height INFINITI FX35 2004 Workshop Manual

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

EM-26
[VQ35DE]
EXHAUST MANIFOLD AND THREE WAY CATALYST
Revision: 2004 November 2004 FX35/FX45
EXHAUST MANIFOLD AND THREE WAY CATALYSTPFP:14004
Removal and InstallationABS004U4
REMOVAL
WARNING:
Perform the work when the exhaust and cooling system have completely cooled down.
1. Remove engine cover with power tool. Refer to EM-19, "
INTAKE MANIFOLD COLLECTOR" .
2. Remove air cleaner case and air duct. Refer to EM-17, "
AIR CLEANER AND AIR DUCT" .
3. Remove front and rear engine undercover and front cross bar with power tool.
4. Disconnect heated oxygen sensors 2 (bank 1 and bank 2) harness connectors.
5. Using heated oxygen sensor wrench (SST), remove heated oxy-
gen sensors 2 (bank 1 and bank 2).
CAUTION:

Be careful not to damage heated oxygen sensor.

Discard any heated oxygen sensor which has been
dropped from a height of more than 0.5 m (19.7 in) onto a
hard surface such as a concrete floor; replace with a new
sensor.
1. Heated oxygen sensor 2 (bank 1) 2. Three way catalyst (right bank) 3. Gasket
4. heated oxygen sensor 1 (bank 1) 5. Exhaust manifold cover (right bank) 6. Exhaust manifold (right bank)
7. Exhaust manifold (left bank) 8. Exhaust manifold cover (left bank) 9. Three way catalyst (left bank)
10. heated oxygen sensor 1 (bank 2) 11. Heated oxygen sensor 2 (bank 2)
SBIA0583E
KBIA1740E

EXHAUST MANIFOLD AND THREE WAY CATALYST
EM-27
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Revision: 2004 November 2004 FX35/FX45
6. Remove exhaust mounting bracket between right/left catalytic converter and transmission. Refer to EX-3,
"EXHAUST SYSTEM" .
7. Remove three way catalyst (right and left bank).
8. Disconnect heated oxygen sensor 1 (bank 1 and bank 2) harness connectors and remove harness clip.
9. Using heated oxygen sensor wrench (SST), remove heated oxy-
gen sensor 1 (bank 1 and bank 2).
CAUTION:

Be careful not to damage heated oxygen sensor.

Discard any heated oxygen sensor which has been
dropped from a height of more than 0.5 m (19.7 in) onto a
hard surface such as a concrete floor; replace with a new
sensor.
10. Remove water pipes on both right and left side. Refer to CO-28, "
WATER OUTLET AND WATER PIPING"
.
11. Remove exhaust manifold cover (right and left bank).
12. Loosen nuts in the reverse order as shown in the figure to
remove exhaust manifold with power tool.
NOTE:
Disregard the numerical order No. 7 and No. 8 in removal.
13. Remove exhaust manifold gaskets.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
SBIA0575E
PBIC2042E

EM-74
[VQ35DE]
TIMING CHAIN
Revision: 2004 November 2004 FX35/FX45
6. After installing rear timing chain case, check surface height dif-
ference between following parts on oil pan mounting surface.

If not within standard, repeat above installation procedure.
7. Position crankshaft so No. 1 piston is set at TDC on the com-
pression stroke.

Make sure that dowel pin hole, dowel pin and crankshaft key
are located as shown in the figure.
NOTE:
Though camshaft does not stop at position as shown in the
figure, for the placement of cam nose, it is generally accepted
camshaft is placed for the same direction of the figure.
CAUTION:
Hole on small dia. side must be used for intake side dowel pin hole. Do not misidentify (ignore
big dia. side).
8. Install timing chains (secondary) and camshaft sprockets.
CAUTION:
Matching marks between timing chain and sprockets slip
easily. Confirm all matching mark positions repeatedly dur-
ing the installation process.
a. Push plunger of secondary chain tensioner and keep it pressed
in with a stopper pin.Standard (Rear timing chain case to cylinder block):
–0.24 to 0.14 mm (–0.0094 to 0.0055 in)
SEM943G
Camshaft dowel pin hole (intake side)
: At cylinder head upper face side in each bank.
Camshaft dowel pin (exhaust side)
: At cylinder head upper face side in each bank.
Crankshaft key
: At cylinder head side of right bank.
KBIA1073E
SEM430G

TIMING CHAIN
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Revision: 2004 November 2004 FX35/FX45
19. Install front timing chain case as follows:
a. Apply liquid gasket to front timing chain case back side as
shown in the figure with tube presser [SST: WS39930000 ( – )].
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-48, "
RECOMMENDED CHEMICAL PRODUCTS AND
SEALANTS".
b. Install dowel pin on rear timing chain case into dowel pin hole on
front timing chain case.
c. Tighten bolts to the specified torque in order as shown in the fig-
ure.
d. After tightening, retighten them to specified torque in numerical
order shown in figure.
20. After installing front timing chain case, check the surface height
difference between the following parts on the oil pan mounting
surface.

If not within specification, repeat the installation procedure.
21. Install right and left intake valve timing control covers as follows:
a. Install seal rings in shaft grooves.
b. Apply liquid gasket to intake valve timing control covers as
shown in the figure with tube presser [SST: WS39930000 ( – )].
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-48, "
RECOMMENDED CHEMICAL PRODUCTS AND
SEALANTS".
PBIC1133E
8 mm (0.31 in) dia. bolts : 1, 2
: 28.4 N·m (2.9 kg-m, 21 ft-lb)
6 mm (0.24 in) dia. bolts : Except the above
: 12.7 N·m (1.3 kg-m, 9 ft-lb)
KBIA1303E
Standard
Front timing chain case to rear timing chain case:
–0.14 to 0.14 mm (–0.005 to 0.0055 in)
SEM943G
SBIA0492E

EM-84
[VQ35DE]
CAMSHAFT
Revision: 2004 November 2004 FX35/FX45
7. Remove secondary timing chain tensioner from cylinder head.

Remove chain tensioner with its stopper pin attached.
NOTE:
Stopper pin was attached when secondary timing chain was
removed.
INSPECTION AFTER REMOVAL
Camshaft Runout
1. Put V block on precise flat bed, and support No. 2 and No. 4
journal of camshaft.
CAUTION:
Do not support journal No. 1 (on the side of camshaft
sprocket) because it has a different diameter from the other
three locations.
2. Set dial gauge vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure cam-
shaft runout on dial gauge. (Total indicator reading)
4. If it exceeds the standard, replace camshaft.
Camshaft Cam Height
1. Measure camshaft cam height.
2. If wear is beyond the limit, replace camshaft.
Camshaft Journal Oil Clearance
Outer Diameter of Camshaft Journal
Measure outer diameter of camshaft journal.
Inner Diameter of Camshaft Bracket

Tighten camshaft bracket bolt with specified torque. Refer to EM-87, "INSTALLATION" .
SBIA0499E
Standard : Less than 0.05 mm (0.0020 in)PBIC0929E
Standard cam height (intake and exhaust)
: 44.865 - 45.055 mm (1.7663 - 1.7738 in)
Cam wear limit
: 0.2 mm (0.008 in)
EMQ0072D
Standard outer diameter:
No. 1: 25.935 - 25.955 mm (1.0211 - 1.0218 in)
No. 2, 3, 4: 23.445 - 23.465 mm (0.9230 - 0.9238 in)
PBIC0040E

EM-86
[VQ35DE]
CAMSHAFT
Revision: 2004 November 2004 FX35/FX45
2. Measure camshaft sprocket runout with dial indicator. (Total indi-
cator reading)

If it exceeds the limit, replace camshaft sprocket.
Valve Lifter
Check if surface of valve lifter has any wear or cracks.

If anything above is found, replace valve lifter.
Valve Lifter Clearance
Outer Diameter of Valve Lifter
Measure outer diameter at 1/2 height of valve lifter with micrometer
since valve lifter is in barrel shape.
Valve Lifter Hole Diameter
Using inside micrometer, measure diameter of valve lifter hole of cyl-
inder head.
Calculation of Valve Lifter Clearance
(Valve lifter clearance) = (hole diameter of valve lifter) – (outer diameter of valve lifter).
If it exceeds the standard, referring to each standard of valve lifter outer diameter and valve lifter hole diame-
ter, replace either or both valve lifter and cylinder head.Limit : 0.15 mm (0.0059 in)
PBIC0930E
KBIA0182E
Valve lifter outer diameter (Intake and exhaust)
: 33.977 - 33.987 mm (1.3377 - 1.3381 in)
JEM798G
Standard (Intake and exhaust)
: 34.000 - 34.016 mm (1.3386 - 1.3392 in)
SEM867E
Standard (Intake and exhaust)
: 0.013 - 0.039 mm (0.0005 - 0.0015 in)

EM-94
[VQ35DE]
OIL SEAL
Revision: 2004 November 2004 FX35/FX45
OIL SEALPFP:00100
Removal and Installation of Valve Oil SealABS004X4
REMOVAL
1. Remove camshaft relating to valve oil seal to be removed. Refer to EM-82, "CAMSHAFT" .
2. Remove valve lifters. Refer to EM-82, "
CAMSHAFT" .
3. Turn crankshaft until the cylinder requiring new oil seals is at TDC. This will prevent valve from dropping
into cylinder.
4. Using valve spring compressor, attachment and adapter (SST),
remove valve collet with magnet hand. Then remove valve
spring and valve spring seat.
5. Remove valve oil seal using valve oil seal puller (SST).
INSTALLATION
1. Apply engine oil on new valve oil seal joint and seal lip.
2. Using valve oil seal drift (SST), press fit valve seal to height “H”
shown in the figure.
NOTE:
Dimension “H”: Height measured before valve spring seat instal-
lation
3. Perform steps in the reverse order of removal for the following operations.
PBIC1803E
PBIC0884E
Intake and exhaust : 14.3 - 14.9 mm (0.563 - 0.587 in)
PBIC0802E

EM-96
[VQ35DE]
OIL SEAL
Revision: 2004 November 2004 FX35/FX45
INSTALLATION
1. Apply engine oil on new front oil seal.
2. Using a suitable drift, press fit until the height of front oil seal is
level with the mounting surface.

Suitable drift: outer diameter 59 mm (2.32 in), inner diameter
49 mm (1.93 in).
CAUTION:
Press fit straight and avoid causing burrs or tilting oil
seal.
3. Perform steps in the reverse order of removal for the following operations.
Removal and Installation of Rear Oil SealABS004X6
REMOVAL
1. Remove oil pan (upper). Refer to EM-30, "OIL PAN AND OIL STRAINER" .
2. Remove transmission assembly. Refer to AT- 2 6 6 , "
TRANSMISSION ASSEMBLY" .
3. Remove drive plate with power tool. Fix crankshaft with a ring gear stopper [SST: KV1011770 (J-44716)],
and remove mounting bolts.

Loosen mounting bolts in diagonal order.
CAUTION:

Do not disassemble drive plate.

Never place drive plate with signal plate facing down.

When handling signal plate, take care not to damage or
scratch it.

Handle signal plate in a manner that prevents it from
becoming magnetized.
4. Use a seal cutter (SST) to cut away liquid gasket and remove
rear oil seal retainer.
CAUTION:
Be careful not to damage mounting surface.
NOTE:
Rear oil seal and retainer form a single part and are handled as
an assembly.
INSTALLATION
1. Remove old liquid gasket on mating surface of cylinder block and oil pan using scraper.
SEM715A
SEM760G
SEM830E

CYLINDER HEAD
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Revision: 2004 November 2004 FX35/FX45
DISASSEMBLY
1. Remove spark plug with spark plug wrench (commercial service tool).
2. Remove valve lifter.

Mark position on valve lifter for assembly.
3. Remove valve collet.

Compress valve spring with valve spring compressor, attach-
ment and adapter (SST). Remove valve collet with magnet
hand.
CAUTION:
When working, take care not to damage valve lifter holes.
4. Remove valve spring retainer and valve spring.
5. Push valve stem to combustion chamber side, and remove
valve.

Inspect valve guide clearance before removal. Refer to EM-
105, "VALVE GUIDE CLEARANCE" .

Mark position on valve for assembly.
6. Remove valve oil seals using valve oil seal puller (SST).
7. Remove valve spring seat.
8. If valve seat must be replaced, refer to EM-107, "
VALVE SEAT CONTACT" .
9. If valve guide must be replaced, refer to EM-105, "
VALVE GUIDE CLEARANCE" .
10. Remove spark plug tube, as necessary.

Using a pair of pliers, pull spark plug tube out of cylinder head.
CAUTION:

Take care not to damage cylinder head.

Once removed, a spark plug tube will be deformed and cannot be reused. Do not remove it
unless absolutely necessary.
ASSEMBLY
1. When valve guide is removed, install it. Refer to EM-105, "VALVE GUIDE CLEARANCE" .
2. When valve seat is removed, install it. Refer to EM-107, "
VALVE SEAT CONTACT" .
3. Install valve oil seals.

Install with valve oil seal drift (SST) to match dimension in
illustration.
4. Install valve spring seat.
10. Cylinder head (right bank) 11. Valve seat 12. Valve (EXH)
13. Valve (INT) 14. Cylinder head (left bank)
PBIC1803E
PBIC0884E
Height “H” (Without valve spring seat installed)
Intake and exhaust : 14.3 - 14.9 mm (0.563 - 0.587 in)
PBIC0802E