lock INFINITI FX35 2005 Service Manual

CYLINDER BLOCK EM-259
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Revision: 2005 July 2005 FX
Main Bearing Selection Table (No. 1 and 5 Journal)
PBIC2375E

EM-260
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CYLINDER BLOCK
Revision: 2005 July 2005 FX
Main Bearing Selection Table (No. 2, 3 and 4 Journal)
PBIC2376E

CYLINDER BLOCK EM-261
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Revision: 2005 July 2005 FX
Main Bearing Grade Table (All Journals)
Unit: mm (in)
Use Undersize Bearing Usage Guide

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

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

EM-262
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CYLINDER BLOCK
Revision: 2005 July 2005 FX
Inspection After DisassemblyABS006IW
CRANKSHAFT END PLAY

Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward with
dial indicator.

If the measured value exceeds the limit, replace thrust bearings,
and measure again. If it still exceeds the limit, replace crank-
shaft also.
CONNECTING ROD SIDE CLEARANCE

Measure the side clearance between connecting rod and crank-
shaft arm with feeler gauge.

If the measured value exceeds the limit, replace connecting rod,
and measure again. If it still exceeds the limit, replace crank-
shaft also.
PISTON TO PISTON PIN OIL CLEARANCE
Piston Pin Hole Diameter
Measure the inner diameter of piston pin hole with inside microme-
ter.
Piston Pin Outer Diameter
Measure the outer diameter of piston pin with micrometer.
Piston to Piston Pin Oil Clearance
(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)

If the calculated value is out of the standard, replace piston and piston pin assembly. Standard : 0.10 - 0.25 mm (0.0039 - 0.0098 in)
Limit : 0.30 mm (0.0118 in)
PBIC2377E
Standard : 0.20 - 0.35 mm (0.0079 - 0.0138 in)
Limit : 0.40 mm (0.0157 in)
PBIC0115E
Standard : 21.993 - 22.005 mm (0.8659 - 0.8663 in)
PBIC0116E
Standard : 21.989 - 22.001 mm (0.8657 - 0.8662 in)
PBIC0117E
Standard : 0.002 - 0.006 mm (0.0001 - 0.0002 in)

CYLINDER BLOCK EM-263
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When replacing piston and piston pin assembly, refer to EM-255, "HOW TO SELECT PISTON" .
NOTE:

Piston is available together with piston pin as assembly.

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

Measure the side clearance of piston ring and piston ring groove
with feeler gauge.

If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit,
replace piston also.
PISTON RING END GAP

Make sure that the cylinder bore inner diameter is within the
specification. Refer to EM-266, "
Cylinder Bore Inner Diameter" .

Lubricate with new engine oil to piston and piston ring, and then
insert piston ring until middle of cylinder with piston, and mea-
sure the piston ring end gap with feeler gauge.

If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit,
re-bore cylinder and use oversize piston and piston rings. Standard:
Top ring : 0.045 - 0.080 mm (0.0018 - 0.0031 in)
2nd ring : 0.030 - 0.070 mm (0.0012 - 0.0028 in)
Oil ring : 0.065 - 0.135 mm (0.0026 - 0.0053 in)
Limit:


Top ring : 0.11 mm (0.0043 in)


2nd ring : 0.1 mm (0.004 in)
SEM024AA
Standard:
Top ring : 0.22 - 0.32 mm (0.0087 - 0.0126 in)
2nd ring : 0.22 - 0.32 mm (0.0087 - 0.0126 in)
Oil ring : 0.20 - 0.50 mm (0.0079 - 0.0197 in)
Limit:



Top ring : 0.56 mm (0.0220 in)



2nd ring : 0.56 mm (0.0220 in)
Oil ring : 0.96 mm (0.0378 in)
PBIC0118E

EM-264
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CYLINDER BLOCK
Revision: 2005 July 2005 FX
CONNECTING ROD BEND AND TORSION

Check with connecting rod aligner.

If it exceeds the limit, replace connecting rod assembly.
CONNECTING ROD BIG END DIAMETER

Install connecting rod bearing cap without installing connecting
rod bearing, and tightening connecting rod bolts to the specified
torque. Refer to EM-249, "
ASSEMBLY" for the tightening proce-
dure.

Measure the inner diameter of connecting rod big end with
inside micrometer.

If out of the standard, replace connecting rod assembly.
CONNECTING ROD BUSHING OIL CLEARANCE
Connecting Rod Bushing Inner Diameter
Measure the inner diameter of connecting rod bushing with inside
micrometer. Bend:
Limit : 0.15 mm (0.0059 in) per 100 mm (3.94 in) length
Torsion: Limit : 0.30 mm (0.0118 in) per 100 mm (3.94 in) length
PBIC2077E
Standard : 55.000 - 55.013 mm (2.1654 - 2.1659 in)
PBIC1641E
Standard : 22.000 - 22.012 mm (0.8661 - 0.8666 in)
PBIC0120E

CYLINDER BLOCK EM-265
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Revision: 2005 July 2005 FX
Piston Pin Outer Diameter
Measure the outer diameter of piston pin with micrometer.
Connecting Rod Bushing Oil Clearance
(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)

If the calculated value exceeds the limit, replace connecting rod assembly and/or piston and piston pin
assembly.

If replacing piston and piston pin assembly, refer to EM-255, "HOW TO SELECT PISTON" .

If replacing connecting rod assembly, refer to EM-269, "CON-
NECTING ROD BEARING OIL CLEARANCE" to select the con-
necting rod bearing.
Factory installed parts grading:

Service parts apply only to grade “0”.
Unit: mm (in)
*: After installing in connecting rod
CYLINDER BLOCK DISTORTION

Using scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or
other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages. Standard : 21.989 - 22.001 mm (0.8657 - 0.8662 in)
PBIC0117E
Standard : 0.005 - 0.017 mm (0.0002 - 0.0007 in)
Limit : 0.030 mm (0.0012 in)
PBIC2164E
Grade 0 1
Connecting rod bushing
inner diameter * 22.000 - 22.006
(0.8661 - 0.8664) 22.006 - 22.012
(0.8664 - 0.8666)
Piston pin hole diameter 21.993 - 21.999
(0.8659- 0.8661) 21.999 - 22.005
(0.8661 - 0.8663)
Piston pin outer diameter 21.989 - 21.995
(0.8657 - 0.8659) 21.995 - 22. 001
(0.8659 - 0.8662)
PBIC2372E

EM-266
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CYLINDER BLOCK
Revision: 2005 July 2005 FX

Measure the distortion on the cylinder block upper face at some
different points in six directions with straightedge and feeler
gauge.

If it exceeds the limit, replace cylinder block.
MAIN BEARING HOUSING INNER DIAMETER

Install main bearing caps and main bearing without installing
main bearings, and tighten main bearing cap bolts to the speci-
fied torque. Refer to EM-249, "
ASSEMBLY" for the tightening
procedure.

Measure the inner diameter of main bearing housing with bore
gauge.

If out of the standard, replace cylinder block and main bearing
caps as assembly.
NOTE:
Cylinder block cannot be replaced as a single part, because it is
machined together with main bearing caps.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter

Using bore gauge, measure cylinder bore for wear, out-of-round
and taper at six different points on each cylinder. (“X” and “Y”
directions at “A”, “B” and “C”) (“Y” is in longitudinal direction of
engine)

If the measured value exceeds the limit, or if there are scratches
and/or seizure on the cylinder inner wall, hone or re-bore the
inner wall.

Oversize piston is provided. When using oversize piston, re-
bore cylinder so that the clearance of the piston-to-cylinder bore
satisfies the standard.
CAUTION:
When using oversize piston, use oversize pistons for all
cylinders with oversize piston rings. Limit : 0.1 mm (0.004 in)
SEM123C
Standard : 68.944 - 68.968 mm (2.7143 - 2.7153 in)
PBIC1643E
Standard inner diameter:
93.000 - 93.030 mm (3.6614 - 3.6626 in)
Wear limit: 0.2 mm (0.008 in)
Out-of-round (Difference between “X” and “Y”): 0.015 mm (0.0006 in)
Taper limit (Difference between “A” and “C”):
0.01 mm (0.0004 in)
Oversize (OS) : 0.2 mm (0.008 in)
PBIC0123E
PBIC0124E

CYLINDER BLOCK EM-267
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Revision: 2005 July 2005 FX
Piston Skirt Diameter

Measure the outer diameter of piston skirt with micrometer.

Measure point “H” (Distance from the top): 42 mm (1.65 in)
Piston to Cylinder Bore Clearance
Calculate by piston skirt diameter and cylinder bore inner diameter (direction “X”, position “B”).
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter).

If the calculated value exceeds the limit, replace piston and piston pin assembly. Refer to EM-255, "HOW
TO SELECT PISTON" .
Re-boring Cylinder Bore
1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.
2. Install main bearing caps and main bearing, and tighten to the specified torque. Otherwise, cylinder bores may be distorted in final assembly.
3. Cut cylinder bores.
NOTE:

When any cylinder needs boring, all other cylinders must also be bored.

Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a
time.
4. Hone cylinders to obtain the specified piston to cylinder bore clearance.
5. Measure finished cylinder bore for the out-of-round and taper.
NOTE:
Measurement should be done after cylinder bore cools down.
CRANKSHAFT MAIN JOURNAL DIAMETER

Measure the outer diameter of crankshaft main journals with micrometer. Standard
: 92.980 - 93.010 mm (3.6606 - 3.6618 in)
PBIC0125E
PBIC0126E
Standard : 0.010 - 0.030 mm (0.0004 - 0.0012 in)
Limit : 0.08 mm (0.0031 in)
Re-bored size calculation: D = A + B – C
where, D: Bored diameter
A: Piston skirt diameter as measured
B: Piston to cylinder bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 in)

EM-268
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CYLINDER BLOCK
Revision: 2005 July 2005 FX

If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to EM-
270, "MAIN BEARING OIL CLEARANCE" .
CRANKSHAFT PIN JOURNAL DIAMETER

Measure the outer diameter of crankshaft pin journal with
micrometer.

If out of the standard, measure the connecting rod bearing oil
clearance. Then use undersize bearing. Refer to EM-269,
"CONNECTING ROD BEARING OIL CLEARANCE" .
CRANKSHAFT OUT-OF-ROUND AND TAPER

Measure the dimensions at four different points as shown in the
figure on each main journal and pin journal with micrometer.

Out-of-round is indicated by the difference in the dimensions
between “X” and “Y” at “A” and “B”.

Taper is indicated by the difference in the dimensions between
“A” and “B” at “X” and “Y”.

If the measured value exceeds the limit, correct or replace crankshaft.

If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then
select the main bearing and/or connecting rod bearing. Refer to EM-270, "
MAIN BEARING OIL CLEAR-
ANCE" and/or EM-269, "CONNECTING ROD BEARING OIL CLEARANCE" .
CRANKSHAFT RUNOUT

Place V-block on precise flat table, and support the journals on
the both end of crankshaft.

Place dial indicator straight up on the No. 3 journal.

While rotating crankshaft, read the movement of the pointer on
dial indicator. (Total indicator reading)

If it exceeds the limit, replace crankshaft. Standard : 63.940 - 63.964 mm (2.5173 - 2.5183 in) dia.
Standard : 51.956 - 51.974 mm (2.0455 - 2.0462 in) dia.
PBIC0127E
Limit: Out-of-round (Difference between “X” and “Y”) : 0.015 mm (0.0006 in)
Taper (Difference between “A” and “B”) : 0.010 mm (0.0004 in)
PBIC1685E
Limit : 0.10 mm (0.004 in)
PBIC2378E