check engine INFINITI FX35 2004 Service Manual
[x] Cancel search | Manufacturer: INFINITI, Model Year: 2004, Model line: FX35, Model: INFINITI FX35 2004Pages: 4449, PDF Size: 99.66 MB
Page 2618 of 4449
![INFINITI FX35 2004 Service Manual INJECTOR CIRCUIT
EC-1277
[VK45DE]
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Revision: 2004 November 2004 FX35/FX45
2. CHECK OVERALL FUNCTION
With CONSULT-II
1. Start engine.
2. Perform “POWER BALANCE” in “ACTI](/img/42/57021/w960_57021-2617.png "INFINITI FX35 2004 Service Manual INJECTOR CIRCUIT
EC-1277
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Revision: 2004 November 2004 FX35/FX45
2. CHECK OVERALL FUNCTION
With CONSULT-II
1. Start engine.
2. Perform “POWER BALANCE” in “ACTI")
INJECTOR CIRCUIT
EC-1277
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Revision: 2004 November 2004 FX35/FX45
2. CHECK OVERALL FUNCTION
With CONSULT-II
1. Start engine.
2. Perform “POWER BALANCE” in “ACTIVE TEST” mode with
CONSULT-II.
3. Make sure that each circuit produces a momentary engine
speed drop.
Without CONSULT-II
1. Start engine.
2. Listen to each injector operating sound.
Clicking noise should be heard.
OK or NG
OK >>INSPECTION END
NG >> GO TO 3.
PBIB0133E
PBIB1986E
Page 2623 of 4449
![INFINITI FX35 2004 Service Manual EC-1282
[VK45DE]
FUEL PUMP CIRCUIT
Revision: 2004 November 2004 FX35/FX45
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground term](/img/42/57021/w960_57021-2622.png "INFINITI FX35 2004 Service Manual EC-1282
[VK45DE]
FUEL PUMP CIRCUIT
Revision: 2004 November 2004 FX35/FX45
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground term")
EC-1282
[VK45DE]
FUEL PUMP CIRCUIT
Revision: 2004 November 2004 FX35/FX45
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
Diagnostic ProcedureABS00CEX
1. CHECK OVERALL FUNCTION
1. Turn ignition switch ON.
2. Pinch fuel feed hose with two fingers.
Fuel pressure pulsation should be felt on the fuel feed hose
for 1 second after ignition switch is turned ON.
OK or NG
OK >>INSPECTION END
NG >> GO TO 2.
2. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-I
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Turn ignition switch ON.
4. Check voltage between ECM terminal 113 and ground with
CONSULT-II or tester.
OK or NG
OK >> GO TO 5.
NG >> GO TO 3.
TER-
MINAL
NO.WIRE
COLORITEM CONDITION DATA (DC Voltage)
11 3 G Y / R F u e l p u m p r e l a y[Ignition switch: ON]
For 1 second after turning ignition switch ON
[Engine is running]0 - 1.5V
[Ignition switch: ON]
More than 1 second after turning ignition
switch ONBATTERY VOLTAGE
(11 - 14V)
PBIB1491E
Voltage: Battery voltage
PBIB1187E
Page 2630 of 4449
![INFINITI FX35 2004 Service Manual REFRIGERANT PRESSURE SENSOR
EC-1289
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Revision: 2004 November 2004 FX35/FX45
Specification data are reference values and are measured between each terminal and ground.](/img/42/57021/w960_57021-2629.png "INFINITI FX35 2004 Service Manual REFRIGERANT PRESSURE SENSOR
EC-1289
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Specification data are reference values and are measured between each terminal and ground.")
REFRIGERANT PRESSURE SENSOR
EC-1289
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Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
Diagnostic ProcedureABS00CF2
1. CHECK REFRIGERANT PRESSURE SENSOR OVERALL FUNCTION
1. Start engine and warm it up to normal operating temperature.
2. Turn A/C switch and blower switch ON.
3. Check voltage between ECM terminal 70 and ground with CON-
SULT-II or tester.
OK or NG
OK >>INSPECTION END
NG >> GO TO 2.
TER-
MINAL
NO.WIRE
COLORITEM CONDITION DATA (DC Voltage)
49 PUSensor power supply
(Refrigerant pressure sen-
sor)[Ignition switch: ON]Approximately 5V
67 B/WSensor ground
(Mass air flow sensor / IAT
sensor / Power steering
pressure sensor / EVAP
control system pressure
sensor / Refrigerant pres-
sure sensor / ECT sensor)[Engine is running]
Warm-up condition
Idle speedApproximately 0V
70 L/R Refrigerant pressure sensor[Engine is running]
Warm-up condition
Both A/C switch and blower switch are ON
(Compressor operates)1.0 - 4.0V
Voltage: 1.0 - 4.0V
PBIB1188E
Page 2655 of 4449
![INFINITI FX35 2004 Service Manual EC-1314
[VK45DE]
SNOW MODE SWITCH
Revision: 2004 November 2004 FX35/FX45
Diagnostic ProcedureABS00CFO
1. CHECK SNOW MODE SWITICH OVERALL FUNCTION-I
1. Turn ignition switch ON.
2. Select “SNOW MODE S](/img/42/57021/w960_57021-2654.png "INFINITI FX35 2004 Service Manual EC-1314
[VK45DE]
SNOW MODE SWITCH
Revision: 2004 November 2004 FX35/FX45
Diagnostic ProcedureABS00CFO
1. CHECK SNOW MODE SWITICH OVERALL FUNCTION-I
1. Turn ignition switch ON.
2. Select “SNOW MODE S")
EC-1314
[VK45DE]
SNOW MODE SWITCH
Revision: 2004 November 2004 FX35/FX45
Diagnostic ProcedureABS00CFO
1. CHECK SNOW MODE SWITICH OVERALL FUNCTION-I
1. Turn ignition switch ON.
2. Select “SNOW MODE SW” in “DATA MONITOR” mode with
CONSULT-II.
3. Check “SNOW MODE SW” indication under the following condi-
tions.
OK or NG
OK >> GO TO 2.
NG >> GO TO 3.
2. CHECK SNOW MODE SWITICH OVERALL FUNCTION-II
1. Start engine.
2. Check the snow mode indicator in the snow mode switch under the following condition.
OK or NG
OK >>INSPECTION END
NG >> GO TO 3.
3. CHECK GROUND CONNECTIONS
1. Turn ignition switch OFF.
2. Loosen and retighten three ground screws on the body.
Refer to EC-791, "
Ground Inspection" .
OK or NG
OK >> GO TO 4.
NG >> Repair or replace ground connections.
CONDITION INDICATION
Snow mode switch: ON ON
Snow mode switch: OFF OFF
PBIB2009E
CONDITION INDICATION
Snow mode switch: ON ON
Snow mode switch: OFF OFF
PBIB2195E
Page 2668 of 4449
![INFINITI FX35 2004 Service Manual ON BOARD REFUELING VAPOR RECOVERY (ORVR)
EC-1327
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Revision: 2004 November 2004 FX35/FX45
ON BOARD REFUELING VAPOR RECOVERY (ORVR)PFP:00032
System DescriptionABS00CFV](/img/42/57021/w960_57021-2667.png "INFINITI FX35 2004 Service Manual ON BOARD REFUELING VAPOR RECOVERY (ORVR)
EC-1327
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ON BOARD REFUELING VAPOR RECOVERY (ORVR)PFP:00032
System DescriptionABS00CFV")
ON BOARD REFUELING VAPOR RECOVERY (ORVR)
EC-1327
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ON BOARD REFUELING VAPOR RECOVERY (ORVR)PFP:00032
System DescriptionABS00CFV
From the beginning of refueling, the air and vapor inside the fuel tank go through refueling EVAP vapor cut
valve and EVAP/ORVR line to the EVAP canister. The vapor is absorbed by the EVAP canister and the air is
released to the atmosphere.
When the refueling has reached the full level of the fuel tank, the refueling EVAP vapor cut valve is closed and
refueling is stopped because of auto shut-off. The vapor which was absorbed by the EVAP canister is purged
during driving.
WARNING:
When conducting inspections below, be sure to observe the following:
Put a “CAUTION: INFLAMMABLE” sign in workshop.
Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
Be sure to furnish the workshop with a CO2 fire extinguisher.
CAUTION:
Before removing fuel line parts, carry out the following procedures:
–Put drained fuel in an explosion-proof container and put lid on securely.
–Release fuel pressure from fuel line. Refer to EC-700, "FUEL PRESSURE RELEASE" .
–Disconnect battery ground cable.
Always replace O-ring when the fuel gauge retainer is removed.
Do not kink or twist hose and tube when they are installed.
Do not tighten hose and clamps excessively to avoid damaging hoses.
After installation, run engine and check for fuel leaks at connection.
Do not attempt to top off the fuel tank after the fuel pump nozzle shuts off automatically.
Continued refueling may cause fuel overflow, resulting in fuel spray and possibly a fire.
PBIB1068E
Page 2685 of 4449
EI-6
SQUEAK AND RATTLE TROUBLE DIAGNOSES
Revision: 2004 November 2004 FX35/FX45
DUPLICATE THE NOISE AND TEST DRIVE
If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information on
the Diagnostic Worksheet regarding the conditions or location of the noise. This information can be used to
duplicate the same conditions when you confirm the repair.
If the noise can be duplicated easily during the test drive, to help identify the source of the noise, try to dupli-
cate the noise with the vehicle stopped by doing one or all of the following:
1) Close a door.
2) Tap or push/pull around the area where the noise appears to be coming from.
3) Rev the engine.
4) Use a floor jack to recreate vehicle “twist”.
5) At idle, apply engine load (electrical load, half-clutch on M/T model, drive position on A/T model).
6) Raise the vehicle on a hoist and hit a tire with a rubber hammer.
Drive the vehicle and attempt to duplicate the conditions the customer states exist when the noise occurs.
If it is difficult to duplicate the noise, drive the vehicle slowly on an undulating or rough road to stress the
vehicle body.
CHECK RELATED SERVICE BULLETINS
After verifying the customer concern or symptom, check ASIST for Technical Service Bulletins (TSBs) related
to that concern or symptom.
If a TSB relates to the symptom, follow the procedure to repair the noise.
LOCATE THE NOISE AND IDENTIFY THE ROOT CAUSE
1. Narrow down the noise to a general area.To help pinpoint the source of the noise, use a listening tool
(Chassis Ear: J-39570,Engine Ear and mechanics stethoscope).
2. Narrow down the noise to a more specific area and identify the cause of the noise by:
removing the components in the area that you suspect the noise is coming from.
Do not use too much force when removing clips and fasteners, otherwise clips and fastener can be broken
or lost during the repair, resulting in the creation of new noise.
tapping or pushing/pulling the component that you suspect is causing the noise.
Do not tap or push/pull the component with excessive force, otherwise the noise will be eliminated only
temporarily.
feeling for a vibration with your hand by touching the component(s) that you suspect is (are) causing the
noise.
placing a piece of paper between components that you suspect are causing the noise.
looking for loose components and contact marks.
Refer to EI-7, "
Generic Squeak and Rattle Troubleshooting" .
REPAIR THE CAUSE
If the cause is a loose component, tighten the component securely.
If the cause is insufficient clearance between components:
–separate components by repositioning or loosening and retightening the component, if possible.
–insulate components with a suitable insulator such as urethane pads, foam blocks, felt cloth tape or ure-
thane tape. A Nissan Squeak and Rattle Kit (J-43980) is available through your authorized Nissan Parts
Department.
CAUTION:
Do not use excessive force as many components are constructed of plastic and may be damaged.
Always check with the Parts Department for the latest parts information.
The following materials are contained in the Nissan Squeak and Rattle Kit (J-43980). Each item can be
ordered separately as needed.
URETHANE PADS [1.5 mm (0.059 in) thick]
Insulates connectors, harness, etc.
76268-9E005: 100 × 135 mm (3.94 × 5.31 in)/76884-71L01: 60 × 85 mm (2.36 × 3.35 in)/76884-71L02:15
× 25 mm (0.59 × 0.98 in)
INSULATOR (Foam blocks)
Insulates components from contact. Can be used to fill space behind a panel.
73982-9E000: 45 mm (1.77 in) thick, 50 × 50 mm (1.97 × 1.97 in)/73982-50Y00: 10 mm (0.39 in) thick,
50 × 50 mm (1.97 × 1.97 in)
Page 2726 of 4449
EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTION EM
A
EM
Revision: 2004 November 2004 FX35/FX45
ENGINE MECHANICAL
VQ35DE
PRECAUTIONS .......................................................... 5
Precautions Necessary for Steering Wheel Rotation
After Battery Disconnect .......................................... 5
OPERATION PROCEDURE ................................. 5
Precautions for Drain Engine Coolant ...................... 5
Precautions for Disconnecting Fuel Piping .............. 5
Precautions for Removal and Disassembly ............. 5
Precautions for Inspection, Repair and Replace-
ment ......................................................................... 5
Precautions for Assembly and Installation ............... 5
Parts Requiring Angle Tightening ............................. 6
Precautions for Liquid Gasket .................................. 6
REMOVAL OF LIQUID GASKET SEALING .......... 6
LIQUID GASKET APPLICATION PROCEDURE ..... 6
PREPARATION ........................................................... 8
Special Service Tools ............................................... 8
Commercial Service Tools ...................................... 10
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING .............................................. 13
NVH Troubleshooting —Engine Noise ................... 13
Use the Chart Below to Help You Find the Cause
of the Symptom. ..................................................... 14
DRIVE BELTS ........................................................... 15
Checking Drive Belts .............................................. 15
Tension Adjustment ................................................ 15
ALTERNATOR AND POWER STEERING OIL
PUMP BELT ........................................................ 16
AIR CONDITIONER COMPRESSOR BELT ....... 16
Removal and Installation ........................................ 16
REMOVAL ........................................................... 16
INSTALLATION ................................................... 16
AIR CLEANER AND AIR DUCT ............................... 17
Removal and Installation ........................................ 17
REMOVAL ........................................................... 17
INSTALLATION ................................................... 17
Changing Air Cleaner Filter .................................... 18
INSPECTION ...................................................... 18
REMOVAL ........................................................... 18
INSTALLATION ................................................... 18INTAKE MANIFOLD COLLECTOR .......................... 19
Removal and Installation ........................................ 19
REMOVAL ........................................................... 19
INSPECTION AFTER REMOVAL ....................... 21
INSTALLATION ................................................... 22
INTAKE MANIFOLD ................................................. 24
Removal and Installation ........................................ 24
REMOVAL ........................................................... 24
INSPECTION AFTER REMOVAL ....................... 24
INSTALLATION ................................................... 25
EXHAUST MANIFOLD AND THREE WAY CATA-
LYST .......................................................................... 26
Removal and Installation ........................................ 26
REMOVAL ........................................................... 26
INSPECTION AFTER REMOVAL ....................... 28
INSTALLATION ................................................... 28
OIL PAN AND OIL STRAINER ................................. 30
Removal and Installation ........................................ 30
2WD MODEL ....................................................... 30
REMOVAL ........................................................... 30
INSPECTION AFTER REMOVAL ....................... 32
INSTALLATION ................................................... 32
INSPECTION AFTER INSTALLATION ................ 35
AWD MODEL ...................................................... 36
REMOVAL ........................................................... 36
INSPECTION AFTER REMOVAL ....................... 38
INSTALLATION ................................................... 39
INSPECTION AFTER INSTALLATION ................ 41
IGNITION COIL ......................................................... 42
Removal and Installation ........................................ 42
REMOVAL ........................................................... 42
INSTALLATION ................................................... 42
SPARK PLUG (PLATINUM-TIPPED TYPE) ............. 43
Removal and Installation ........................................ 43
REMOVAL ........................................................... 43
INSPECTION AFTER REMOVAL ....................... 43
INSTALLATION ................................................... 44
Page 2727 of 4449
EM-2Revision: 2004 November 2004 FX35/FX45 FUEL INJECTOR AND FUEL TUBE ........................ 45
Removal and Installation ........................................ 45
REMOVAL ........................................................... 46
INSTALLATION .................................................... 47
INSPECTION AFTER INSTALLATION ................ 49
ROCKER COVER ..................................................... 51
Removal and Installation ........................................ 51
REMOVAL ........................................................... 51
INSTALLATION .................................................... 52
FRONT TIMING CHAIN CASE ................................. 54
Removal and Installation ........................................ 54
REMOVAL ........................................................... 54
INSTALLATION .................................................... 58
INSPECTION AFTER INSTALLATION ................ 62
TIMING CHAIN .......................................................... 63
Removal and Installation ........................................ 63
REMOVAL ........................................................... 64
INSPECTION AFTER REMOVAL ........................ 71
INSTALLATION .................................................... 71
INSPECTION AFTER INSTALLATION ................ 80
CAMSHAFT ............................................................... 82
Removal and Installation ........................................ 82
REMOVAL ........................................................... 83
INSPECTION AFTER REMOVAL ........................ 84
INSTALLATION .................................................... 87
Valve Clearance ...................................................... 89
INSPECTION ....................................................... 89
ADJUSTMENT .................................................... 92
OIL SEAL .................................................................. 94
Removal and Installation of Valve Oil Seal ............. 94
REMOVAL ........................................................... 94
INSTALLATION .................................................... 94
Removal and Installation of Front Oil Seal ............. 95
REMOVAL ........................................................... 95
INSTALLATION .................................................... 96
Removal and Installation of Rear Oil Seal .............. 96
REMOVAL ........................................................... 96
INSTALLATION .................................................... 96
CYLINDER HEAD ..................................................... 98
On-Vehicle Service ................................................. 98
CHECKING COMPRESSION PRESSURE ......... 98
Removal and Installation ........................................ 99
REMOVAL ........................................................... 99
INSPECTION AFTER REMOVAL ......................100
INSTALLATION ..................................................101
Disassembly and Assembly ..................................102
DISASSEMBLY .................................................103
ASSEMBLY .......................................................103
Inspection After Disassembly ...............................104
VALVE DIMENSIONS ........................................104
VALVE GUIDE CLEARANCE ............................105
VALVE GUIDE REPLACEMENT .......................105
VALVE SEAT CONTACT ...................................107
VALVE SEAT REPLACEMENT .........................107
VALVE SPRING SQUARENESS .......................108
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD ..............................109
ENGINE ASSEMBLY ...............................................110
Removal and Installation .......................................110
2WD MODEL .....................................................110
REMOVAL .......................................................... 111
INSTALLATION ..................................................113
INSPECTION AFTER INSTALLATION ..............113
AWD MODEL .....................................................115
REMOVAL ..........................................................115
INSTALLATION ..................................................118
INSPECTION AFTER INSTALLATION ..............118
CYLINDER BLOCK .................................................120
Disassembly and Assembly ..................................120
DISASSEMBLY ..................................................121
ASSEMBLY ........................................................126
How to Select Piston and Bearing ........................131
DESCRIPTION ..................................................131
HOW TO SELECT PISTON ...............................131
HOW TO SELECT CONNECTING ROD BEAR-
ING .....................................................................132
HOW TO SELECT MAIN BEARING ..................133
Inspection After Disassembly ................................136
CRANKSHAFT END PLAY ................................136
CONNECTING ROD SIDE CLEARANCE .........136
PISTON TO PISTON PIN OIL CLEARANCE .....136
PISTON RING SIDE CLEARANCE ...................137
PISTON RING END GAP ..................................137
CONNECTING ROD BEND AND TORSION .....138
CONNECTING ROD BEARING HOUSING
DIAMETER (BIG END) ......................................138
CONNECTING ROD BUSHING OIL CLEAR-
ANCE (SMALL END) .........................................138
CYLINDER BLOCK DISTORTION ....................139
MAIN BEARING HOUSING INNER DIAMETER .140
PISTON TO CYLINDER BORE CLEARANCE ..140
CRANKSHAFT MAIN JOURNAL DIAMETER ...141
CRANKSHAFT PIN JOURNAL DIAMETER ......142
CRANKSHAFT OUT-OF-ROUND AND TAPER .142
CRANKSHAFT RUNOUT ..................................142
CONNECTING ROD BEARING OIL CLEAR-
ANCE .................................................................142
MAIN BEARING OIL CLEARANCE ...................143
MAIN BEARING CRUSH HEIGHT ....................144
CONNECTING ROD BEARING CRUSH
HEIGHT .............................................................144
MAIN BEARING CAP BOLT OUTER DIAMETER .144
CONNECTING ROD BOLT OUTER DIAMETER .144
DRIVE PLATE ....................................................145
OIL JET ..............................................................145
OIL JET RELIEF VALVE ....................................145
SERVICE DATA AND SPECIFICATIONS (SDS) ....146
Standard and Limit ................................................146
GENERAL SPECIFICATIONS ...........................146
DRIVE BELT ......................................................147
INTAKE MANIFOLD COLLECTOR, INTAKE
Page 2728 of 4449
EM-3
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EMA
Revision: 2004 November 2004 FX35/FX45MANIFOLD AND EXHAUST MANIFOLD ......... 147
SPARK PLUG ................................................... 147
CAMSHAFT AND CAMSHAFT BEARING ........ 148
CYLINDER HEAD ............................................. 150
CYLINDER BLOCK ........................................... 153
PISTON, PISTON RING AND PISTON PIN ...... 154
CONNECTING ROD ......................................... 155
CRANKSHAFT .................................................. 156
MAIN BEARING ................................................ 157
CONNECTING ROD BEARING ........................ 158
VK45DE
PRECAUTIONS ...................................................... 159
Precautions Necessary for Steering Wheel Rotation
After Battery Disconnect ...................................... 159
OPERATION PROCEDURE ............................. 159
Precautions for Drain Engine Coolant .................. 159
Precautions for Disconnecting Fuel Piping .......... 159
Precautions for Removal and Disassembly ......... 159
Precautions for Inspection, Repair and Replace-
ment ..................................................................... 159
Precautions for Assembly and Installation ........... 159
Parts Requiring Angle Tightening ......................... 160
Precautions for Liquid Gasket .............................. 160
REMOVAL OF LIQUID GASKET SEALING ...... 160
LIQUID GASKET APPLICATION PROCEDURE . 160
PREPARATION ....................................................... 162
Special Service Tools ........................................... 162
Commercial Service Tools .................................... 164
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ............................................ 166
NVH Troubleshooting —Engine Noise ................. 166
Use the Chart Below to Help You Find the Cause
of the Symptom. ................................................... 167
ENGINE ROOM COVER ........................................ 168
Removal and Installation ...................................... 168
REMOVAL ......................................................... 168
INSTALLATION ................................................. 168
DRIVE BELTS ......................................................... 169
Checking Drive Belts ............................................ 169
Tension Adjustment .............................................. 169
Removal and Installation ...................................... 169
REMOVAL ......................................................... 169
INSTALLATION ................................................. 170
Drive Belt Auto Tensioner and Idler Pulley ........... 171
REMOVAL ......................................................... 171
INSTALLATION ................................................. 171
AIR CLEANER AND AIR DUCT ............................. 172
Removal and Installation ...................................... 172
REMOVAL ......................................................... 172
INSTALLATION ................................................. 172
Changing Air Cleaner Filter .................................. 173
REMOVAL ......................................................... 173
INSTALLATION ................................................. 173INTAKE MANIFOLD ...............................................174
Removal and Installation ......................................174
REMOVAL .........................................................174
INSPECTION AFTER REMOVAL .....................176
INSTALLATION .................................................176
INSPECTION AFTER INSTALLATION ..............177
EXHAUST MANIFOLD AND THREE WAY CATA-
LYST ........................................................................178
Removal and Installation ......................................178
REMOVAL .........................................................178
INSPECTION AFTER REMOVAL .....................180
INSTALLATION .................................................180
OIL PAN AND OIL STRAINER ...............................181
Removal and Installation ......................................181
REMOVAL .........................................................181
INSPECTION AFTER REMOVAL .....................183
INSTALLATION .................................................183
INSPECTION AFTER INSTALLATION ..............183
IGNITION COIL .......................................................185
Removal and Installation ......................................185
REMOVAL .........................................................185
INSTALLATION .................................................185
SPARK PLUG (PLATINUM-TIPPED TYPE) ...........186
Removal and Installation ......................................186
REMOVAL .........................................................186
INSPECTION AFTER REMOVAL .....................186
INSTALLATION .................................................187
FUEL INJECTOR AND FUEL TUBE ......................188
Removal and Installation ......................................188
REMOVAL .........................................................188
INSTALLATION .................................................190
INSPECTION AFTER INSTALLATION ..............192
ROCKER COVER ...................................................193
Removal and Installation ......................................193
REMOVAL .........................................................193
INSTALLATION .................................................195
TIMING CHAIN ........................................................196
Removal and Installation ......................................196
REMOVAL .........................................................197
INSPECTION AFTER REMOVAL .....................201
INSTALLATION .................................................201
INSPECTION AFTER INSTALLATION ..............207
CAMSHAFT ............................................................208
Removal and Installation ......................................208
REMOVAL .........................................................208
INSPECTION AFTER REMOVAL .....................209
INSTALLATION .................................................212
Valve Clearance ...................................................214
INSPECTION ....................................................214
ADJUSTMENT ..................................................217
OIL SEAL ................................................................221
Removal and Installation of Valve Oil Seal ...........221
REMOVAL .........................................................221
INSTALLATION .................................................221
Removal and Installation of Front Oil Seal ...........222
REMOVAL .........................................................222
Page 2729 of 4449
EM-4Revision: 2004 November 2004 FX35/FX45INSTALLATION ..................................................222
Removal and Installation of Rear Oil Seal ............223
REMOVAL .........................................................223
INSTALLATION ..................................................223
CYLINDER HEAD ...................................................224
On-Vehicle Service ...............................................224
CHECKING COMPRESSION PRESSURE .......224
Removal and Installation ......................................225
REMOVAL .........................................................225
INSPECTION AFTER REMOVAL ......................226
INSTALLATION ..................................................226
Disassembly and Assembly ..................................228
DISASSEMBLY .................................................228
ASSEMBLY .......................................................229
Inspection After Disassembly ...............................230
VALVE DIMENSIONS ........................................230
VALVE GUIDE CLEARANCE ............................231
VALVE GUIDE REPLACEMENT .......................231
VALVE SEAT CONTACT ...................................232
VALVE SEAT REPLACEMENT .........................233
VALVE SPRING SQUARENESS .......................234
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD .............................235
ENGINE ASSEMBLY ..............................................236
Removal and Installation ......................................236
REMOVAL .........................................................236
INSTALLATION ..................................................239
INSPECTION AFTER INSTALLATION ..............239
CYLINDER BLOCK .................................................240
Disassembly and Assembly ..................................240
DISASSEMBLY .................................................241
ASSEMBLY .......................................................244
How to Select Piston and Bearing ........................250
DESCRIPTION ..................................................250
HOW TO SELECT PISTON ...............................250
HOW TO SELECT CONNECTING ROD BEAR-
ING ....................................................................251HOW TO SELECT MAIN BEARING ..................252
Inspection After Disassembly ................................256
CRANKSHAFT END PLAY ................................256
CONNECTING ROD SIDE CLEARANCE .........256
PISTON TO PISTON PIN OIL CLEARANCE .....256
PISTON RING SIDE CLEARANCE ...................257
PISTON RING END GAP ..................................257
CONNECTING ROD BEND AND TORSION .....258
CONNECTING ROD BIG END DIAMETER ......258
CONNECTING ROD BUSHING OIL CLEAR-
ANCE .................................................................258
CYLINDER BLOCK DISTORTION ....................259
MAIN BEARING HOUSING INNER DIAMETER .260
PISTON TO CYLINDER BORE CLEARANCE ..260
CRANKSHAFT MAIN JOURNAL DIAMETER ...261
CRANKSHAFT PIN JOURNAL DIAMETER ......262
CRANKSHAFT OUT-OF-ROUND AND TAPER .262
CRANKSHAFT RUNOUT ..................................262
CONNECTING ROD BEARING OIL CLEAR-
ANCE .................................................................263
MAIN BEARING OIL CLEARANCE ...................264
CRUSH HEIGHT OF MAIN BEARING ..............265
CRUSH HEIGHT OF CONNECTING ROD
BEARING ...........................................................265
DRIVE PLATE ....................................................265
SERVICE DATA AND SPECIFICATIONS (SDS) ....266
Standard and Limit ................................................266
GENERAL SPECIFICATIONS ...........................266
DRIVE BELTS ....................................................266
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD .................................................................266
SPARK PLUG ....................................................267
CAMSHAFT AND CAMSHAFT BEARING .........267
CYLINDER HEAD ..............................................269
CYLINDER BLOCK ............................................272
PISTON, PISTON RING AND PISTON PIN ......273
CONNECTING ROD ..........................................274
CRANKSHAFT ...................................................275
MAIN BEARING .................................................277
CONNECTING ROD BEARING .........................278