check engine INFINITI FX35 2005 Service Manual
[x] Cancel search | Manufacturer: INFINITI, Model Year: 2005, Model line: FX35, Model: INFINITI FX35 2005Pages: 4731, PDF Size: 60.13 MB
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![INFINITI FX35 2005 Service Manual EC-1346
[VK45DE]
IGNITION SIGNAL
Revision: 2005 July 2005 FX
3. CHECK OVERALL FUNCTION
Without CONSULT-II
1. Let engine idle.
2. Read the voltage signal between ECM terminals 46, 60, 61, 62, 65, 7](/img/42/57020/w960_57020-2738.png "INFINITI FX35 2005 Service Manual EC-1346
[VK45DE]
IGNITION SIGNAL
Revision: 2005 July 2005 FX
3. CHECK OVERALL FUNCTION
Without CONSULT-II
1. Let engine idle.
2. Read the voltage signal between ECM terminals 46, 60, 61, 62, 65, 7")
EC-1346
[VK45DE]
IGNITION SIGNAL
Revision: 2005 July 2005 FX
3. CHECK OVERALL FUNCTION
Without CONSULT-II
1. Let engine idle.
2. Read the voltage signal between ECM terminals 46, 60, 61, 62, 65, 79, 80, 81 and ground with an oscilloscope.
3. Verify that the oscilloscope screen shows the signal wave as shown below.
NOTE:
The pulse cycle changes depending on rpm at idle.
OK or NG
OK >> INSPECTION END
NG >> GO TO 10.
4. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-I
1. Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
2. Check voltage between ECM terminals 119, 120 and ground with CONSULT-II or tester.
OK or NG
OK >> GO TO 5.
NG >> Go to EC-855, "
POWER SUPPLY AND GROUND CIR-
CUIT" .
PBIB1549E
PBIB0044E
Voltage: Battery voltage
MBIB0034E
Page 2743 of 4731
![INFINITI FX35 2005 Service Manual EC-1350
[VK45DE]
IGNITION SIGNAL
Revision: 2005 July 2005 FX
7. Remove fuel pump fuse in IPDM E/R to release fuel pressure.
NOTE:
Do not use CONSULT-II to release fuel pressure, or fuel pres-
sure a](/img/42/57020/w960_57020-2742.png "INFINITI FX35 2005 Service Manual EC-1350
[VK45DE]
IGNITION SIGNAL
Revision: 2005 July 2005 FX
7. Remove fuel pump fuse in IPDM E/R to release fuel pressure.
NOTE:
Do not use CONSULT-II to release fuel pressure, or fuel pres-
sure a")
EC-1350
[VK45DE]
IGNITION SIGNAL
Revision: 2005 July 2005 FX
7. Remove fuel pump fuse in IPDM E/R to release fuel pressure.
NOTE:
Do not use CONSULT-II to release fuel pressure, or fuel pres-
sure applies again during the following procedure.
8. Start engine.
9. After engine stalls, crank it two or three times to release all fuel pressure.
10. Turn ignition switch OFF.
11. Remove all ignition coil harness connectors to avoid the electri- cal discharge from the ignition coils.
12. Remove ignition coil and spark plug of the cylinder to be checked.
13. Crank engine for five seconds or more to remove combustion gas in the cylinder.
14. Connect spark plug and harness connector to ignition coil.
15. Fix ignition coil using a rope etc. with gap of 13 - 17 mm between the edge of the spark plug and grounded metal portion
as shown in the figure.
16. Crank engine for about three seconds, and check whether spark is generated between the spark plug and the grounded metal
portion.
CAUTION:
Do not approach to the spark plug and the ignition coil
within 50cm. Be careful not to get an electrical shock
while checking, because the electrical discharge voltage
becomes 20kV or more.
It might cause to damage the ignition coil if the gap of 17 mm or more is taken.
NOTE:
When the gap is 13 mm or less, the spark might be generated even if the coil is malfunctioning.
17. If NG, replace ignition coil with power transistor.
CONDENSER
1. Turn ignition switch OFF.
2. Disconnect condenser harness connector.
3. Check resistance between condenser terminals 1 and 2.
Removal and InstallationABS007WU
IGNITION COIL WITH POWER TRANSISTOR
Refer to EM-189, "IGNITION COIL" .
Spark should be generated.
PBIB1482E
PBIB2325E
Resistance: Above 1 M
Ω at 25 °C (77 °F)
PBIB0794E
Page 2746 of 4731
![INFINITI FX35 2005 Service Manual INJECTOR CIRCUIT EC-1353
[VK45DE]
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Revision: 2005 July 2005 FX
Specification data are reference values and are measured between each terminal and ground.
Pulse](/img/42/57020/w960_57020-2745.png "INFINITI FX35 2005 Service Manual INJECTOR CIRCUIT EC-1353
[VK45DE]
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Specification data are reference values and are measured between each terminal and ground.
Pulse")
INJECTOR CIRCUIT EC-1353
[VK45DE]
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Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)
Diagnostic ProcedureABS00E5T
1. INSPECTION START
Turn ignition switch to START.
Is any cylinder ignited?
Ye s o r N o
Yes (With CONSULT-II)>>GO TO 2.
Yes (Without CONSULT-II)>>GO TO 3.
No >> GO TO 3.
2. CHECK OVERALL FUNCTION
With CONSULT-II
1. Start engine.
2. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II.
3. Make sure that each circuit produces a momentary engine speed drop.
OK or NG
OK >> INSPECTION END
NG >> GO TO 3.
TER-
MINAL
NO. WIRE
COLOR ITEM CONDITION DATA (DC Voltage)
21
22
23
40
41
42
44
63 W
R
P
PU
BR
B
OR
G Injector No. 5
Injector No. 3
Injector No. 1
Injector No. 6
Injector No. 4
Injector No. 2
Injector No. 7
Injector No. 8 [Engine is running]
Warm-up condition
Idle speed
NOTE:
The pulse cycle changes depending on rpm
at idle BATTERY VOLTAGE
(11 - 14V)
[Engine is running]
Warm-up condition
Engine speed: 2,000 rpm BATTERY VOLTAGE
(11 - 14V)
PBIB0042E
PBIB0043E
PBIB0133E
Page 2753 of 4731
![INFINITI FX35 2005 Service Manual EC-1360
[VK45DE]
FUEL PUMP CIRCUIT
Revision: 2005 July 2005 FX
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals whe](/img/42/57020/w960_57020-2752.png "INFINITI FX35 2005 Service Manual EC-1360
[VK45DE]
FUEL PUMP CIRCUIT
Revision: 2005 July 2005 FX
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals whe")
EC-1360
[VK45DE]
FUEL PUMP CIRCUIT
Revision: 2005 July 2005 FX
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
Diagnostic ProcedureABS007X4
1. CHECK OVERALL FUNCTION
1. Turn ignition switch ON.
2. Pinch fuel feed hose with two fingers. Fuel pressure pulsation should be felt on the fuel feed hose
for 1 second after ignition switch is turned ON.
OK or NG
OK >> INSPECTION END
NG >> GO TO 2.
2. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-I
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Turn ignition switch ON.
4. Check voltage between ECM terminal 113 and ground with CONSULT-II or tester.
OK or NG
OK >> GO TO 5.
NG >> GO TO 3.
TER-
MINAL NO. WIRE
COLOR ITEM CONDITION DATA (DC Voltage)
11 3 G Y / R F u e l p u m p r e l a y [Ignition switch: ON]
For 1 second after turning ignition switch ON
[Engine is running] 0 - 1.5V
[Ignition switch: ON]
More than 1 second after turning ignition
switch ON BATTERY VOLTAGE
(11 - 14V)
PBIB1491E
Voltage: Battery voltage
PBIB1187E
Page 2759 of 4731
![INFINITI FX35 2005 Service Manual EC-1366
[VK45DE]
REFRIGERANT PRESSURE SENSOR
Revision: 2005 July 2005 FX
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground ter](/img/42/57020/w960_57020-2758.png "INFINITI FX35 2005 Service Manual EC-1366
[VK45DE]
REFRIGERANT PRESSURE SENSOR
Revision: 2005 July 2005 FX
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground ter")
EC-1366
[VK45DE]
REFRIGERANT PRESSURE SENSOR
Revision: 2005 July 2005 FX
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
Diagnostic ProcedureABS007X9
1. CHECK REFRIGERANT PRESSURE SENSOR OVERALL FUNCTION
1. Start engine and warm it up to normal operating temperature.
2. Turn A/C switch and blower switch ON.
3. Check voltage between ECM terminal 70 and ground with CON- SULT-II or tester.
OK or NG
OK >> INSPECTION END
NG >> GO TO 2.
2. CHECK GROUND CONNECTIONS
1. Turn ignition switch OFF.
2. Loosen and retighten three ground screws on the body. Refer to EC-861, "
Ground Inspection" .
OK or NG
OK >> GO TO 3.
NG >> Repair or replace ground connections.
TER-
MINAL NO. WIRE
COLOR ITEM CONDITION DATA (DC Voltage)
49 PU Sensor power supply
(Refrigerant pressure sen-
sor) [Ignition switch: ON]
Approximately 5V
67 B/W Sensor ground [Engine is running]
Warm-up condition
Idle speed Approximately 0V
70 L/R Refrigerant pressure sensor [Engine is running]
Warm-up condition
Both A/C switch and blower fan motor
switch: ON (Compressor operates) 1.0 - 4.0V
Voltage: 1.0 - 4.0V
PBIB1188E
PBIB2195E
Page 2783 of 4731
![INFINITI FX35 2005 Service Manual EC-1390
[VK45DE]
SNOW MODE SWITCH
Revision: 2005 July 2005 FX
Diagnostic ProcedureABS00A2L
1. CHECK SNOW MODE SWITICH OVERALL FUNCTION-I
1. Turn ignition switch ON.
2. Select “SNOW MODE SW” in](/img/42/57020/w960_57020-2782.png "INFINITI FX35 2005 Service Manual EC-1390
[VK45DE]
SNOW MODE SWITCH
Revision: 2005 July 2005 FX
Diagnostic ProcedureABS00A2L
1. CHECK SNOW MODE SWITICH OVERALL FUNCTION-I
1. Turn ignition switch ON.
2. Select “SNOW MODE SW” in")
EC-1390
[VK45DE]
SNOW MODE SWITCH
Revision: 2005 July 2005 FX
Diagnostic ProcedureABS00A2L
1. CHECK SNOW MODE SWITICH OVERALL FUNCTION-I
1. Turn ignition switch ON.
2. Select “SNOW MODE SW” in “DATA MONITOR” mode with CONSULT-II.
3. Check “SNOW MODE SW” indication under the following condi- tions.
OK or NG
OK >> GO TO 2.
NG >> GO TO 3.
2. CHECK SNOW MODE SWITICH OVERALL FUNCTION-II
1. Turn ignition switch ON.
2. Start engine.
3. Check the snow mode indicator in the snow mode switch under the following condition.
OK or NG
OK >> INSPECTION END
NG >> GO TO 7.
3. CHECK DTC WITH “UNIFIED METER AND A/C AMP.”
Refer to DI-32, "
SELF-DIAGNOSTIC RESULTS" .
OK or NG
OK >> GO TO 4.
NG >> Go to DI-28, "
UNIFIED METER AND A/C AMP" .
4. CHECK SNOW MODE SWITCH POWER SUPPLY CIRCUIT
1. Turn ignition switch OFF.
2. Disconnect snow mode switch harness connector.
3. Turn ignition switch ON.
4. Check voltage between snow mode switch terminal 1 and ground with CONSULT-II or tester.
OK or NG
OK >> GO TO 6.
NG >> GO TO 5.
CONDITION INDICATION
Snow mode switch: ON ON
Snow mode switch: OFF OFF
PBIB2009E
CONDITION INDICATION
Snow mode switch: ON ON
Snow mode switch: OFF OFF
Voltage: Battery voltage.
PBIB2562E
Page 2795 of 4731
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)
Page 2836 of 4731
EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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ENGINE MECHANICAL
VQ35DE
PRECAUTIONS .......................................................... 5
Precautions Necessary for Steering Wheel Rotation
After Battery Disconnect ..................................... ..... 5
OPERATION PROCEDURE ............................ ..... 5
Precautions for Drain Engine Coolant and Engine
Oil ........................................................................ ..... 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 .......... ..... 6
Precautions for 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
A/C COMPRESSOR BELT .............................. ... 16
Removal and Installation ..................................... ... 16
REMOVAL ........................................................ ... 16
INSTALLATION ................................................ ... 16
AIR CLEANER AND AIR DUCT ............................ ... 17
Components ........................................................ ... 17
Removal and Installation ..................................... ... 17
REMOVAL ........................................................ ... 17
INSPECTION AFTER REMOVAL .................... ... 17 INSTALLATION ................................................
... 18
Changing Air Cleaner Filter ................................. ... 18
INSPECTION ................................................... ... 18
REMOVAL ........................................................ ... 18
INSTALLATION ................................................ ... 18
INTAKE MANIFOLD COLLECTOR ....................... ... 19
Components ........................................................ ... 19
Removal and Installation ..................................... ... 19
REMOVAL ........................................................ ... 19
INSPECTION AFTER REMOVAL .................... ... 21
INSTALLATION ................................................ ... 22
INTAKE MANIFOLD .............................................. ... 24
Components ........................................................ ... 24
Removal and Installation ..................................... ... 24
REMOVAL ........................................................ ... 24
INSPECTION AFTER REMOVAL .................... ... 25
INSTALLATION ................................................ ... 25
EXHAUST MANIFOLD AND THREE WAY CATA-
LYST ....................................................................... ... 26
Components ........................................................ ... 26
Removal and Installation ..................................... ... 26
REMOVAL ........................................................ ... 26
INSPECTION AFTER REMOVAL .................... ... 28
INSTALLATION ................................................ ... 28
OIL PAN AND OIL STRAINER .............................. ... 30
Components (2WD Model) .................................. ... 30
Removal and Installation (2WD Model) ............... ... 30
REMOVAL ........................................................ ... 30
INSPECTION AFTER REMOVAL .................... ... 32
INSTALLATION ................................................ ... 32
INSPECTION AFTER INSTALLATION ............. ... 35
Components (AWD Model) .................................. ... 35
Removal and Installation (AWD Model) ............... ... 36
REMOVAL ........................................................ ... 36
INSPECTION AFTER REMOVAL .................... ... 38
INSTALLATION ................................................ ... 38
INSPECTION AFTER INSTALLATION ............. ... 41
Page 2837 of 4731
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-
Page 2838 of 4731
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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