service INFINITI FX35 2006 Service Manual

CYLINDER HEAD EM-239
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Revision: 2006 December 2006 FX35/FX45
VALVE GUIDE CLEARANCE
Valve Stem Diameter
Measure the diameter of valve stem with micrometer.
Valve Guide Inner Diameter
Measure the inner diameter of valve guide with inside micrometer.
Valve Guide Clearance
(Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter).

If the calculated value exceeds the limit, replace valve and/or valve guide. When valve guide must be
replaced, refer to EM-239, "
VALVE GUIDE REPLACEMENT" .
VALVE GUIDE REPLACEMENT
When valve guide is removed, replace with oversized [0.2 mm (0.008 in)] valve guide.
1. To remove valve guide, heat cylinder head to 110 to 130 °C (230
to 266 °F) by soaking in heated oil.
2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US ton, 2.0 lmp ton) pressure] or hammer and valve guide drift
(commercial service tool).
CAUTION:
Cylinder head contains heat. When working, wear protec-
tive equipment to avoid getting burned. Standard
Intake : 5.972 - 5.980 mm (0.2351 - 0.2354 in)
Exhaust : 5.962 - 5.970 mm (0.2347 - 0.2350 in)
SEM938C
Standard Intake and Exhaust : 6.000 - 6.018 mm (0.2362 - 0.2369 in)
Valve guide clearance:
Standard Intake : 0.020 - 0.046 mm (0.0008 - 0.0018 in)
Exhaust : 0.030 - 0.056 mm (0.0012 - 0.0022 in)
Limit Intake : 0.08 mm (0.003 in)
Exhaust : 0.1 mm (0.004 in)
SEM008A
SEM931C

EM-240
[VK45DE]
CYLINDER HEAD
Revision: 2006 December 2006 FX35/FX45
3. Using valve guide reamer (commercial service tool), ream cylin- der head valve guide hole.
4. Heat cylinder head to 110 to 130 °C (230 to 266 °F) by soaking in
heated oil.
5. Using valve guide drift (commercial service tool), press valve guide from camshaft side to the dimensions as in the figure.
CAUTION:
Cylinder head contains heat. When working, wear protec-
tive equipment to avoid getting burned.
6. Using valve guide reamer (commercial service tool), apply reamer finish to valve guide. Valve guide hole diameter (for service parts):
Intake and exhaust: 10.175 - 10.196 mm (0.4006 - 0.4014 in)
SEM932C
SEM008A
PBIC0078E
Standard: Intake and exhaust: 6.000 - 6.018 mm (0.2362 - 0.2369 in)
SEM932C

CYLINDER HEAD EM-241
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Revision: 2006 December 2006 FX35/FX45
VALVE SEAT CONTACT

After confirming that the dimensions of valve guides and valves
are within the specifications, perform this procedure.

Apply prussian blue (or white lead) onto contacting surface of
valve seat to check the condition of the valve contact on the sur-
face.

Check if the contact area band is continuous all around the cir-
cumference.

If not, grind to adjust valve fitting and check again. If the contact-
ing surface still has “NG” conditions even after the re-check,
replace valve seat. Refer to EM-241, "
VALVE SEAT REPLACE-
MENT" .
VALVE SEAT REPLACEMENT
When valve seat is removed, replace with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess in cylinder head. Set the machine depth stop to ensure this. Refer to EM-280, "
Va l v e S e a t" .
CAUTION:
Prevent to scratch cylinder head by excessive boring.
2. Ream cylinder head recess diameter for service valve seat.

Be sure to ream in circles concentric to valve guide center.
This will enable valve to fit correctly.
3. Heat cylinder head to 110 to 130 °C (230 to 266 °F) by soaking in
heated oil.
4. Provide valve seats cooled well with dry ice. Force fit valve seat into cylinder head. CAUTION:

Avoid directly touching cold valve seats.

Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
5. Using valve seat cutter set (commercial service tool) or valve seat grinder, finish seat to the specified dimensions. Refer to
EM-280, "
Valve Seat" .
CAUTION:
When using valve seat cutter, firmly grip cutter handle with
both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper
pressure on with cutter or cutting many different times may
result in stage valve seat.
SBIA0322E
Oversize [0.5 mm (0.020 in)]
Intake : 37.500 - 37.516 mm (1.4764 - 1.4770 in)
Exhaust : 32.700 - 32.716 mm (1.2874 - 1.2880 in)
SEM795A
SEM008A
SEM934C

ENGINE ASSEMBLY EM-245
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Revision: 2006 December 2006 FX35/FX45
8. Remove rear plate cover from oil pan. Then remove bolts fixing drive plate to torque converter. Refer to EM-187, "
OIL PAN AND OIL STRAINER" and AT- 2 6 6 , "TRANSMISSION ASSEMBLY" .
9. Remove transmission joint bolts which pierce at oil pan lower rear side. Refer to AT- 2 6 6 , "
TRANSMIS-
SION ASSEMBLY" .
10. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Refer to PS-12, "
STEERING COLUMN" .
11. Remove rear propeller shaft. Refer to PR-7, "
REAR PROPELLER SHAFT" .

After disconnection, plug the opening on transmission side.
12. Remove front drive shaft (both side). Refer to FAX-12, "
FRONT DRIVE SHAFT" .
13. Remove front propeller shaft. Refer to PR-4, "
FRONT PROPELLER SHAFT" .
14. Remove three way catalyst (both bank). Refer to EM-183, "
EXHAUST MANIFOLD AND THREE WAY
CATALYST" .
Removal Work
1. Install engine slingers into front of cylinder head (left bank) and
front of cylinder head (right bank).
2. Lift with hoist and secure engine in position.
3. Use manual lift table caddy (commercial service tool) or equivalently rigid tool such as transmission jack. Securely support bottom of suspension member and transmission.
CAUTION:
Put a piece of wood or something similar as the supporting surface, secure a completely stable
condition.
4. Remove engine rear member mounting bolts.
5. Remove front suspension member mounting nuts with power tool. Refer to FSU-6, "
FRONT SUSPEN-
SION ASSEMBLY" .
6. Carefully lower jack, or raise lift to remove engine, transmission front final drive and front suspension member assembly. When
performing work, observe the following caution:
CAUTION:

Confirm there is no interference with vehicle.

Make sure that all connection points have been discon-
nected.

Keep in mind the center of vehicle gravity changes. If
necessary, use jack(s) to support vehicle at rear jacking
point(s) to prevent it from falling it off the lift. Slinger bolts:
: 33.4 N·m (3.4 kg-m, 25 ft-lb)
PBIC1556E
PBIC1557E

CYLINDER BLOCK EM-251
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Revision: 2006 December 2006 FX35/FX45
c. Using hammer handle or similar tool, push piston and connect- ing rod assembly out to the cylinder head side.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod big
end.
9. Remove connecting rod bearings from connecting rod and connecting rod bearing cap. CAUTION:
Identify installation positions, and store them without mixing them up.
10. Remove piston rings from piston.

Before removing the piston rings, check the piston ring side clearance. Refer to EM-266, "PISTON
RING SIDE CLEARANCE" .

Use piston ring expander (commercial service tool).
CAUTION:

When removing piston rings, be careful not to damage
piston.

Be careful not to damage piston rings by expanding them
excessively.
11. Remove piston from connecting rod as follows:
a. Using snap ring pliers, remove the snap rings.
b. Heat piston to 60 to 70 °C (140 to 158 °F) with industrial use drier
or equivalent.
PBIC0086E
PBIC0087E
PBIC0088E
PBIC0089E

CYLINDER BLOCK EM-255
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Revision: 2006 December 2006 FX35/FX45
7. Install each main bearing cap bolt as follows:
a. Apply new engine oil to threads and seating surface of main bearing cap bolts, and tighten all bolts temporarily.
b. Tighten main bearing cap bolt (M12) in order of 1 to 10.
c. Tighten main bearing cap sub bolt (M9) in order of 11 to 20.
d. Tighten main bearing cap bolt (M12) to 40 degrees clockwise in order of 1 to 10. (Angle tightening)
CAUTION:
Use angle wrench (SST) to check tightening angle in step
“d” and “e”. Do not make judgment by visual inspection.
e. Tighten main bearing cap sub bolt (M9) to 30 degrees clockwise in order of 11 to 20. (Angle tightening)
f. Tighten side bolt (M10) in order of 21 to 30.

After installing main bearing cap bolts, make sure that crankshaft can be rotated smoothly.

Check the crankshaft end play. Refer to EM-265, "CRANKSHAFT END PLAY" .
g. Install cover of cylinder block rear left side (next to the starter motor housing).
8. Install new rear oil seal on rear oil seal retainer.

Install new rear oil seal so that each seal lip is oriented as
shown in the figure.

Install rear oil seal to rear oil seal retainer with rear oil seal
drift (commercial service tool).

Tap until flattened with front edge of rear oil seal retainer. Do
not damage or scratch outer circumference of oil seal.

Make sure the garter spring is in position and seal lips not
inverted.
9. Install rear oil seal retainer.

Apply new engine oil to both oil seal lip and dust seal lip. : 39.2 N·m (4.0 kg-m, 29 ft-lb)
: 29.4 N·m (3.0 kg-m, 22 ft-lb)
PBIC0090E
PBIC0096E
: 49 N·m (5.0 kg-m, 36 ft-lb)
SEM715A
Rear oil seal drift Outer diameter : 102 mm (4.02 in)
Inner diameter : 86 mm (3.39 in)
PBIC0097E

EM-256
[VK45DE]
CYLINDER BLOCK
Revision: 2006 December 2006 FX35/FX45

Apply a continuous bead of liquid gasket with tube presser
[SST: WS39930000 ( — )] to rear oil seal retainer as
shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-48, "
RECOMMENDED CHEMICAL PRODUCTS AND
SEALANTS".
10. Install piston to connecting rod.
a. Using snap ring pliers, install new snap ring to the groove of the piston rear side.

Insert it fully into groove to install.
b. Install piston to connecting rod.

Using industrial use drier or similar tool, heat piston until piston pin can be pushed in by hand without
excess force [approx. 60 to 70 °C (140 to 158 °F)]. From the front to the rear, insert piston pin into piston
and connecting rod.

Assemble so that the front mark on the piston head and the oil
holes and the cylinder No. on connecting rod are positioned
as shown in the figure.
c. Using snap ring pliers, install new snap rings to the groove of the piston front side.

Insert it fully into groove to install.

After installing, make sure that connecting rod moves
smoothly.
11. Using piston ring expander (commercial service tool), install pis- ton rings.
CAUTION:

When installing piston rings, be careful not to damage
piston.

Be careful not to damage piston rings by expending them
excessively.

Position each ring with the gap as shown in the figure, refer-
ring to the piston front mark.

Install top ring and second ring with the stamped surface fac-
ing upward.
12. Install connecting rod bearings to connecting rod and connecting rod bearing cap.

Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply
engine oil to the back surface, but thoroughly clean it.
SBIA0391E
PBIC0099E
PBIC0087E
Stamped mark
Top ring : R
Second ring : 2R
PBIC0100E

EM-258
[VK45DE]
CYLINDER BLOCK
Revision: 2006 December 2006 FX35/FX45
16. Install knock sensor.

Install it with its connector facing the rear of engine.

Install the sub-harness with its shorter branch line to the right
bank.
CAUTION:

Do not tighten mounting bolts while holding connector.

If any impact by dropping is applied to knock sensor,
replace it with new one.
NOTE:

Make sure that there is no foreign material on the cylinder
block mating surface and the back surface of knock sensor.

Make sure that knock sensor does not interfere with other parts.
17. Note the following, and assemble in the reverse order of disassembly after this step. Drive plate

When installing drive plate to crankshaft, be sure to correctly
align crankshaft side guide pin and drive plate side guide pin
hole.
–If these are not aligned correctly, engine runs roughly and
“MIL” turns on.

Install drive plate, reinforcement plate and pilot converter (if
not installed in step 4) as shown in the figure.

Face chamfered or rounded edge side to crankshaft.

Holding ring gear with ring gear stopper [SST: J-45476].

Tighten mounting bolts crosswise over several times.

When install pilot converter, using drift [outer diameter:
approx. 35 mm (1.38 in)]. Press-fit as far as it will go.
How to Select Piston and Bearing NBS003IS
DESCRIPTION
PBIC0105E
PBIC0106E
PBIC1965E
Selection points Selection parts Selection items Selection methods
Between cylinder block and
crankshaft Main bearing Main bearing grade
(bearing thickness) Determined by match of cylin-
der block bearing housing
grade (inner diameter of hous-
ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Between crankshaft and con-
necting rod Connecting rod bearing Connecting rod bearing grade
(bearing thickness) Combining service grades for
connecting rod big end diame-
ter and crankshaft pin outer
diameter determine connecting
rod bearing selection.
Between cylinder block and pis-
ton Piston and piston pin assembly
(Piston is available together
with piston pin as assembly.) Piston grade
(piston skirt diameter) Piston grade = cylinder bore
grade (inner diameter of bore)
Between piston and connecting
rod* ———

CYLINDER BLOCK EM-259
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Revision: 2006 December 2006 FX35/FX45
*: For the service parts, the grade for fitting cannot be selected between piston pin and connecting rod. (Only “0” grade is a vailable.) The
information at the shipment from the plant is described as a reference.

The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.

For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.

For details of the measurement method of each part, the reuse standards, and the selection method of the
selective fitting parts, refer to the text.
HOW TO SELECT PISTON
When New Cylinder Block is Used:
Check the cylinder bore grade (“1”, “2” or “3”) on the rear upper side
between cylinder block banks, and select piston of the same grade.
NOTE:
Piston is available with piston pin as a set for the service part. (Only
“0” grade piston pin is available.)
When Cylinder Block is Reused:
1. Measure the cylinder bore inner diameter. Refer to EM-269, "Cylinder Bore Inner Diameter" .
2. Determine the bore grade by comparing the measurement with the values the “Cylinder bore inner diame- ter” of the “Piston Selection Table”. Select piston of the same grade.
Piston Selection Table
Unit: mm (in)
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.)

No second grade mark is available on piston.
PBIC2371E
PBIC2372E
Grade 1 2 (or no mark) 3
Cylinder bore inner diameter 93.000 - 93.010
(3.6614 - 3.6618) 93.010 - 93.020
(3.6618 - 3.6622) 93.020 - 93.030
(3.6622 - 3.6626)
Piston skirt diameter 92.980 - 92.990
(3.6606 - 3.6610) 92.990 - 93.000
(3.6610 - 3.6614) 93.000 - 93.010
(3.6614 - 3.6618)

CYLINDER BLOCK EM-261
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Revision: 2006 December 2006 FX35/FX45
HOW TO SELECT MAIN BEARING
When New Cylinder Block and Crankshaft are Used:
1. “Main Bearing Selection Table” rows correspond to main bearing housing grade on rear upper side between cylinder block banks.
2. “Main Bearing Selection Table” columns correspond to main journal diameter grade on front side of crankshaft.
3. Select main bearing grade at the point where selected row and column meat in “Main Bearing Selection Table”.
CAUTION:

Initial clearance for No. 1, 5 journal and No. 2, 3, 4 journal is different. Use two different selection
table for each part.

No. 1, 5 journal and No. 2, 3, 4 journal have the same signs but different measures. Do not con-
fuse.
4. Apply sign at crossing in above step 3 to “Main Bearing Grade Table”. NOTE:

“Main Bearing Grade Table” applies to all journals.

Service parts is available as a set of both upper and lower.
When Cylinder Block and Crankshaft are Reused:
1. Measure the cylinder block main bearing housing inner diameter and the crankshaft main journal diame- ter. Refer to EM-269, "
MAIN BEARING HOUSING INNER DIAMETER" and EM-270, "CRANKSHAFT
MAIN JOURNAL DIAMETER" .
2. Correspond the measured dimension in “Cylinder block main bearing housing inner diameter” row of “Main Bearing Selection Table”.
3. Correspond the measured dimension in “Crankshaft main journal diameter” column of “Main Bearing Selection Table”.
4. Follow step 3 and later in “When New Cylinder Block and Crankshaft are Used:”.
PBIC2371E
PBIC2374E