INFINITI FX35 2004 Service Manual

EM-246
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CYLINDER BLOCK
Revision: 2004 November 2004 FX35/FX45

Press-fit pilot converter with its chamfering side facing crank-
shaft as shown in the figure.

It is possible to remove pilot converter without hoisting engine
with engine stand.
5. Install crankshaft to cylinder block.

While turning crankshaft by hand, make sure it turns smoothly.
6. Install main bearing caps.

Align the identification number to the journal position to install.

Install the upper side of the identification number facing the
front of engine. (The number shall be read correctly from the
rear of engine.)

Using plastic hammer or similar tool, tap them lightly to seat
them on the installation position.
NOTE:
Main bearing cap cannot be replaced as a single parts, because
it is machined together with cylinder block.
7. Install each main bearing cap bolt as follows:
a. Apply new engine oil to threads and seating surface of main
bearing cap bolts, and tighten all bolts temporarily.
b. Tighten main bearing cap bolt (M12) in order of 1 to 10.
c. Tighten main bearing cap sub bolt (M9) in order of 11 to 20.
d. Tighten main bearing cap bolt (M12) to 40 degrees clockwise in
order of 1 to 10. (Angle tightening)
CAUTION:
Use angle wrench (SST) to check tightening angle in step
“d” and “e”. Do not make judgment by visual inspection.
e. Tighten main bearing cap sub bolt (M9) to 30 degrees clockwise
in order of 11 to 20. (Angle tightening)
f. Tighten side bolt (M10) in order of 21 to 30.

After installing main bearing cap bolts, make sure that crankshaft can be rotated smoothly.

Check the crankshaft end play. Refer to EM-256, "CRANKSHAFT END PLAY" .
g. Install cover of cylinder block rear left side (next to the starter motor housing).
SEM537E
PBIC0095E
: 39.2 N·m (4.0 kg-m, 29 ft-lb)
: 29.4 N·m (3.0 kg-m, 22 ft-lb)
PBIC0090E
PBIC0096E
: 49 N·m (5.0 kg-m, 36 ft-lb)

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Revision: 2004 November 2004 FX35/FX45
8. Install rear oil seal to rear oil seal retainer with suitable drift.

Tap until flattened with front edge of rear oil seal retainer. Do
not damage or scratch outer circumference of oil seal.

Install new rear oil seal so that each seal lip is oriented as
shown in the figure.
9. Install rear oil seal retainer.

Apply a continuous bead of liquid gasket with tube presser
[SST: WS39930000 ( — )] to rear oil seal retainer as
shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-48, "
RECOMMENDED CHEMICAL PRODUCTS AND
SEALANTS".

Apply new engine oil to both oil seal lip and dust seal lip.
10. Install piston to connecting rod.
a. Using snap ring pliers, install new snap ring to the groove of the piston rear side.

Insert it fully into groove to install.
b. Install piston to connecting rod.

Using industrial use drier or similar tool, heat piston until piston pin can be pushed in by hand without
excess force [approx. 60 to 70°C (140 to 158°F)]. From the front to the rear, insert piston pin into piston
and connecting rod.

Assemble so that the front mark on the piston head and the oil
holes and the cylinder No. on connecting rod are positioned
as shown in the figure.
c. Using snap ring pliers, install new snap rings to the groove of the
piston front side.

Insert it fully into groove to install.

After installing, make sure that connecting rod moves
smoothly.Suitable drift
Outer diameter : 102 mm (4.02 in)
Inner diameter : 86 mm (3.39 in)
PBIC0097E
SEM715A
SBIA0391E
PBIC0099E

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Revision: 2004 November 2004 FX35/FX45
11. Using piston ring expander (commercial service tool), install pis-
ton rings.
CAUTION:
Be careful not to damage piston.

Position each ring with the gap as shown in the figure, refer-
ring to the piston front mark.

Install top ring and second ring with the stamped surface fac-
ing upward.
12. Install connecting rod bearings to connecting rod and connecting rod cap.

Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply
engine oil to the back surface, but thoroughly clean it.

When installing, align the connecting rod bearing stopper pro-
trusion with the cutout of connecting rod and connecting rod
cap to install.

Ensure the oil holes on connecting rod and that on the corre-
sponding bearing are aligned.
13. Install piston and connecting rod assembly to crankshaft.

Position the crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.

Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin.

Match the cylinder position with the cylinder No. on connecting rod to install.

Be sure that front mark on piston head is facing front of
engine.

Using piston ring compressor [SST: EM03470000 (J8037)],
install piston with the front mark on the piston head facing the
front of engine.
CAUTION:
Be careful not to damage cylinder wall and crankshaft pin,
resulting from an interference of the connecting rod big
end.
14. Install connecting rod cap.

Match the stamped cylinder number marks on connecting rod
with those on cap to install.Stamped mark
Top ring : R
Second ring : 2R
PBIC0100E
PBIC2370E
PBIC0102E
PBIC2164E

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15. Tighten the connecting rod nuts as follows:
a. Apply engine oil to the threads and seats of connecting rod bolts
and nuts.
b. Tighten nuts.
c. Then tighten all nuts 60 degrees clockwise. (Angle tightening)
CAUTION:
Use angle wrench (SST) to check tightening angle. Do not
make judgment by visual inspection.

After tightening nuts, make sure that the crankshaft rotates
smoothly.

Check the connecting rod side clearance. Refer to EM-256, "CONNECTING ROD SIDE CLEARANCE"
.
16. Install knock sensor.

Install it with its connector facing the rear of engine.

Install the sub-harness with its shorter branch line to the right
bank.
CAUTION:

Do not tighten mounting bolts while holding connector.

If any impact by dropping is applied to knock sensor,
replace it with new one.
NOTE:

Make sure that there is no foreign material on the cylinder
block mating surface and the back surface of the knock sen-
sor.

Make sure that the knock sensor does not interfere with other parts.
17. Install in the reverse order of removal after this step.
18. Remove engine assembly from engine stand.
19. Install drive plate.

Align guide pin of crankshaft rear end with pin holes of each
parts to install.

Install drive plate, reinforcement plate and pilot converter (if
not installed in step 4) as shown in the figure.

Face chamfered or rounded edge side to crankshaft.

Holding ring gear with ring gear stopper [SST: J-45476].

Tighten mounting bolts crosswise over several times.

When install pilot converter, using drift [outer diameter:
approx. 35 mm (1.38 in)]. Press-fit as far as it will go. : 14.7 N·m (1.5 kg-m, 11 ft-lb)
PBIC0104E
PBIC0105E
PBIC0106E
PBIC1965E

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Revision: 2004 November 2004 FX35/FX45
How to Select Piston and Bearing ABS006IV
DESCRIPTION
*: For the service parts, the grade for fitting cannot be selected between piston pin and connecting rod. (Only “0” grade is available.) The
information at the shipment from the plant is described as a reference.

The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.

For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.

For details of the measurement method of each part, the reuse standards, and the selection method of the
selective fitting parts, refer to the text.
HOW TO SELECT PISTON
When New Cylinder Block Is Used:
Check the cylinder bore grade (“0”, “1” or “2”) on the rear upper side
between cylinder block banks, and select piston of the same grade.
NOTE:
Piston is available with piston pin as a set for the service part. (Only
“0” grade piston pin is available.)
When Cylinder Block Is Reused:
1. Measure the cylinder bore inner diameter. Refer to EM-260, "Cylinder Bore Inner Diameter" .
2. Determine the bore grade by comparing the measurement with the values the “Cylinder bore inner diame-
ter” of the “Piston Selection Table”. Select piston of the same grade.
Selection points Selection parts Selection items Selection methods
Between cylinder block to
crankshaftMain bearingMain bearing grade
(bearing thickness)Determined by match of cylin-
der block bearing housing
grade (inner diameter of hous-
ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Between crankshaft to connect-
ing rodConnecting rod bearingConnecting rod bearing grade
(bearing thickness)Combining service grades for
connecting rod big end diame-
ter and crankshaft pin outer
diameter determine connecting
rod bearing selection.
Between cylinder block to pis-
tonPiston and piston pin assembly
(Piston is available together
with piston pin as assembly.)Piston grade
(piston skirt diameter)Piston grade = cylinder bore
grade (inner diameter of bore)
Between piston to connecting
rod*———
PBIC2371E
PBIC2372E

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Revision: 2004 November 2004 FX35/FX45
Piston Selection Table
Unit: mm (in)
NOTE:

Piston is available together with piston pin as assembly.

Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no
piston pin grades can be selected. (Only “0” grade is available.)

No second grade mark is available on piston.
HOW TO SELECT CONNECTING ROD BEARING
When New Connecting Rod and Crankshaft Are Used:
Check pin diameter grade (“0”, “1” or “2”) on front of crankshaft, and
select connecting rod bearing of the same grade.
NOTE:
There is no grading for connecting rod big end diameter.
When Crankshaft and Connecting Rod Are Reused:
1. Measure the connecting rod big end diameter. Refer to EM-258, "CONNECTING ROD BIG END DIAME-
TER" .
2. Make sure that the connecting rod big end diameter is within the standard value.
3. Measure the crankshaft pin journal diameter. Refer to EM-262, "
CRANKSHAFT PIN JOURNAL DIAME-
TER" .
4. Determine the grade of crankshaft pin diameter grade by corresponding to the measured dimension in
“Crankshaft pin journal diameter” column of “Connecting Rod Bearing Selection Table”.
5. Select connecting rod bearing of the same grade.
Connecting Rod Bearing Selection Table
Unit: mm (in)
Unit: mm (in)
Under Size Bearings Usage Guide

When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod
bearings, use undersize (US) bearings.

When using undersize bearing, measure the connecting rod bearing inner diameter with bearing installed,
and grind crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard.
Grade 1 2 (or no mark) 3
Cylinder bore inner diameter93.000 / 93.010
(3.6614 / 3.6618)93.010 / 93.020
(3.6618 / 3.6622)93.020 / 93.030
(3.6622 / 3.6626)
Piston skirt diameter92.980 / 92.990
(3.6606 / 3.6610)92.990 / 93.000
(3.6610 / 3.6614)93.000 / 93.010
(3.6614 / 3.6618)
PBIC2374E
Connecting rod big end diameter 55.000 - 55.013 (2.1654 - 2.1659)
Crankshaft pin journal diameter Grade (Mark) Dimension (Bearing thickness range) Bearing grade No. Color
51.968 - 51.974 (2.0460 - 2.0462) 0 1.500 - 1.503 (0.0591 - 0.0592) STD 0 No color
51.962 - 51.968 (2.0457 - 2.0460) 1 1.503 - 1.506 (0.0592 - 0.0593) STD 1 Brown
51.956 - 51.962 (2.0455 - 2.0457) 2 1.506 - 1.509 (0.0593 - 0.0594) STD 2 Green

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Revision: 2004 November 2004 FX35/FX45
CAUTION:
In grinding crankshaft pin to use undersize bearings, keep
the fillet R [1.5 mm (0.059 in)].
Bearing undersize table
Unit: mm (in)
HOW TO SELECT MAIN BEARING
When New Cylinder Block and Crankshaft Are Used:
1. “Main Bearing Selection Table” rows correspond to main bearing
housing grade on rear upper side between cylinder block banks.
2. “Main Bearing Selection Table” columns correspond to main
journal diameter grade on front side of crankshaft.
3. Select main bearing grade at the point where selected row and column meat in “Main Bearing Selection
Table”.
CAUTION:

Initial clearance for No. 1, 5 journal and No. 2, 3, 4 journal is different. Use two different selection
table for each part.

No. 1, 5 journal and No. 2, 3, 4 journal have the same signs but different measures. Do not con-
fuse.
4. Apply sign at crossing in above step 3 to “Main Bearing Grade Table”.
NOTE:

“Main Bearing Grade Table” applies to all journals.

Service parts is available as a set of both upper and lower.
PBIC2373E
Size Thickness
US 0.25 (0.0098) 1.626 - 1.634 (0.0640 - 0.0643)
PBIC2371E
PBIC2374E

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When Cylinder Block and Crankshaft Are Reused:
1. Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter. Refer
to EM-260, "
MAIN BEARING HOUSING INNER DIAMETER" and EM-261, "CRANKSHAFT MAIN
JOURNAL DIAMETER" .
2. Correspond the measured dimension in “Cylinder block main bearing housing inner diameter” row of
“Main Bearing Selection Table”.
3. Correspond the measured dimension in “Crankshaft main journal diameter” column of “Main Bearing
Selection Table”.
4. Follow step 3 and later in “When New Cylinder Block and Crankshaft are Used:”.
Main Bearing Selection Table (No. 1 and 5 Journal)
PBIC2375E

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Revision: 2004 November 2004 FX35/FX45
Main Bearing Selection Table (No. 2, 3 and 4 Journal)
PBIC2376E

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Main Bearing Grade Table (All Journals)
Unit: mm (in)
Use Undersize Bearing Usage Guide

When the specified main bearing oil clearance is not obtained with standard size main bearings, use
underside (US) bearing.

When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and
grind main journal so that the main bearing oil clearance satisfies the standard.
CAUTION:
In grinding crankshaft main journal to use undersize bear-
ings, keep the fillet R [1.5 mm (0.059 in)].
Bearing undersize table
Unit: mm (in) Grade number Thickness Identification color Remarks
0 2.483 - 2.486 (0.0978 - 0.0979) Black
Grade and color are the same
for upper and lower bearings. 1 2.486 - 2.489 (0.0979 - 0.0980) Brown
2 2.489 - 2.492 (0.0980 - 0.0981) Green
3 2.492 - 2.495 (0.0981 - 0.0982) Yellow
4 2.495 - 2.498 (0.0982 - 0.0983) Blue
5 2.498 - 2.501 (0.0983 - 0.0985) Pink
6 2.501 - 2.504 (0.0985 - 0.0986) Purple
7 2.504 - 2.507 (0.0986 - 0.0987) White
8 2.507 - 2.510 (0.0987 - 0.0988) Red
01UPR 2.483 - 2.486 (0.0978 - 0.0979) Black
Grade and color are different
for upper and lower bearings. LWR 2.486 - 2.489 (0.0979 - 0.0980) Brown
12UPR 2.486 - 2.489 (0.0979 - 0.0980) Brown
LWR 2.489 - 2.492 (0.0980 - 0.0981) Green
23UPR 2.489 - 2.492 (0.0980 - 0.0981) Green
LWR 2.492 - 2.495 (0.0981 - 0.0982) Yellow
34UPR 2.492 - 2.495 (0.0981 - 0.0982) Yellow
LWR 2.495 - 2.498 (0.0982 - 0.0983) Blue
45UPR 2.495 - 2.498 (0.0982 - 0.0983) Blue
LWR 2.498 - 2.501 (0.0983 - 0.0985) Pink
56UPR 2.498 - 2.501 (0.0983 - 0.0985) Pink
LWR 2.501 - 2.504 (0.0985 - 0.0986) Purple
67UPR 2.501 - 2.504 (0.0985 - 0.0986) Purple
LWR 2.504 - 2.507 (0.0986 - 0.0987) White
78UPR 2.504 - 2.507 (0.0986 - 0.0987) White
LWR 2.507 - 2.510 (0.0987 - 0.0988) Red
PBIC2373E
Size Thickness
US 0.25 (0.0098) 2.618 - 2.626 (0.1031 - 0.1034)