belt INFINITI FX35 2004 Repair Manual
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![INFINITI FX35 2004 Repair Manual PRECAUTIONS
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Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
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Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE")
PRECAUTIONS
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Revision: 2004 November 2004 FX35/FX45
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
ABS00A2R
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING:
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
On Board Diagnostic (OBD) System of Engine and A/TABS006JZ
The ECM has an on board diagnostic system. It will light up the malfunction indicator lamp (MIL) to warn the
driver of a malfunction causing emission deterioration.
CAUTION:
Be sure to turn the ignition switch OFF and disconnect the negative battery cable before any
repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves,
etc. will cause the MIL to light up.
Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MIL to light up due to the open circuit. (Be sure the connector is free from water, grease,
dirt, bent terminals, etc.)
Certain systems and components, especially those related to OBD, may use a new style slide-
locking type harness connector. For description and how to disconnect, refer to PG-74, "
HAR-
NESS CONNECTOR" .
Be sure to route and secure the harnesses properly after work. The interference of the harness
with a bracket, etc. may cause the MIL to light up due to the short circuit.
Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube
may cause the MIL to light up due to the malfunction of the EVAP system or fuel injection system,
etc.
Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM and
TCM (Transmission control module) before returning the vehicle to the customer.
PrecautionABS006K0
Always use a 12 volt battery as power source.
Do not attempt to disconnect battery cables while engine is
running.
Before connecting or disconnecting the ECM harness con-
nector, turn ignition switch OFF and disconnect negative
battery cable. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition
switch is turned OFF.
Before removing parts, turn ignition switch OFF and then
disconnect negative battery cable.
SEF289H
Page 2011 of 4449
![INFINITI FX35 2004 Repair Manual EC-670
[VK45DE]
PRECAUTIONS
Revision: 2004 November 2004 FX35/FX45
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
ABS00BYX
Th](/img/42/57021/w960_57021-2010.png "INFINITI FX35 2004 Repair Manual EC-670
[VK45DE]
PRECAUTIONS
Revision: 2004 November 2004 FX35/FX45
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
ABS00BYX
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EC-670
[VK45DE]
PRECAUTIONS
Revision: 2004 November 2004 FX35/FX45
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
ABS00BYX
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING:
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
On Board Diagnostic (OBD) System of Engine and A/TABS00BYY
The ECM has an on board diagnostic system. It will light up the malfunction indicator lamp (MIL) to warn the
driver of a malfunction causing emission deterioration.
CAUTION:
Be sure to turn the ignition switch OFF and disconnect the negative battery cable before any
repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves,
etc. will cause the MIL to light up.
Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MIL to light up due to the open circuit. (Be sure the connector is free from water, grease,
dirt, bent terminals, etc.)
Certain systems and components, especially those related to OBD, may use a new style slide-
locking type harness connector. For description and how to disconnect, refer to PG-74, "
HAR-
NESS CONNECTOR" .
Be sure to route and secure the harnesses properly after work. The interference of the harness
with a bracket, etc. may cause the MIL to light up due to the short circuit.
Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube
may cause the MIL to light up due to the malfunction of the EVAP system or fuel injection system,
etc.
Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM and
TCM (Transmission control module) before returning the vehicle to the customer.
PrecautionABS00BYZ
Always use a 12 volt battery as power source.
Do not attempt to disconnect battery cables while engine is
running.
Before connecting or disconnecting the ECM harness con-
nector, turn ignition switch OFF and disconnect negative
battery cable. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition
switch is turned OFF.
Before removing parts, turn ignition switch OFF and then
disconnect battery ground cable.
SEF289H
Page 2680 of 4449
EI-1
EXTERIOR & INTERIOR
I BODY
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SECTION EI
A
B
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Revision: 2004 November 2004 FX35/FX45
EXTERIOR & INTERIOR
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Precautions for Work ................................................ 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 4
SQUEAK AND RATTLE TROUBLE DIAGNOSES ..... 5
Work Flow ................................................................ 5
CUSTOMER INTERVIEW ..................................... 5
DUPLICATE THE NOISE AND TEST DRIVE ....... 6
CHECK RELATED SERVICE BULLETINS ........... 6
LOCATE THE NOISE AND IDENTIFY THE
ROOT CAUSE ...................................................... 6
REPAIR THE CAUSE ........................................... 6
CONFIRM THE REPAIR ....................................... 7
Generic Squeak and Rattle Troubleshooting ........... 7
INSTRUMENT PANEL .......................................... 7
CENTER CONSOLE ............................................. 7
DOORS ................................................................. 7
TRUNK .................................................................. 8
SUNROOF/HEADLINING ..................................... 8
SEATS ................................................................... 8
UNDERHOOD ....................................................... 8
Diagnostic Worksheet .............................................. 9
CLIP AND FASTENER ..............................................11
Clip and Fastener .................................................... 11
FRONT BUMPER ..................................................... 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 16
INSTALLATION ................................................... 16
FRONT FILLET MOLDING ASSEMBLY ............. 17REAR BUMPER ........................................................ 18
Removal and Installation ........................................ 18
REMOVAL ........................................................... 20
INSTALLATION ................................................... 21
REAR BUMPER FASCIA .................................... 21
REAR BUMPER CLOSING ................................. 22
DRAFTER GUARD ............................................. 22
REAR FILLET MOLDING ASSEMBLY ................ 22
FRONT GRILLE ........................................................ 23
Removal and Installation ........................................ 23
REMOVAL ........................................................... 23
INSTALLATION ................................................... 23
COWL TOP ............................................................... 24
Removal and Installation ........................................ 24
REMOVAL ........................................................... 24
INSTALLATION ................................................... 24
FENDER PROTECTOR ............................................ 25
Removal and Installation ........................................ 25
REMOVAL ........................................................... 25
INSTALLATION ................................................... 25
DOOR OUTSIDE MOLDING ..................................... 26
Removal and Installation ........................................ 26
FRONT DOOR OUTSIDE MOLDING .................. 26
REAR DOOR OUTSIDE MOLDING .................... 26
DOOR OUTSIDE LOWER MOLDING ...................... 27
Removal and Installation ........................................ 27
FRONT AND REAR DOOR OUTSIDE LOWER
MOLDING ............................................................ 27
DOOR PARTING SEAL ............................................ 28
Removal and Installation ........................................ 28
REMOVAL ........................................................... 28
INSTALLATION ................................................... 28
CENTER MUD GUARD ............................................ 29
Removal and Installation ........................................ 29
REMOVAL ........................................................... 29
INSTALLATION ................................................... 29
WINDSHIELD MOLDING .......................................... 30
Removal and Installation ........................................ 30
REMOVAL ........................................................... 30
INSTALLATION ................................................... 30
Page 2682 of 4449
PRECAUTIONS
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Revision: 2004 November 2004 FX35/FX45
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
AIS0057U
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING:
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for WorkAIS0057V
After removing and installing the opening/closing parts, be sure to carry out fitting adjustments to check
their operation.
Check the lubrication level, damage, and wear of each part. If necessary, grease or replace it.
Page 2717 of 4449
EI-38
BODY SIDE TRIM
Revision: 2004 November 2004 FX35/FX45
3. Remove center pillar lower garnish.
NOTE:
Insert screwdriver rolled with cloth between panel on vehicle and
clips, then disconnect clips.
Installation
Install in the reverse order of removal.
NOTE:
To install, check if all clips are matched over holes of panel on vehicle, then push on.
CENTER PILLAR UPPER GARNISH
Removal
1. Remove seat belt shoulder anchor. Refer to SB-4, "Removal and Installation of Front Seat Belt" .
2. Remove front and rear kicking plate.
3. Remove front and rear body side welt.
4. Remove center pillar lower garnish.
5. Remove center pillar upper cap and bolt.
6. Remove center pillar upper garnish.
Installation
Install in the reverse order of removal.
DASH SIDE FINISHER
Removal
1. Remove front kicking plate.
2. Remove front body side welt.
3. Remove nut.
4. Remove dash side finisher.
NOTE:
Insert screwdriver rolled with cloth between panel on vehicle and
clips, then disconnect clips.
Installation
Install in the reverse order of removal.
NOTE:
To install, check if all clips are matched over holes of panel on vehicle, then push on.
PIIA4341E
PIIA4342E
PIIA4343E
Page 2722 of 4449
HEADLINING
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Revision: 2004 November 2004 FX35/FX45
REMOVAL
1. Remove front pillar garnish. Refer to EI-37, "Removal and Installation" .
2. Remove kicking plate (front/rear). Refer to EI-37, "
Removal and Installation" .
3. Remove body side welt. Refer to EI-37, "
Removal and Installation" .
4. Remove seat belt shoulder anchor (front/rear). Refer to SB-4, "
Removal and Installation of Front Seat
Belt" and SB-6, "Removal and Installation of Rear Seat Belt" .
5. Remove center pillar garnish (lower/upper) and luggage side finisher assembly and rear pillar upper gar-
nish assembly. Refer to EI-37, "
Removal and Installation" and EI-44, "Removal and Installation" .
6. Remove assist grip caps and screw. Remove assist grip.
7. Remove sun-visor (drive and passenger), and disconnect harness connector with lamp model.
8. Remove sun-visor holder.
9. Remove DVD display rear. Refer to AV- 1 9 9 , "
Removal and Installation for DVD Display Unit" .
10. Remove map lamp (spot lamp). Refer to LT- 1 5 0 , "
Removal and Installation" .
11. Disconnect harness connector at front left side of headlining.
12. Put front seat to front most and recline seatback to backward.
13. Remove headlining, turn and take out from back door.
CAUTION:
Always remove or install in a pair.
Cover surroundings with waste to avoid scratches or damages.
Do not bend headlining too hard.
14. Remove following parts after removing headlining.
Room lamp
Personal lamp
INSTALLATION
Install in the reverse order of removal.
1. Headlining 2. Assist grip (rear) 3. Assist grip (front)
4. Sun-visor holder (right) 5. Sun-visor (right) 6. Sun-visor cover (right)
7. Map lamp (spot lamp) 8. Sun-visor (left) 9. Sun-visor cover (left)
10. Sun-visor holder (left) 11. Finisher 12. Room lamp
13. Personal lamp 14. Fastener 15. DVD display rear
PIIA4952E
Page 2724 of 4449
LUGGAGE FLOOR TRIM
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Revision: 2004 November 2004 FX35/FX45
REMOVAL
1. Remove tonneau cover.
2. Remove luggage side hook and remove net hook (left/right).
3. Remove luggage floor board assembly. Remove bolt with power tool.
4. Remove luggage floor side board assembly (left/right).
5. Remove back door weather strip.
6. Remove rear plate assembly.
7. Remove roof rear garnish assembly.
8. Remove luggage floor cover assembly (left/right).
9. Remove rear door kicking plate (left/right).
10. Remove rear body side welt.
11. Remove rear wheel house finisher assembly (left/right).
12. Remove luggage side finisher assembly bolt and remove luggage side finisher assembly (left/right).
13. Remove rear seat belt anchor (left/right). Refer to SB-6, "
Removal and Installation of Rear Seat Belt" .
14. Remove rear pillar upper garnish assembly cap and bolt, then remove rear pillar upper garnish assembly
(left/right).
15. Remove spare tire clamp.
16. Remove sub-woofer box connector and remove sub-woofer box.
17. Remove spare tire.
18. Remove towing hook, wheel nut wrench, spanner, tire stopper, jack rod and jack complete.
19. Remove luggage side box bolt and luggage side box assembly (left/right).
INSTALLATION
Install in the reverse order of removal.
7.Luggage floor side board assembly
(left)8.Rear wheel house finisher assembly
(left)9.Luggage side finisher assembly
(left)
10. Clamp 11. Sub woofer box 12. Spare tire
13. Luggage side box (left) 14. Rear plate assembly 15. Luggage side box (right)
16. Cap 17. Luggage floor board assembly 18.Luggage floor board assembly
(option for Canada)
19.Luggage floor side board assembly
(right)20. Net hook 21.Luggage side finisher assembly
(right)
22. Luggage side hook 23.Rear wheel house finisher assembly
(right)24. Cap
25.Rear pillar upper garnish assembly
(right)26. Luggage finisher mask (right) 27. Luggage finisher mask (left)
28. Tonneau cover 29. Net
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