... 138                .
  Disassembly and Assembly ................................... 96      .           OIL JET ............................................................. 138
                                                                                                                                                          .
    DISASSEMBLY .................................................. 97  .           OIL JET RELIEF VALVE ................................... 138           .
    ASSEMBLY ........................................................ 97
                                                                       .        SERVICE DATA AND SPECIFICATIONS (SDS) ... 139                             .
  Inspection After Disassembly ................................ 99     .         Standard and Limit ............................................... 139   .
    VALVE DIMENSIONS ......................................... 99      .           GENERAL SPECIFICATIONS .......................... 139                  .
    VALVE GUIDE CLEARANCE ............................. 99             .           DRIVE BELT ..................................................... 140   .
    VALVE GUIDE REPLACEMENT ........................ 99                .           INTAKE MANIFOLD COLLECTOR, INTAKE
    VALVE SEAT CONTACT .................................. 101          .           MANIFOLD AND EXHAUST MANIFOLD ......... 140                            .
    VALVE SEAT REPLACEMENT ........................ 101                .           SPARK PLUG ................................................... 140     .
    VALVE SPRING SQUARENESS ...................... 102                 .           CAMSHAFT AND CAMSHAFT BEARING ........ 141                             .
    VALVE SPRING DIMENSIONS AND VALVE                                              CYLINDER HEAD ............................................. 143        .
    SPRING PRESSURE LOAD ............................ 102              .           CYLINDER BLOCK ........................................... 146         .
ENGINE ASSEMBLY ............................................. 104      .           PISTON, PISTON RING AND PISTON PIN ..... 147                           .
  Removal and Installation ..................................... 104   .           CONNECTING ROD ......................................... 148           .
    REMOVAL ........................................................ 105
                                                                       .           CRANKSHAFT .................................................. 149      .
    INSTALLATION ................................................. 107 .           MAIN BEARING ................................................ 150      .
    INSPECTION AFTER INSTALLATION ............. 108                    .           CONNECTING ROD BEARING ........................ 151                    .
CYLINDER BLOCK ................................................ 110    .




Edition: 2004 September                                                   EM-2                                                         2005 G35 Coupe
                                             PRECAUTIONS

PRECAUTIONS                                                                                             PFP:00001
                                                                                                                       A
Precautions for Battery Service                                                                             ABS00B3K


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                                                                     ABS00A05   C
Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel Piping                                                                   ABS00A06   D
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.
q   After disconnecting pipes, plug openings to stop fuel leakage.                                                     E

Precautions for Removal and Disassembly                                                                     ABS00A07


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 bolts and nuts, 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                                                          ABS00A08
                                                                                                                       I
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and Installation                                                                   ABS00A09
                                                                                                                       J

q   Use torque wrench to tighten bolts or nuts to specification.
q   When tightening bolts and nuts, 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   Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
    make sure that dowel pins are installed in the original position.
q   Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
                                                                                                                       M
    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   After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
    exhaust systems for leakage.




Edition: 2004 September                             EM-3                                        2005 G35 Coupe
                                               PRECAUTIONS

Parts Requiring Angle Tightening                                                                           ABS00A0A


q    Use angle wrench [SST: KV10112100 (BT8653-A)] for the final tightening of the following engine parts:



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