lock INFINITI FX35 2005 Service Manual

EC-1382
[VK45DE]
ASCD BRAKE SWITCH
Revision: 2005 July 2005 FX
3. CHECK ASCD BRAKE SWITCH POWER SUPPLY CIRCUIT
1. Turn ignition switch OFF.
2. Disconnect ASCD brake switch harness connector.
3. Turn ignition switch ON.
4. Check voltage between ASCD brake switch terminal 1 and ground with CONSULT-II or tester.
OK or NG
OK >> GO TO 5.
NG >> GO TO 4.
4. DETECT MALFUNCTIONING PART
Check the following.

Fuse block (J/B) connector E201

10A fuse

Harness for open or short between ASCD brake switch and fuse
>> Repair open circuit or short to ground or short to power in harness or connectors.
5. CHECK ASCD BRAKE SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 108 and ASCD brake switch terminal 2. Refer to Wiring Diagram.
4. Also check harness for short to ground or short to power.
OK or NG
OK >> GO TO 7.
NG >> GO TO 6.
6. DETECT MALFUNCTIONING PART
Check the following.

Harness connectors E211, M41

Harness for open or short between ECM and ASCD brake switch
>> Repair open circuit or short to ground or short to power in harness or connectors.
PBIB2558E
Voltage: Battery voltage
PBIB0857E
Continuity should exist.

ASCD BRAKE SWITCH EC-1383
[VK45DE]
C
D E
F
G H
I
J
K L
M A
EC
Revision: 2005 July 2005 FX
7. CHECK ASCD BRAKE SWITCH
Refer to EC-1278, "
Component Inspection"
OK or NG
OK >> GO TO 13.
NG >> Replace ASCD brake switch.
8. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT
1. Turn ignition switch OFF.
2. Disconnect stop lamp switch harness connector.
3. Check voltage between stop lamp switch terminal 1 and ground with CONSULT -II or tester.
OK or NG
OK >> GO TO 10.
NG >> GO TO 9.
9. DETECT MALFUNCTIONING PART
Check the following.

Fuse block (J/B) connector E201

10A fuse

Harness for open or short between stop lamp switch and battery
>> Repair open circuit or short to ground or short to power in harness or connectors.
10. CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 101 and stop lamp switch terminal 2. Refer to Wiring Diagram.
3. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 12.
NG >> GO TO 11.
PBIB2558E
Voltage: Battery voltage
PBIB1184E
Continuity should exist.

SQUEAK AND RATTLE TROUBLE DIAGNOSES EI-5
C
D E
F
G H
J
K L
M A
B
EI
Revision: 2005 July 2005 FX
SQUEAK AND RATTLE TROUBLE DIAGNOSESPFP:00000
Work FlowAIS00375
CUSTOMER INTERVIEW
Interview the customer if possible, to determine the conditions that exist when the noise occurs. Use the Diag-
nostic Worksheet during the interview to document the facts and conditions when the noise occurs and any
customer's comments; refer to EI-9, "
Diagnostic Worksheet" . This information is necessary to duplicate the
conditions that exist when the noise occurs.

The customer may not be able to provide a detailed description or the location of the noise. Attempt to
obtain all the facts and conditions that exist when the noise occurs (or does not occur).

If there is more than one noise in the vehicle, be sure to diagnose and repair the noise that the customer
is concerned about. This can be accomplished by test driving the vehicle with the customer.

After identifying the type of noise, isolate the noise in terms of its characteristics. The noise characteristics
are provided so the customer, service adviser and technician are all speaking the same language when
defining the noise.

Squeak —(Like tennis shoes on a clean floor)
Squeak characteristics include the light contact/fast movement/brought on by road conditions/hard sur-
faces=higher pitch noise/softer surfaces=lower pitch noises/edge to surface=chirping

Creak—(Like walking on an old wooden floor)
Creak characteristics include firm contact/slow movement/twisting with a rotational movement/pitch
dependent on materials/often brought on by activity.

Rattle—(Like shaking a baby rattle)
Rattle characteristics include the fast repeated contact/vibration or similar movement/loose parts/missing
clip or fastener/incorrect clearance.

Knock —(Like a knock on a door)
Knock characteristics include hollow sounding/sometimes repeating/often brought on by driver action.

Tick—(Like a clock second hand)
Tick characteristics include gentle contacting of light materials/loose components/can be caused by driver
action or road conditions.

Thump—(Heavy, muffled knock noise)
Thump characteristics include softer knock/dead sound often brought on by activity.

Buzz—(Like a bumble bee)
Buzz characteristics include high frequency rattle/firm contact.

Often the degree of acceptable noise level will vary depending upon the person. A noise that you may
judge as acceptable may be very irritating to the customer.

Weather conditions, especially humidity and temperature, may have a great effect on noise level.
SBT842

EI-6
SQUEAK AND RATTLE TROUBLE DIAGNOSES
Revision: 2005 July 2005 FX
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.
NOTE:
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)

SQUEAK AND RATTLE TROUBLE DIAGNOSES EI-7
C
D E
F
G H
J
K L
M A
B
EI
Revision: 2005 July 2005 FX
INSULATOR (Light foam block)
80845-71L00: 30 mm (1.18 in) thick, 30 × 50 mm (1.18 × 1.97 in)
FELT CLOTHTAPE
Used to insulate where movement does not occur. Ideal for instrument panel applications.
68370-4B000: 15 × 25 mm (0.59 × 0.98 in) pad/68239-13E00: 5 mm (0.20 in) wide tape roll The following
materials, not found in the kit, can also be used to repair squeaks and rattles.
UHMW(TEFLON) TAPE
Insulates where slight movement is present. Ideal for instrument panel applications.
SILICONE GREASE
Used in place of UHMW tape that will be visible or not fit.
Note: Will only last a few months.
SILICONE SPRAY
Use when grease cannot be applied.
DUCT TAPE
Use to eliminate movement.
CONFIRM THE REPAIR
Confirm that the cause of a noise is repaired by test driving the vehicle. Operate the vehicle under the same
conditions as when the noise originally occurred. Refer to the notes on the Diagnostic Worksheet.
Generic Squeak and Rattle TroubleshootingAIS00376
Refer to Table of Contents for specific component removal and installation information.
INSTRUMENT PANEL
Most incidents are caused by contact and movement between:
1. The cluster lid A and instrument panel
2. Acrylic lens and combination meter housing
3. Instrument panel to front pillar garnish
4. Instrument panel to windshield
5. Instrument panel mounting pins
6. Wiring harnesses behind the combination meter
7. A/C defroster duct and duct joint
These incidents can usually be located by tapping or moving the components to duplicate the noise or by
pressing on the components while driving to stop the noise. Most of these incidents can be repaired by apply-
ing felt cloth tape or silicon spray (in hard to reach areas). Urethane pads can be used to insulate wiring har-
ness.
CAUTION:
Do not use silicone spray to isolate a squeak or rattle. If you saturate the area with silicone, you will
not be able to recheck the repair.
CENTER CONSOLE
Components to pay attention to include:
1. Shifter assembly cover to finisher
2. A/C control unit and cluster lid C
3. Wiring harnesses behind audio and A/C control unit
The instrument panel repair and isolation procedures also apply to the center console.
DOORS
Pay attention to the:
1. Finisher and inner panel making a slapping noise
2. Inside handle escutcheon to door finisher
3. Wiring harnesses tapping
4. Door striker out of alignment causing a popping noise on starts and stops
Tapping or moving the components or pressing on them while driving to duplicate the conditions can isolate
many of these incidents. You can usually insulate the areas with felt cloth tape or insulator foam blocks from
the Nissan Squeak and Rattle Kit (J-43980) to repair the noise.

EI-8
SQUEAK AND RATTLE TROUBLE DIAGNOSES
Revision: 2005 July 2005 FX
TRUNK
Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner.
In addition look for:
1. Trunk lid dumpers out of adjustment
2. Trunk lid striker out of adjustment
3. The trunk lid torsion bars knocking together
4. A loose license plate or bracket
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-
ing the noise.
SUNROOF/HEADLINING
Noises in the sunroof/headlining area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sun-visor shaft shaking in the holder
3. Front or rear windshield touching headlining and squeaking
Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these
incidents. Repairs usually consist of insulating with felt cloth tape.
SEATS
When isolating seat noise it's important to note the position the seat is in and the load placed on the seat when
the noise is present. These conditions should be duplicated when verifying and isolating the cause of the
noise.
Cause of seat noise include:
1. Headrest rods and holder
2. A squeak between the seat pad cushion and frame
3. The rear seatback lock and bracket
These noises can be isolated by moving or pressing on the suspected components while duplicating the con-
ditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component
or applying urethane tape to the contact area.
UNDERHOOD
Some interior noise may be caused by components under the hood or on the engine wall. The noise is then
transmitted into the passenger compartment.
Causes of transmitted under-hood noise include:
1. Any component mounted to the engine wall
2. Components that pass through the engine wall
3. Engine wall mounts and connectors
4. Loose radiator mounting pins
5. Hood bumpers out of adjustment
6. Hood striker out of adjustment
These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best
method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM
or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or
insulating the component causing the noise.

DOOR FINISHER EI-35
C
D E
F
G H
J
K L
M A
B
EI
Revision: 2005 July 2005 FX
5. Remove lock knob cable, inside handle cable and illumination
harness connector (front door only) from backside of inside han-
dle assembly.
6. Remove inside handle screws, and remove it from finisher.
Installation
Install in the reverse order of removal.
CAUTION:
To install finisher, check if all clips are matched over holes of panel on vehicle, then push it.
PIIA4959E

EM-2Revision: 2005 July 2005 FX
IGNITION COIL ......................................................
... 42
Components ........................................................ ... 42
Removal and Installation ..................................... ... 42
REMOVAL ........................................................ ... 42
INSTALLATION ................................................. ... 42
SPARK PLUG (PLATINUM-TIPPED TYPE) .......... ... 43
Components ........................................................ ... 43
Removal and Installation ..................................... ... 43
REMOVAL ........................................................ ... 43
INSPECTION AFTER REMOVAL ..................... ... 43
INSTALLATION ................................................. ... 44
FUEL INJECTOR AND FUEL TUBE ..................... ... 45
Components ........................................................ ... 45
Removal and Installation ..................................... ... 45
REMOVAL ........................................................ ... 45
INSTALLATION ................................................. ... 47
INSPECTION AFTER INSTALLATION ............. ... 50
ROCKER COVER .................................................. ... 51
Components ........................................................ ... 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 ............. ... 63
TIMING CHAIN ....................................................... ... 64
Components ........................................................ ... 64
Removal and Installation ..................................... ... 65
REMOVAL ........................................................ ... 65
INSPECTION AFTER REMOVAL ..................... ... 72
INSTALLATION ................................................. ... 73
INSPECTION AFTER INSTALLATION ............. ... 82
CAMSHAFT ............................................................ ... 84
Components ........................................................ ... 84
Removal and Installation ..................................... ... 85
REMOVAL ........................................................ ... 85
INSPECTION AFTER REMOVAL ..................... ... 86
INSTALLATION ................................................. ... 89
INSPECTION AFTER INSTALLATION ............. ... 92
Valve Clearance ................................................... ... 93
INSPECTION .................................................... ... 93
ADJUSTMENT ................................................. ... 96
OIL SEAL ............................................................... ... 97
Removal and Installation of Valve Oil Seal .......... ... 97
REMOVAL ........................................................ ... 97
INSTALLATION ................................................. ... 97
Removal and Installation of Front Oil Seal .......... ... 98
REMOVAL ........................................................ ... 98
INSTALLATION ................................................. ... 98
Removal and Installation of Rear Oil Seal ........... ... 98
REMOVAL ........................................................ ... 98
INSTALLATION ................................................. ... 99
CYLINDER HEAD .................................................. .100
On-Vehicle Service .............................................. .100
CHECKING COMPRESSION PRESSURE ...... .100
Components ........................................................ .101 Removal and Installation ......................................
.101
REMOVAL ......................................................... .101
INSPECTION AFTER REMOVAL ..................... .102
INSTALLATION ................................................. .103
INSPECTION AFTER INSTALLATION ............. .104
Disassembly and Assembly ................................. .105
COMPONENTS ................................................ .105
DISASSEMBLY ................................................. .105
ASSEMBLY ....................................................... .106
Inspection After Disassembly ............................... .107
VALVE DIMENSIONS ....................................... .107
VALVE GUIDE CLEARANCE ........................... .107
VALVE GUIDE REPLACEMENT ...................... .108
VALVE SEAT CONTACT ................................... .109
VALVE SEAT REPLACEMENT ......................... .109
VALVE SPRING SQUARENESS ...................... .110
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD ............................. . 111
ENGINE ASSEMBLY .............................................. .112
Components (2WD Model) .................................. .112
Removal and Installation (2WD Model) ............... .112
REMOVAL ......................................................... .113
INSTALLATION ................................................. .115
INSPECTION AFTER INSTALLATION ............. .116
Components (AWD Model) .................................. .117
Removal and Installation (AWD Model) ............... .117
REMOVAL ......................................................... .118
INSTALLATION ................................................. .120
INSPECTION AFTER INSTALLATION ............. .121
CYLINDER BLOCK ................................................ .122
Components ......................................................... .122
Disassembly and Assembly ................................. .123
DISASSEMBLY ................................................. .123
ASSEMBLY ....................................................... .128
How to Select Piston and Bearing ....................... .135
DESCRIPTION ................................................. .135
HOW TO SELECT PISTON .............................. .135
HOW TO SELECT CONNECTING ROD BEAR-
ING .................................................................... .136
HOW TO SELECT MAIN BEARING ................. .137
Inspection After Disassembly ............................... .140
CRANKSHAFT END PLAY ............................... .140
CONNECTING ROD SIDE CLEARANCE ........ .140
PISTON TO PISTON PIN OIL CLEARANCE .... .140
PISTON RING SIDE CLEARANCE .................. .141
PISTON RING END GAP ................................. .141
CONNECTING ROD BEND AND TORSION .... .142
CONNECTING ROD BIG END DIAMETER ..... .142
CONNECTING ROD BUSHING OIL CLEAR-
ANCE ................................................................ .142
CYLINDER BLOCK DISTORTION ................... .143
MAIN BEARING HOUSING INNER DIAMETER .144
PISTON TO CYLINDER BORE CLEARANCE . .144
CRANKSHAFT MAIN JOURNAL DIAMETER .. .145
CRANKSHAFT PIN JOURNAL DIAMETER ..... .146
CRANKSHAFT OUT-OF-ROUND AND TAPER .146
CRANKSHAFT RUNOUT ................................. .146
CONNECTING ROD BEARING OIL CLEAR-

EM-3
C
D E
F
G H
I
J
K L
M
EM A
Revision: 2005 July 2005 FX
ANCE ...............................................................
. 146
MAIN BEARING OIL CLEARANCE ................. . 147
MAIN BEARING CRUSH HEIGHT ................... . 148
CONNECTING ROD BEARING CRUSH
HEIGHT ............................................................ . 148
MAIN BEARING CAP BOLT OUTER DIAMETER . 148
CONNECTING ROD BOLT OUTER DIAMETER . 149
DRIVE PLATE .................................................. . 149
OIL JET ............................................................ . 149
OIL JET RELIEF VALVE .................................. . 149
SERVICE DATA AND SPECIFICATIONS (SDS) ... . 150
Standard and Limit .............................................. . 150
GENERAL SPECIFICATIONS ......................... . 150
DRIVE BELT .................................................... . 151
INTAKE MANIFOLD COLLECTOR, INTAKE
MANIFOLD AND EXHAUST MANIFOLD ........ . 151
SPARK PLUG .................................................. . 151
CAMSHAFT AND CAMSHAFT BEARING ....... . 152
CYLINDER HEAD ............................................ . 154
CYLINDER BLOCK .......................................... . 157
PISTON, PISTON RING AND PISTON PIN ..... . 158
CONNECTING ROD ........................................ . 159
CRANKSHAFT ................................................. . 160
MAIN BEARING ............................................... . 161
CONNECTING ROD BEARING ....................... . 162
VK45DE
PRECAUTIONS ..................................................... . 163
Precautions Necessary for Steering Wheel Rotation
After Battery Disconnect ..................................... . 163
OPERATION PROCEDURE ............................ . 163
Precautions for Drain Engine Coolant and Engine
Oil ........................................................................ . 163
Precautions for Disconnecting Fuel Piping ......... . 163
Precautions for Removal and Disassembly ........ . 163
Precautions for Inspection, Repair and Replace-
ment .................................................................... . 163
Precautions for Assembly and Installation .......... . 163
Parts Requiring Angle Tightening ........................ . 164
Precautions for Liquid Gasket ............................. . 164
REMOVAL OF LIQUID GASKET SEALING ..... . 164
LIQUID GASKET APPLICATION PROCEDURE . 164
PREPARATION ...................................................... . 166
Special Service Tools .......................................... . 166
Commercial Service Tools ................................... . 168
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ........................................... . 170
NVH Troubleshooting — Engine Noise ............... . 170
Use the Chart Below to Help You Find the Cause
of the Symptom. .................................................. . 171
ENGINE ROOM COVER ....................................... . 172
Components ........................................................ . 172
Removal and Installation ..................................... . 172
REMOVAL ........................................................ . 172
INSTALLATION ................................................ . 172
DRIVE BELTS ........................................................ . 173
Components ........................................................ . 173 Checking Drive Belts ...........................................
.173
Tension Adjustment ............................................. .173
Removal and Installation ..................................... .173
REMOVAL ........................................................ .173
INSTALLATION ................................................ .174
Components ........................................................ .175
Drive Belt Auto Tensioner and Idler Pulley .......... .175
REMOVAL ........................................................ .175
INSTALLATION ................................................ .175
AIR CLEANER AND AIR DUCT ............................ .176
Components ........................................................ .176
Removal and Installation ..................................... .176
REMOVAL ........................................................ .176
INSPECTION AFTER REMOVAL .................... .177
INSTALLATION ................................................ .177
Changing Air Cleaner Filter ................................. .177
REMOVAL ........................................................ .177
INSTALLATION ................................................ .177
INTAKE MANIFOLD .............................................. .178
Components ........................................................ .178
Removal and Installation ..................................... .179
REMOVAL ........................................................ .179
INSPECTION AFTER REMOVAL .................... .180
INSTALLATION ................................................ .180
INSPECTION AFTER INSTALLATION ............. .181
EXHAUST MANIFOLD AND THREE WAY CATA-
LYST ....................................................................... .182
Components ........................................................ .182
Removal and Installation ..................................... .182
REMOVAL ........................................................ .182
INSPECTION AFTER REMOVAL .................... .184
INSTALLATION ................................................ .184
OIL PAN AND OIL STRAINER .............................. .185
Components ........................................................ .185
Removal and Installation ..................................... .185
REMOVAL ........................................................ .185
INSPECTION AFTER REMOVAL .................... .187
INSTALLATION ................................................ .187
INSPECTION AFTER INSTALLATION ............. .188
IGNITION COIL ...................................................... .189
Components ........................................................ .189
Removal and Installation ..................................... .189
REMOVAL ........................................................ .189
INSTALLATION ................................................ .189
SPARK PLUG (PLATINUM-TIPPED TYPE) .......... .190
Components ........................................................ .190
Removal and Installation ..................................... .190
REMOVAL ........................................................ .190
INSPECTION AFTER REMOVAL .................... .190
INSTALLATION ................................................ .191
FUEL INJECTOR AND FUEL TUBE ..................... .192
Components ........................................................ .192
Removal and Installation ..................................... .192
REMOVAL ........................................................ .192
INSTALLATION ................................................ .194
INSPECTION AFTER INSTALLATION ............. .196

EM-4Revision: 2005 July 2005 FX
ROCKER COVER ..................................................
.197
Components ........................................................ .197
Removal and Installation ..................................... .197
REMOVAL ........................................................ .197
INSTALLATION ................................................. .199
TIMING CHAIN ....................................................... .200
Components ........................................................ .200
Removal and Installation ..................................... .201
REMOVAL ........................................................ .201
INSPECTION AFTER REMOVAL ..................... .205
INSTALLATION ................................................. .205
INSPECTION AFTER INSTALLATION ............. .211
CAMSHAFT ............................................................ .212
Components ........................................................ .212
Removal and Installation ..................................... .212
REMOVAL ........................................................ .212
INSPECTION AFTER REMOVAL ..................... .213
INSTALLATION ................................................. .216
INSPECTION AFTER INSTALLATION ............. .218
Valve Clearance ................................................... .219
INSPECTION .................................................... .219
ADJUSTMENT ................................................. .222
OIL SEAL ............................................................... .225
Removal and Installation of Valve Oil Seal .......... .225
REMOVAL ........................................................ .225
INSTALLATION ................................................. .225
Removal and Installation of Front Oil Seal .......... .226
REMOVAL ........................................................ .226
INSTALLATION ................................................. .226
Removal and Installation of Rear Oil Seal ........... .227
REMOVAL ........................................................ .227
INSTALLATION ................................................. .227
CYLINDER HEAD .................................................. .229
On-Vehicle Service .............................................. .229
CHECKING COMPRESSION PRESSURE ...... .229
Components ........................................................ .230
Removal and Installation ..................................... .230
REMOVAL ........................................................ .230
INSPECTION AFTER REMOVAL ..................... .231
INSTALLATION ................................................. .231
Disassembly and Assembly ................................. .233
COMPONENTS ................................................ .233
DISASSEMBLY ................................................ .233
ASSEMBLY ...................................................... .234
Inspection After Disassembly .............................. .235
VALVE DIMENSIONS ....................................... .235
VALVE GUIDE CLEARANCE ........................... .236
VALVE GUIDE REPLACEMENT ...................... .236
VALVE SEAT CONTACT .................................. .238
VALVE SEAT REPLACEMENT ........................ .238
VALVE SPRING SQUARENESS ...................... .239
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD ............................ .239 ENGINE ASSEMBLY ..............................................
.240
Components ......................................................... .240
Removal and Installation ...................................... .240
REMOVAL ......................................................... .240
INSTALLATION ................................................. .243
INSPECTION AFTER INSTALLATION ............. .243
CYLINDER BLOCK ................................................ .245
Components ......................................................... .245
Disassembly and Assembly ................................. .246
DISASSEMBLY ................................................. .246
ASSEMBLY ....................................................... .249
How to Select Piston and Bearing ....................... .255
DESCRIPTION ................................................. .255
HOW TO SELECT PISTON .............................. .255
HOW TO SELECT CONNECTING ROD BEAR-
ING .................................................................... .256
HOW TO SELECT MAIN BEARING ................. .257
Inspection After Disassembly ............................... .262
CRANKSHAFT END PLAY ............................... .262
CONNECTING ROD SIDE CLEARANCE ........ .262
PISTON TO PISTON PIN OIL CLEARANCE .... .262
PISTON RING SIDE CLEARANCE .................. .263
PISTON RING END GAP ................................. .263
CONNECTING ROD BEND AND TORSION .... .264
CONNECTING ROD BIG END DIAMETER ..... .264
CONNECTING ROD BUSHING OIL CLEAR-
ANCE ................................................................ .264
CYLINDER BLOCK DISTORTION ................... .265
MAIN BEARING HOUSING INNER DIAMETER .266
PISTON TO CYLINDER BORE CLEARANCE . .266
CRANKSHAFT MAIN JOURNAL DIAMETER .. .267
CRANKSHAFT PIN JOURNAL DIAMETER ..... .268
CRANKSHAFT OUT-OF-ROUND AND TAPER .268
CRANKSHAFT RUNOUT ................................. .268
CONNECTING ROD BEARING OIL CLEAR-
ANCE ................................................................ .269
MAIN BEARING OIL CLEARANCE .................. .270
CRUSH HEIGHT OF MAIN BEARING ............. .271
CRUSH HEIGHT OF CONNECTING ROD
BEARING .......................................................... .271
DRIVE PLATE ................................................... .271
SERVICE DATA AND SPECIFICATIONS (SDS) ... .272
Standard and Limit ............................................... .272
GENERAL SPECIFICATIONS .......................... .272
DRIVE BELTS ................................................... .272
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD ................................................................ .272
SPARK PLUG ................................................... .273
CAMSHAFT AND CAMSHAFT BEARING ........ .273
CYLINDER HEAD ............................................. .275
CYLINDER BLOCK ........................................... .278
PISTON, PISTON RING AND PISTON PIN ..... .279
CONNECTING ROD ......................................... .280
CRANKSHAFT .................................................. .281
MAIN BEARING ................................................ .283
CONNECTING ROD BEARING ........................ .284