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ENGINE MECHANICAL


B ENGINE

                                                                                                                                                                       A


                                                                                                                                                                       EM
                                                                                                   SECTION
                                                                                          ENGINE MECHANICAL                                                            C


                                                                                                                                                                       D


                                                                                                                                                                       E
                                                                   CONTENTS
PRECAUTIONS ......................................................... 3  .         INTAKE MANIFOLD COLLECTOR ......................... 18                     .        F
 Precautions for Draining Engine 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
                                                                         .         INTAKE MANIFOLD ................................................ 22        .
 Precautions for Assembly and Installation .............. 3              .           Removal and Installation ....................................... 22      .
                                                                                                                                                                       H
 Parts Requiring Angular Tightening ........................ 4           .            REMOVAL .......................................................... 22   .
 Precautions for Liquid Gasket ................................. 4       .            INSPECTION AFTER REMOVAL ...................... 22                      .
   REMOVAL OF LIQUID GASKET SEALING ......... 4                          .            INSTALLATION .................................................. 23      .
   LIQUID GASKET APPLICATION PROCEDURE 4                                 .....     EXHAUST MANIFOLD AND THREE WAY CATA-                                                 I
PREPARATION .......................................................... 6 .         LYST ......................................................................... 24
                                                                                                                                                              .
 Special Service Tools .............................................. 6  .           Removal and Installation ....................................... 24      .
 Commercial Service Tools ....................................... 8      .            REMOVAL .......................................................... 24   .        J
NOISE, VIBRATION AND HARSHNESS (NVH)                                                  INSPECTION AFTER REMOVAL ...................... 25                      .
TROUBLESHOOTING ..............................................11         .            INSTALLATION .................................................. 26      .
 NVH Troubleshooting -- Engine Noise ..................11                .         OIL PAN AND OIL STRAINER ................................ 28               .
                                                                                                                                                                       K
 Use the Chart Below to Help You Find the Cause                                      Removal and Installation ....................................... 28      .
 of the Symptom. .................................................... 12 .            REMOVAL .......................................................... 29   .
DRIVE BELTS .......................................................... 13.            INSPECTION AFTER REMOVAL ...................... 31                      .
 Checking Drive Belts ............................................. 13   .            INSTALLATION .................................................. 31      .        L
 Tension Adjustment ............................................... 13   .            INSPECTION AFTER INSTALLATION ............... 33                        .
   ALTERNATOR, POWER STEERING OIL PUMP                                             IGNITION COIL ........................................................ 34  .
   AND FAN BELT .................................................. 14    .           Removal and Installation ....................................... 34      .        M
   AIR CONDITIONER COMPRESSOR BELT ...... 14                             .            REMOVAL .......................................................... 34   .
 Removal and Installation ....................................... 15     .            INSTALLATION .................................................. 34      .
   REMOVAL .......................................................... 15 .         SPARK PLUG (PLATINUM-TIPPED TYPE) ............ 35                          .
   INSTALLATION .................................................. 15    .           Removal and Installation ....................................... 35      .
AIR CLEANER AND AIR DUCT .............................. 16               .            REMOVAL .......................................................... 35   .
 Removal and Installation ....................................... 16     .            INSPECTION AFTER REMOVAL ...................... 35                      .
   REMOVAL .......................................................... 16 .            INSTALLATION .................................................. 36      .
   INSTALLATION .................................................. 16    .         FUEL INJECTOR AND FUEL TUBE ....................... 37                     .
 Changing Air Cleaner Filter ................................... 17      .           Removal and Installation ....................................... 37      .
   INSPECTION ..................................................... 17   .            REMOVAL .......................................................... 38   .
   REMOVAL .......................................................... 17 .            INSTALLATION .................................................. 39      .
   INSTALLATION .................................................. 17    .            INSPECTION AFTER INSTALLATION ............... 41                        .
                                                                                   ROCKER COVER .................................................... 43       .
                                                                                     Removal and Installation ....................................... 43      .
                                                                                      REMOVAL .......................................................... 43   .
                                                                                      INSTALLATION .................................................. 44      .


Revision; 2004 April                                                         EM-1                                                          2003 G35 Sedan
FRONT TIMING CHAIN CASE ................................ 46            .           ING .................................................................... 118
                                                                                                                                                          .
  Removal and Installation ....................................... 46  .           HOW TO SELECT MAIN BEARING ................. 119                       .
    REMOVAL .......................................................... 46
                                                                       .         Inspection After Disassembly ............................... 123         .
    INSTALLATION ................................................... 49.           CRANKSHAFT END PLAY ............................... 123                .
TIMING CHAIN ......................................................... 54
                                                                       .           CONNECTING ROD SIDE CLEARANCE ........ 123                             .
  Removal and Installation ....................................... 54  .           PISTON AND PISTON PIN CLEARANCE ........ 123                           .
    REMOVAL .......................................................... 55
                                                                       .           PISTON RING SIDE CLEARANCE .................. 124                      .
    INSPECTION AFTER REMOVAL ....................... 60                .           PISTON RING END GAP ................................. 124              .
    INSTALLATION ................................................... 61.           CONNECTING ROD BEND AND TORSION .... 124                               .
CAMSHAFT .............................................................. 71
                                                                       .           CONNECTING ROD BEARING HOUSING
  Removal and Installation ....................................... 71  .           DIAMETER (BIG END) ..................................... 125           .
    REMOVAL .......................................................... 72
                                                                       .           CONNECTING ROD BUSHING OIL CLEAR-
    INSPECTION AFTER REMOVAL ....................... 73                .           ANCE (SMALL END) ........................................ 125          .
    INSTALLATION ................................................... 76.           CYLINDER BLOCK DISTORTION ................... 126                      .
  Valve Clearance ..................................................... 78
                                                                       .           INNER DIAMETER OF MAIN BEARING HOUS-
    INSPECTION ...................................................... 78
                                                                       .           ING .................................................................... 126
                                                                                                                                                          .
    ADJUSTMENT ................................................... 81  .           PISTON TO CYLINDER BORE CLEARANCE . 127
OIL SEAL ................................................................. 83
                                                                       .           OUTER DIAMETER OF CRANKSHAFT JOUR-
  Removal and Installation of Valve Oil Seal ............ 83           .           NAL ................................................................... 128
                                                                                                                                                          .
    REMOVAL .......................................................... 83
                                                                       .           OUTER DIAMETER OF CRANKSHAFT PIN ... 128                               .
    INSTALLATION ................................................... 83.           OUT-OF-ROUND AND TAPER OF CRANK-
  Removal and Installation of Front Oil Seal ............ 84           .           SHAFT .............................................................. 128
                                                                                                                                                          .
    REMOVAL .......................................................... 84
                                                                       .           CRANKSHAFT RUNOUT ................................. 129                .
    INSTALLATION ................................................... 85.           CONNECTING ROD BEARING OIL CLEAR-
  Removal and Installation of Rear Oil Seal ............. 85           .           ANCE ................................................................ 129
                                                                                                                                                          .
    REMOVAL .......................................................... 85
                                                                       .           MAIN BEARING OIL CLEARANCE .................. 130                      .
    INSTALLATION ................................................... 85.           CRUSH HEIGHT OF MAIN BEARING ............. 130                         .
CYLINDER HEAD .................................................... 87  .           CRUSH HEIGHT OF CONNECTING ROD
  On-Vehicle Service ................................................ 87
                                                                       .           BEARING .......................................................... 131 .
    CHECKING COMPRESSION PRESSURE ........ 87                          .           OUTER DIAMETER OF MAIN BEARING CAP
  Removal and Installation ....................................... 88  .           BOLT ................................................................. 131
                                                                                                                                                          .
    REMOVAL .......................................................... 88
                                                                       .           OUTER DIAMETER OF CONNECTING ROD
    INSPECTION AFTER REMOVAL ....................... 89                .           BOLT ................................................................. 131
                                                                                                                                                          .
    INSTALLATION ................................................... 90.           FLYWHEEL DEFLECTION (M/T MODELS) ..... 131                             .
  Disassembly and Assembly ................................... 91      .           MOVEMENT AMOUNT OF FLYWHEEL (M/T
    DISASSEMBLY .................................................. 91  .           MODELS) .......................................................... 131 .
  Inspection After Disassembly ................................ 92     .           DRIVE PLATE (A/T MODELS) .......................... 132                .
    VALVE DIMENSIONS ......................................... 92      .           OIL JET ............................................................. 132
                                                                                                                                                          .
    VALVE GUIDE CLEARANCE ............................. 92             .           OIL JET RELIEF VALVE ...................................132            .
    VALVE GUIDE REPLACEMENT ........................ 93                .        SERVICE DATA AND SPECIFICATIONS (SDS) ... 133                             .
    VALVE SEAT CONTACT .................................... 95         .         Standard and Limit ............................................... 133   .
    VALVE SEAT REPLACEMENT .......................... 95               .           GENERAL SPECIFICATIONS .......................... 133                  .
    VALVE SPRING SQUARENESS ........................ 96                .           INTAKE MANIFOLD COLLECTOR, INTAKE
    VALVE SPRING DIMENSIONS AND VALVE                                              MANIFOLD AND EXHAUST MANIFOLD ......... 133                            .
    SPRING PRESSURE LOAD .............................. 96             .           DRIVE BELT ..................................................... 134   .
    ASSEMBLY ........................................................ 96
                                                                       .           SPARK PLUG ................................................... 134     .
ENGINE ASSEMBLY ............................................... 98     .           CYLINDER HEAD ............................................. 134        .
  Removal and Installation ....................................... 98  .           VALVE ............................................................... 135
                                                                                                                                                          .
    REMOVAL .......................................................... 99
                                                                       .           CAMSHAFT AND CAMSHAFT BEARING ........ 139                             .
    INSTALLATION ................................................. 101 .           CYLINDER BLOCK ........................................... 139         .
    INSPECTION AFTER INSTALLATION ............. 102                    .           PISTON, PISTON RING AND PISTON PIN ..... 140                           .
CYLINDER BLOCK ................................................ 103    .           CONNECTING ROD ......................................... 141           .
  Disassembly and Assembly ................................. 103       .           CRANKSHAFT .................................................. 142      .
    DISASSEMBLY ................................................ 106   .           AVAILABLE MAIN BEARING ............................ 143                .
    ASSEMBLY .......................................................111.           CONNECTING ROD BEARING ........................ 143                    .
  How to Select Piston and Bearing ....................... 117         .           BEARING OIL CLEARANCE ............................ 144                 .
    DESCRIPTION ................................................. 117  .           MISCELLANEOUS COMPONENTS ................. 144                         .
    HOW TO SELECT PISTON .............................. 118            .         Tightening Torque ................................................ 144   .
    HOW TO SELECT CONNECTING ROD BEAR-

Revision; 2004 April                                                      EM-2                                                         2003 G35 Sedan
                                             PRECAUTIONS

PRECAUTIONS                                                                                             PFP:00001
                                                                                                                       A
Precautions for Draining Engine Coolant                                                                     ABS0046W


q   Drain engine coolant when engine is cooled.
                                                                                                                       EM
Precautions for Disconnecting Fuel Piping                                                                   ABS0046X


q   Before starting work, make sure no fire or spark producing items are in the work area.
q   Release fuel pressure before disassembly.                                                                          C
q   After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly                                                                     ABS00DAH
                                                                                                                       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                                                          ABS0046Z   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                                                                   ABS00470


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 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.         K
    Before assembly, oil sliding surfaces well.
q   Release air within route when refilling after draining coolant.
q   After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and             L
    exhaust systems for leakage.

                                                                                                                       M




Revision; 2004 April                                EM-3                                        2003 G35 Sedan
                                              PRECAUTIONS

Parts Requiring Angular Tightening                                                                         ABS00471


q    Use an angle wrench for the final tightening of the following engine parts:



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