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ENGINE MECHANICAL


B ENGINE

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                                                                                                   SECTION
                                                                                          ENGINE MECHANICAL
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                                                                   CONTENTS
PRECAUTIONS ......................................................... 4  .         INTAKE MANIFOLD COLLECTOR ......................... 19                     .        F
 Precautions for Draining Engine Coolant ................ 4              .           Removal and Installation ....................................... 19      .
 Precautions for Disconnecting Fuel Piping ............. 4               .            REMOVAL .......................................................... 19   .
 Precautions for Removal and Disassembly ............ 4                  .            INSPECTION AFTER REMOVAL ...................... 21                      .        G
 Precautions for Inspection, Repair and Replace-                                      INSTALLATION .................................................. 22      .
 ment ........................................................................ 4
                                                                         .         INTAKE MANIFOLD ................................................ 24        .
 Precautions for Assembly and Installation .............. 4              .           Removal and Installation ....................................... 24      .
                                                                                                                                                                       H
 Parts Requiring Angle Tightening ............................ 5         .            REMOVAL .......................................................... 24   .
 Precautions for Liquid Gasket ................................. 5       .            INSPECTION AFTER REMOVAL ...................... 24                      .
   REMOVAL OF LIQUID GASKET SEALING ......... 5                          .            INSTALLATION .................................................. 25      .
   LIQUID GASKET APPLICATION PROCEDURE 5                                 .....     EXHAUST MANIFOLD AND THREE WAY CATA-                                                 I
PREPARATION .......................................................... 7 .         LYST ......................................................................... 26
                                                                                                                                                              .
 Special Service Tools (SST) .................................... 7      .           Removal and Installation ....................................... 26      .
 Commercial Service Tools ....................................... 9      .            REMOVAL .......................................................... 26   .        J
NOISE, VIBRATION AND HARSHNESS (NVH)                                                  INSPECTION AFTER REMOVAL ...................... 28                      .
TROUBLESHOOTING ............................................. 12         .            INSTALLATION .................................................. 28      .
 NVH Troubleshooting --Engine Noise .................. 12                .         OIL PAN AND OIL STRAINER ................................ 30               .
                                                                                                                                                                       K
 Use the Chart Below to Help You Find the Cause                                      Removal and Installation (2WD Model) ................. 30                .
 of the Symptom. .................................................... 13 .            REMOVAL .......................................................... 30   .
DRIVE BELTS .......................................................... 14.            INSPECTION AFTER REMOVAL ...................... 32                      .
 Checking Drive Belts ............................................. 14   .            INSTALLATION .................................................. 32      .        L
 Tension Adjustment ............................................... 14   .            INSPECTION AFTER INSTALLATION ............... 35                        .
   ALTERNATOR AND POWER STEERING OIL                                                 Removal and Installation (AWD Model) ................. 36                .
   PUMP BELT ....................................................... 15  .            REMOVAL .......................................................... 36   .        M
   A/C COMPRESSOR BELT ................................ 15               .            INSPECTION AFTER REMOVAL ...................... 39                      .
 Removal and Installation ....................................... 15     .            INSTALLATION .................................................. 39      .
   REMOVAL .......................................................... 15 .            INSPECTION AFTER INSTALLATION ............... 42                        .
   INSTALLATION .................................................. 16    .         IGNITION COIL ........................................................ 43  .
AIR CLEANER AND AIR DUCT .............................. 17               .           Removal and Installation ....................................... 43      .
 Removal and Installation ....................................... 17     .            REMOVAL .......................................................... 43   .
   REMOVAL .......................................................... 17 .            INSTALLATION .................................................. 43      .
   INSTALLATION .................................................. 17    .         SPARK PLUG (PLATINUM-TIPPED TYPE) ............ 44                          .
 Changing Air Cleaner Filter ................................... 18      .           Removal and Installation ....................................... 44      .
   INSPECTION ..................................................... 18   .            REMOVAL .......................................................... 44   .
   REMOVAL .......................................................... 18 .            INSPECTION AFTER REMOVAL ...................... 44                      .
   INSTALLATION .................................................. 18    .            INSTALLATION .................................................. 45      .




Edition; 2004 September                                                      EM-1                                                          2005 G35 Sedan
FUEL INJECTOR AND FUEL TUBE ....................... 46                 .           SPRING PRESSURE LOAD ............................. 112                 .
  Removal and Installation ....................................... 46  .        ENGINE ASSEMBLY .............................................. 113        .
    REMOVAL .......................................................... 47
                                                                       .         Removal and Installation (2WD Model) ............... 113                 .
    INSTALLATION ................................................... 48.           REMOVAL ......................................................... 114  .
    INSPECTION AFTER INSTALLATION ............... 51                   .           INSTALLATION ................................................. 116     .
ROCKER COVER .................................................... 52   .           INSPECTION AFTER INSTALLATION ............. 117                        .
  Removal and Installation ....................................... 52  .         Removal and Installation (AWD Model) ............... 118                 .
    REMOVAL .......................................................... 52
                                                                       .           REMOVAL ......................................................... 119  .
    INSTALLATION ................................................... 53.           INSTALLATION ................................................. 121     .
FRONT TIMING CHAIN CASE ................................ 55            .           INSPECTION AFTER INSTALLATION ............. 122                        .
  Removal and Installation ....................................... 55  .        CYLINDER BLOCK ................................................ 123       .
    REMOVAL .......................................................... 55
                                                                       .         Disassembly and Assembly ................................. 123           .
    INSTALLATION ................................................... 58.           DISASSEMBLY ................................................. 124      .
    INSPECTION AFTER INSTALLATION ............... 63                   .           ASSEMBLY ....................................................... 129   .
TIMING CHAIN ......................................................... 64
                                                                       .         How to Select Piston and Bearing ....................... 136             .
  Removal and Installation ....................................... 64  .           DESCRIPTION ................................................. 136      .
    REMOVAL .......................................................... 65
                                                                       .           HOW TO SELECT PISTON .............................. 136                .
    INSPECTION AFTER REMOVAL ....................... 72                .           HOW TO SELECT CONNECTING ROD BEAR-
    INSTALLATION ................................................... 73.           ING .................................................................... 137
                                                                                                                                                          .
    INSPECTION AFTER INSTALLATION ............... 82                   .           HOW TO SELECT MAIN BEARING ................. 138                       .
CAMSHAFT .............................................................. 84
                                                                       .         Inspection After Disassembly ............................... 141         .
  Removal and Installation ....................................... 84  .           CRANKSHAFT END PLAY ............................... 141                .
    REMOVAL .......................................................... 85
                                                                       .           CONNECTING ROD SIDE CLEARANCE ........ 141                             .
    INSPECTION AFTER REMOVAL ....................... 86                .           PISTON TO PISTON PIN OIL CLEARANCE .... 141                            .
    INSTALLATION ................................................... 89.           PISTON RING SIDE CLEARANCE .................. 142                      .
    INSPECTION AFTER INSTALLATION ............... 92                   .           PISTON RING END GAP ................................. 142              .
  Valve Clearance ..................................................... 93
                                                                       .           CONNECTING ROD BEND AND TORSION .... 143                               .
    INSPECTION ...................................................... 93
                                                                       .           CONNECTING ROD BIG END DIAMETER ..... 143                              .
    ADJUSTMENT ................................................... 96  .           CONNECTING ROD BUSHING OIL CLEAR-
OIL SEAL ................................................................. 97
                                                                       .           ANCE ................................................................ 143
                                                                                                                                                          .
  Removal and Installation of Valve Oil Seal ............ 97           .           CYLINDER BLOCK DISTORTION ................... 144                      .
    REMOVAL .......................................................... 97
                                                                       .           MAIN BEARING HOUSING INNER DIAMETER.145
    INSTALLATION ................................................... 97.           PISTON TO CYLINDER BORE CLEARANCE . 145
  Removal and Installation of Front Oil Seal ............ 98           .           CRANKSHAFT MAIN JOURNAL DIAMETER .. 146                                .
    REMOVAL .......................................................... 98
                                                                       .           CRANKSHAFT PIN JOURNAL DIAMETER ..... 147                              .
    INSTALLATION ................................................... 99.           CRANKSHAFT OUT-OF-ROUND AND TAPER.147
  Removal and Installation of Rear Oil Seal ............. 99           .           CRANKSHAFT RUNOUT ................................. 147                .
    REMOVAL .......................................................... 99
                                                                       .           CONNECTING ROD BEARING OIL CLEAR-
    INSTALLATION ................................................... 99.           ANCE ................................................................ 147
                                                                                                                                                          .
CYLINDER HEAD .................................................. 101   .           MAIN BEARING OIL CLEARANCE .................. 148                      .
  On-Vehicle Service .............................................. 101.           CRUSH HEIGHT OF MAIN BEARING ............. 149                         .
    CHECKING COMPRESSION PRESSURE ...... 101                           .           CRUSH HEIGHT OF CONNECTING ROD
  Removal and Installation ..................................... 102   .           BEARING .......................................................... 149 .
    REMOVAL ........................................................ 102
                                                                       .           MAIN BEARING CAP BOLT OUTER DIAMETER                                   .149
    INSPECTION AFTER REMOVAL ..................... 103                 .           CONNECTING ROD BOLT OUTER DIAMETER.150
    INSTALLATION ................................................. 104 .           FLYWHEEL DEFLECTION ............................... 150                .
  Disassembly and Assembly ................................. 105       .           MOVEMENT AMOUNT OF FLYWHEEL .......... 150                             .
    DISASSEMBLY ................................................ 106   .           DRIVE PLATE (A/T MODELS) .......................... 151                .
    ASSEMBLY ...................................................... 107.           OIL JET ............................................................. 151
                                                                                                                                                          .
  Inspection After Disassembly .............................. 108      .           OIL JET RELIEF VALVE ................................... 151           .
    VALVE DIMENSIONS ....................................... 108       .        SERVICE DATA AND SPECIFICATIONS (SDS) ... 152                             .
    VALVE GUIDE CLEARANCE ........................... 108              .         Standard and Limit ............................................... 152   .
    VALVE GUIDE REPLACEMENT ...................... 109                 .           GENERAL SPECIFICATIONS .......................... 152                  .
    VALVE SEAT CONTACT .................................. 110          .           DRIVE BELT ..................................................... 153   .
    VALVE SEAT REPLACEMENT ........................ 110                .           INTAKE MANIFOLD COLLECTOR, INTAKE
    VALVE SPRING SQUARENESS .......................111                 .
    VALVE SPRING DIMENSIONS AND VALVE



Edition; 2004 September                                                   EM-2                                                         2005 G35 Sedan
   MANIFOLD AND EXHAUST MANIFOLD ......... 153                  .
   SPARK PLUG ................................................... 153
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   CAMSHAFT AND CAMSHAFT BEARING ....... 154                    .
   CYLINDER HEAD ............................................ 156
                                                                .
   CYLINDER BLOCK .......................................... 159.                          EM
   PISTON, PISTON RING AND PISTON PIN ..... 160                 .
   CONNECTING ROD ........................................ 161  .
   CRANKSHAFT ................................................. 162
                                                                .
   MAIN BEARING ............................................... 163
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   CONNECTING ROD BEARING ....................... 164           .

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Edition; 2004 September                                            EM-3   2005 G35 Sedan
                                             PRECAUTIONS

PRECAUTIONS                                                                                             PFP:00001

Precautions for Draining Engine Coolant                                                                     ABS0046W


Drain engine coolant when engine is cooled.
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 disconnecting and disassembly.
q   After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly                                                                     ABS0046Y


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 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
    used where noted in the step.
Precautions for Inspection, Repair and Replacement                                                          ABS0046Z


Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and Installation                                                                   ABS00470


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
    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.
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
    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-4                                        2005 G35 Sedan
                                               PRECAUTIONS

Parts Requiring Angle Tightening                                                                         ABS00471

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



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