Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Infiniti M45 Y34 2003-2004 Approved M45-Y34-2003 em

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ENGINE MECHANICAL


B ENGINE

                                                                                                                                                                       A




                                                                                                   SECTION
                                                                                          ENGINE MECHANICAL
                                                                                                                               EM                                      EM



                                                                                                                                                                       C


                                                                                                                                                                       D


                                                                                                                                                                       E
                                                                   CONTENTS
PRECAUTIONS ......................................................... 3  .         INTAKE MANIFOLD ................................................ 17        .        F
 Precautions for Drain Coolant ................................. 3       .           Removal and Installation ....................................... 17      .
 Precautions for Disconnecting Fuel Piping ............. 3               .            REMOVAL .......................................................... 17   .
 Precautions for Removal and Disassembly ............ 3                  .            INSPECTION AFTER REMOVAL ...................... 19                      .        G
 Precautions for Inspection, Repair and Replace-                                      INSTALLATION .................................................. 19      .
 ment ........................................................................ 3
                                                                         .            INSPECTION AFTER INSTALLATION ............... 21                        .
 Precautions for Assembly and Installation .............. 3              .         EXHAUST MANIFOLD AND THREE WAY CATA-
                                                                                                                                                                       H
 Parts Requiring Angular Tightening ........................ 3           .         LYST ......................................................................... 22
                                                                                                                                                              .
 Precautions for Liquid Gasket ................................. 4       .           Removal and Installation ....................................... 22      .
   REMOVAL OF LIQUID GASKET SEALING ......... 4                          .            REMOVAL .......................................................... 22   .
   LIQUID GASKET APPLICATION PROCEDURE 4                                 .....        INSPECTION AFTER REMOVAL ...................... 23                      .         I
PREPARATION .......................................................... 5 .            INSTALLATION .................................................. 24      .
 Special Service Tools .............................................. 5  .         OIL PAN AND OIL STRAINER ................................ 25               .
 Commercial Service Tools ....................................... 7      .           Removal and Installation ....................................... 25      .        J
NOISE, VIBRATION AND HARSHNESS (NVH)                                                  REMOVAL .......................................................... 25   .
TROUBLESHOOTING ............................................... 9        .            INSPECTION AFTER REMOVAL ...................... 26                      .
 NVH Troubleshooting --Engine Noise .................... 9               .            INSTALLATION .................................................. 26      .
                                                                                                                                                                       K
 Use the Chart Below to Help You Find the Cause                                       INSPECTION AFTER INSTALLATION ............... 27                        .
 of the Symptom. .................................................... 10 .         IGNITION COIL ........................................................ 28  .
ENGINE ROOM COVER ..........................................11           .           Removal and Installation ....................................... 28      .
 Removal and Installation ........................................11     .            REMOVAL .......................................................... 28   .        L
   REMOVAL ...........................................................11 .            INSTALLATION .................................................. 28      .
   INSTALLATION ...................................................11    .         SPARK PLUG (PLATINUM-TIPPED TYPE) ............ 29                          .
DRIVE BELTS .......................................................... 12.           Removal and Installation ....................................... 29      .        M
 Checking Drive Belts ............................................. 12   .            REMOVAL .......................................................... 29   .
 Tension Adjustment ............................................... 12   .            INSPECTION AFTER REMOVAL ...................... 29                      .
 Removal and Installation ....................................... 12     .            INSTALLATION .................................................. 30      .
   REMOVAL .......................................................... 12 .         FUEL INJECTOR AND FUEL TUBE ....................... 31                     .
   INSTALLATION .................................................. 13    .           Removal and Installation ....................................... 31      .
 Drive Belt Auto Tensioner and Idler Pulley ............ 14              .            REMOVAL .......................................................... 31   .
   REMOVAL .......................................................... 14 .            INSTALLATION .................................................. 32      .
   INSTALLATION .................................................. 14    .            INSPECTION AFTER INSTALLATION ............... 32                        .
AIR CLEANER AND AIR DUCT .............................. 15               .         ROCKER COVER .................................................... 33       .
 Removal and Installation ....................................... 15     .           Removal and Installation ....................................... 33      .
   REMOVAL .......................................................... 15 .            REMOVAL .......................................................... 33   .
   INSTALLATION .................................................. 15    .            INSTALLATION .................................................. 34      .
   CHANGING AIR CLEANER FILTER .................. 16                     .




Revision; 2004 April                                                         EM-1                                                                    2003 M45
TIMING CHAIN ......................................................... 35
                                                                       .         Disassembly and Assembly ...................................72           .
  Removal and Installation ....................................... 35  .           DISASSEMBLY ...................................................73      .
    REMOVAL .......................................................... 36
                                                                       .           ASSEMBLY .........................................................76   .
    INSPECTION AFTER REMOVAL ....................... 39                .         How to Select Piston and Bearing .........................80             .
    INSTALLATION ................................................... 39.           DESCRIPTION ...................................................80      .
CAMSHAFT .............................................................. 46
                                                                       .           HOW TO SELECT PISTON ................................81                .
  Removal and Installation ....................................... 46  .           HOW TO SELECT CONNECTING ROD BEAR-
    REMOVAL .......................................................... 47
                                                                       .           ING ......................................................................82
                                                                                                                                                          .
    INSTALLATION ................................................... 47.           HOW TO SELECT MAIN BEARING ...................83                       .
    INSPECTION AFTER REMOVAL ....................... 50                .         Inspection After Disassembly .................................86         .
  Valve Clearance ..................................................... 52
                                                                       .           CRANKSHAFT SIDE CLEARANCE ...................86                        .
    INSPECTION ...................................................... 52
                                                                       .           CONNECTING ROD SIDE CLEARANCE ..........87                             .
    ADJUSTMENT ................................................... 54  .           PISTON AND PISTON PIN CLEARANCE ..........87                           .
OIL SEAL ................................................................. 57
                                                                       .           PISTON RING SIDE CLEARANCE ....................88                      .
  Removal and Installation of Valve Oil Seal ............ 57           .           PISTON RING END GAP ...................................88              .
    REMOVAL .......................................................... 57
                                                                       .           CONNECTING ROD BEND AND TORSION ......89                               .
    INSTALLATION ................................................... 57.           CONNECTING ROD BEARING (BIG END) .......89                             .
  Removal and Installation of Front Oil Seal ............ 58           .           CONNECTING ROD BUSHING OIL CLEAR-
    REMOVAL .......................................................... 58
                                                                       .           ANCE (SMALL END) ..........................................89          .
    INSTALLATION ................................................... 58.           CYLINDER BLOCK DISTORTION .....................90                      .
  Removal and Installation of Rear Oil Seal ............. 59           .           INNER DIAMETER OF MAIN BEARING HOUS-
    REMOVAL .......................................................... 59
                                                                       .           ING ......................................................................91
                                                                                                                                                          .
    INSTALLATION ................................................... 59.           PISTON TO CYLINDER BORE CLEARANCE ...91
CYLINDER HEAD .................................................... 60  .           OUTER DIAMETER OF CRANKSHAFT JOUR-
  On-Vehicle Service ................................................ 60
                                                                       .           NAL .....................................................................92
                                                                                                                                                          .
    CHECKING COMPRESSION PRESSURE ........ 60                          .           OUTER DIAMETER OF CRANKSHAFT PIN .....93                               .
  Removal and Installation ....................................... 61  .           OUT-OF-ROUND AND TAPER OF CRANK-
    REMOVAL .......................................................... 61
                                                                       .           SHAFT ................................................................93
                                                                                                                                                          .
    INSPECTION AFTER REMOVAL ....................... 62                .           CRANKSHAFT RUNOUT ...................................93                .
    INSTALLATION ................................................... 62.           OIL CLEARANCE OF CONNECTING ROD
  Disassembly and Assembly ................................... 63      .           BEARING ............................................................93 .
    DISASSEMBLY .................................................. 63  .           OIL CLEARANCE OF MAIN BEARING ..............94                         .
    ASSEMBLY ........................................................ 64
                                                                       .           CRUSH HEIGHT OF MAIN BEARING ...............95                         .
  Inspection After Disassembly ................................ 64     .        SERVICE DATA AND SPECIFICATIONS (SDS) .....96                             .
    CYLINDER HEAD DISTORTION ....................... 64                .         Standard and Limit .................................................96   .
    VALVE DIMENSIONS ......................................... 65      .           GENERAL SPECIFICATIONS ............................96                  .
    VALVE GUIDE CLEARANCE ............................. 65             .           INTAKE MANIFOLD AND EXHAUST MANI-
    VALVE GUIDE REPLACEMENT ........................ 65                .           FOLD ..................................................................96
                                                                                                                                                          .
    VALVE SEAT CONTACT .................................... 66         .           DRIVE BELTS .....................................................96    .
    VALVE SEAT REPLACEMENT .......................... 67               .           CYLINDER HEAD ...............................................97        .
    VALVE SPRING SQUARENESS ........................ 68                .           VALVE .................................................................97
                                                                                                                                                          .
    VALVE SPRING DIMENSIONS AND VALVE                                              CAMSHAFT AND CAMSHAFT BEARING ........ 101                             .
    SPRING PRESSURE LOAD .............................. 68             .           CYLINDER BLOCK ........................................... 102         .
ENGINE ASSEMBLY ............................................... 69     .           PISTON, PISTON RING AND PISTON PIN ..... 103                           .
  Removal and Installation ....................................... 69  .           CONNECTING ROD ......................................... 104           .
    REMOVAL .......................................................... 69
                                                                       .           CRANKSHAFT .................................................. 105      .
    INSTALLATION ................................................... 71.           MAIN BEARING ................................................ 106      .
    INSPECTION AFTER INSTALLATION ............... 71                   .           CONNECTING ROD BEARING ........................ 107                    .
CYLINDER BLOCK .................................................. 72   .         Tightening torque ................................................. 108  .




Revision; 2004 April                                                      EM-2                                                                   2003 M45
                                             PRECAUTIONS

PRECAUTIONS                                                                                             PFP:00001
                                                                                                                       A
Precautions for Drain Coolant                                                                               ABS000OV


q   Drain coolant when engine is cooled.
                                                                                                                       EM
Precautions for Disconnecting Fuel Piping                                                                  ABS000OW


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.                                                        C
q   After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly                                                                     ABS000OX
                                                                                                                       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                                                          ABS000OY   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                                                                   ABS000OZ


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 oil or 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 coolant, fuel, oil, and exhaust systems           L
    for leakage.
Parts Requiring Angular Tightening                                                                          ABS000P0
                                                                                                                       M
q   Use an angle wrench for the final tightening of the following engine parts:



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