seat adjustment INFINITI M35 2006 Factory User Guide
[x] Cancel search | Manufacturer: INFINITI, Model Year: 2006, Model line: M35, Model: INFINITI M35 2006Pages: 5621, PDF Size: 65.56 MB
Page 1312 of 5621
BRC-1
BRAKE CONTROL SYSTEM
F BRAKES
CONTENTS
C
D
E
G
H
I
J
K
L
M
SECTION BRC
A
B
BRC
Revision: 2006 January2006 M35/M45
BRAKE CONTROL SYSTEM
VDC/TCS/ABS
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Precautions for Procedures without Cowl Top Cover ..... 3
Precautions for Brake System .................................. 3
Precautions for Brake Control .................................. 4
PREPARATION ........................................................... 5
Special Service Tools ............................................... 5
Commercial Service Tools ........................................ 5
ON-VEHICLE SERVICE ............................................. 6
Adjustment of Steering Angle Sensor Neutral Posi-
tion ........................................................................... 6
SYSTEM DESCRIPTION ............................................ 7
System Diagram ....................................................... 7
Function ................................................................... 7
ABS ....................................................................... 7
EBD ....................................................................... 7
TCS ....................................................................... 7
VDC ....................................................................... 8
ECD ....................................................................... 8
Operation That Is Not "System Error" ...................... 8
ABS ....................................................................... 8
TCS ....................................................................... 8
VDC ....................................................................... 8
Fail-Safe Function .................................................... 8
ABS, EBD SYSTEM .............................................. 8
VDC / TCS ............................................................ 9
Hydraulic Circuit Diagram ........................................ 9
CAN COMMUNICATION .......................................... 10
System Description ................................................ 10
TROUBLE DIAGNOSIS .............................................11
How to Perform Trouble Diagnoses ........................ 11
BASIC CONCEPT ................................................ 11
DIAGNOSIS FLOW CHART ............................... 12
ASKING COMPLAINTS ...................................... 13
EXAMPLE OF DIAGNOSIS WORKSHEET ........ 13
Component Parts Location ..................................... 14
Schematic .............................................................. 15Wiring Diagram — VDC — ..................................... 16
CONSULT-II Functions (ABS) ................................ 22
CONSULT-II MAIN FUNCTION ........................... 22
CONSULT-II BASIC OPERATION PROCEDURE
... 22
Self-Diagnosis .....................................................
... 23
OPERATION PROCEDURE ................................ 23
ERASE MEMORY ............................................... 23
DISPLAY ITEM LIST ........................................... 24
Data Monitor ........................................................... 27
OPERATION PROCEDURE ................................ 27
DISPLAY ITEM LIST ........................................... 27
Active Test .............................................................. 30
OPERATION PROCEDURE ................................ 30
TEST ITEMS ....................................................... 31
For Fast and Accurate Diagnosis ........................... 32
PRECAUTIONS FOR DIAGNOSIS ..................... 32
Basic Inspection ..................................................... 33
BASIC INSPECTION 1: BRAKE FLUID LEVEL,
LEAK INSPECTION AND BRAKE PAD .............. 33
BASIC INSPECTION 2: LOOSENESS OF
POWER SYSTEM TERMINALS AND BATTERY ... 33
BASIC INSPECTION 3: ABS WARNING LAMP,
BRAKE WARNING LAMP, VDC OFF INDICATOR
LAMP AND SLIP INDICATOR LAMP .................. 33
Inspection 1: Wheel Sensor Circuit ........................ 34
Inspection 2: Engine System .................................. 36
Inspection 3: ABS Actuator and Electric Unit (Con-
trol Unit) .................................................................. 36
Inspection 4: ABS Actuator and Electric Unit (Con-
trol Unit) Power Supply and Ground Circuit ............ 37
Inspection 5: ABS Motor and Motor Relay Circuit ... 38
Inspection 6: Solenoid, VDC Change-Over Valve
and Actuator Relay Circuit ...................................... 40
Inspection 7: Pressure Sensor Circuit .................... 41
Inspection 8: Steering Angle Sensor Circuit ........... 41
Inspection 9: Park/Neutral Position (PNP) Switch
Circuit ..................................................................... 43
Inspection 10: Stop Lamp Switch Circuit ................ 44
Inspection 11: Yaw Rate/Side G Sensor Circuit ..... 45
Page 1435 of 5621
DI-2Revision: 2006 January2006 M35/M45 A/T INDICATOR ........................................................ 56
System Description ................................................. 56
MANUAL MODE .................................................. 56
NOT MANUAL MODE ......................................... 56
Wiring Diagram — AT/IND — ................................. 57
A/T Indicator Is Malfunction .................................... 59
WARNING CHIME .................................................. ... 60
System Description ................................................. 60
POWER SUPPLY AND GROUND CIRCUIT ....... 60
IGNITION KEY WARNING CHIME (WITH INTEL-
LIGENT KEY) ...................................................... 61
LIGHT WARNING CHIME ................................... 61
SEAT BELT WARNING CHIME ........................... 61
Component Parts and Harness Connector Location ... 62
Schematic ............................................................... 63
Wiring Diagram — CHIME — ................................. 64
Terminals and Reference Value for Combination
Meter ...................................................................... 67
Terminals and Reference Value for Unified Meter
and A/C Amp. ......................................................... 67
Terminals and Reference Value for BCM ................ 68
CONSULT-II Function (BCM) .................................. 69
CONSULT-II BASIC OPERATION ....................... 69
DATA MONITOR .................................................. 70
ACTIVE TEST ..................................................... 71
SELF-DIAG RESULTS ........................................ 71
CONSULT-II Function (METER A/C AMP) ............. 71
Trouble Diagnosis ................................................... 71
HOW TO PERFORM TROUBLE DIAGNOSIS .... 71
PRELIMINARY INSPECTION ............................. 71
SYMPTOM CHART ............................................. 72
Meter Buzzer Circuit Inspection .............................. 72
Lighting Switch Signal Inspection ........................... 73
Front Door Switch (Driver Side) Signal Inspection ... 73
Seat Belt Buckle Switch Signal Inspection ............. 74
Electrical Component Inspection ............................ 76
FRONT DOOR SWITCH (DRIVER SIDE) ........... 76
SEAT BELT BUCKLE SWITCH (DRIVER SIDE) ... 76
CAN COMMUNICATION ........................................... 77
System Description ................................................. 77
CAN Communication Unit ....................................... 77
LANE DEPARTURE WARNING SYSTEM ................ 78
Precautions for Lane Departure Warning (LDW)
system .................................................................... 78
System Description ................................................. 78
LDW SYSTEM OPERATION ............................... 78
POWER SUPPLY AND GROUND CIRCUIT ....... 80
Action Test ...........................................................
... 80
LDW SYSTEM RUNNING TEST ......................... 80
Camera Aiming Adjustment .................................... 81
OUTLINE ............................................................. 81
PREPARATION ................................................... 81TARGET SETTING .............................................. 81
VEHICLE HEIGHT CHECK ................................. 84
AIMING ADJUSTMENT ....................................... 84
Component Parts and Harness Connector Location ... 88
Wiring Diagram — LDW — ..................................... 89
Terminals and Reference Value for LDW Camera
Unit .......................................................................... 91
CONSULT-II Function (LDW) .................................. 91
DESCRIPTION .................................................... 91
CONSULT-II BASIC OPERATION ....................... 91
WORK SUPPORT ............................................... 92
SELF-DIAG RESULTS ......................................... 92
DATA MONITOR .................................................. 93
ACTIVE TEST ...................................................... 94
Trouble Diagnosis ................................................... 95
HOW TO PERFORM TROUBLE DIAGNOSIS .... 95
PRELIMINARY INSPECTION .............................. 95
SYMPTOM CHART .............................................. 96
Power Supply and Ground Circuit Inspection ......... 96
DTC [C1B00] CAMERA UNIT MALF ...................... 97
DTC [C1B01] CAM AIMING INCMP ....................... 97
DTC [C1B02] VHCL SPD DATA MALF ................... 97
DTC [C1B03] ABNRML TEMP DETECT ................ 97
DTC [U1000] CAN COMM CIRCUIT ...................... 98
DTC [U1010] CONTROL UNIT (CAN) .................... 98
LDW Chime Circuit Inspection ................................ 98
LDW Switch Circuit Inspection ................................ 99
LDW Indicator Lamp Circuit Inspection .................102
Turn Signal Input Inspection .................................103
Electrical Component Inspection ..........................103
LDW SWITCH ....................................................103
Removal and Installation for LDW Camera Unit ...103
REMOVAL ..........................................................103
INSTALLATION ..................................................103
Removal and Installation for LDW Chime .............104
REMOVAL ..........................................................104
INSTALLATION ..................................................104
Removal and Installation for LDW Switch .............104
COMPASS ...............................................................105
System Description ...............................................105
DIRECTION DISPLAY .......................................105
Zone Variation Change Procedure ........................105
Correction Functions of the Compass Display ......105
AUTOMATIC CORRECTION .............................105
MANUAL CORRECTION PROCEDURE ...........105
Wiring Diagram – COMPAS – ...............................106
Removal and Installation of Compass ...................107
CLOCK ....................................................................108
Wiring Diagram — CLOCK — ...............................108
Removal and Installation of Clock .........................109
REMOVAL ..........................................................109
INSTALLATION ..................................................109
Page 1544 of 5621
EC-1
ENGINE CONTROL SYSTEM
B ENGINE
CONTENTS
C
D
E
F
G
H
I
J
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L
M
SECTION EC
A
EC
Revision: 2006 January2006 M35/M45
ENGINE CONTROL SYSTEM
VQ35DE
INDEX FOR DTC ...................................................... 16
DTC No. Index ....................................................... 16
Alphabetical Index .................................................. 20
PRECAUTIONS ........................................................ 24
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” ................................................................ 24
Precautions for Procedures without Cowl Top Cover ... 24
On Board Diagnostic (OBD) System of Engine and
A/T .......................................................................... 24
Precaution .............................................................. 25
PREPARATION ......................................................... 28
Special Service Tools ............................................. 28
Commercial Service Tools ...................................... 29
ENGINE CONTROL SYSTEM .................................. 30
System Diagram ..................................................... 30
Multiport Fuel Injection (MFI) System .................... 31
Electronic Ignition (EI) System ............................... 33
Fuel Cut Control (At No Load and High Engine
Speed) .................................................................... 34
AIR CONDITIONING CUT CONTROL ..................... 35
Input/Output Signal Chart ....................................... 35
System Description ................................................ 35
AUTOMATIC SPEED CONTROL DEVICE (ASCD) ... 36
System Description ................................................ 36
Component Description .......................................... 37
CAN COMMUNICATION .......................................... 38
System Description ................................................ 38
EVAPORATIVE EMISSION SYSTEM ....................... 39
Description ............................................................. 39
Component Inspection ........................................... 42
Removal and Installation ........................................ 43
How to Detect Fuel Vapor Leakage ....................... 43
ON BOARD REFUELING VAPOR RECOVERY
(ORVR) ...................................................................... 46
System Description ................................................ 46
Diagnostic Procedure ............................................. 47
Component Inspection ........................................... 49POSITIVE CRANKCASE VENTILATION ................. 51
Description .............................................................. 51
Component Inspection ............................................ 51
IVIS (INFINITI VEHICLE IMMOBILIZER SYSTEM-
NATS) ........................................................................ 53
Description .............................................................. 53
ON BOARD DIAGNOSTIC (OBD) SYSTEM ............ 54
Introduction ..................................................
........... 54
Two Trip Detection Logic ........................................ 54
Emission-Related Diagnostic Information ............... 55
Malfunction Indicator Lamp (MIL) ........................... 69
OBD System Operation Chart ................................ 72
BASIC SERVICE PROCEDURE ............................... 77
Basic Inspection ..................................................... 77
Idle Speed and Ignition Timing Check .................... 82
Idle Mixture Ratio Adjustment ................................. 84
VIN Registration ..................................................... 95
Accelerator Pedal Released Position Learning ...... 95
Throttle Valve Closed Position Learning ................. 95
Idle Air Volume Learning ........................................ 96
Fuel Pressure Check .............................................. 98
TROUBLE DIAGNOSIS ..........................................100
Trouble Diagnosis Introduction .............................100
DTC Inspection Priority Chart ...............................106
Fail-Safe Chart .....................................................108
Symptom Matrix Chart ..........................................109
Engine Control Component Parts Location ..........113
Vacuum Hose Drawing .........................................121
Circuit Diagram .....................................................122
ECM Harness Connector Terminal Layout ...........124
ECM Terminals and Reference Value ...................124
CONSULT-II Function (ENGINE) ..........................133
Generic Scan Tool (GST) Function .......................146
CONSULT-II Reference Value in Data Monitor .....149
Major Sensor Reference Graph in Data Monitor
Mode .....................................................................153
TROUBLE DIAGNOSIS - SPECIFICATION VALUE .155
Description ............................................................155
Testing Condition ..................................................155
Page 1551 of 5621
EC-8Revision: 2006 January2006 M35/M45 Wiring Diagram .....................................................708
Diagnostic Procedure ...........................................709
Component Inspection ..........................................713
ASCD INDICATOR .................................................
.714
Component Description ........................................714
CONSULT-II Reference Value in Data Monitor Mode
.714
Wiring Diagram .....................................................715
Diagnostic Procedure ...........................................716
SNOW MODE SWITCH ...........................................717
Description ............................................................717
CONSULT-II Reference Value in the Data Monitor
Mode .....................................................................717
Wiring Diagram .....................................................718
Diagnostic Procedure ...........................................719
Component Inspection ..........................................721
MIL AND DATA LINK CONNECTOR ......................722
Wiring Diagram .....................................................722
SERVICE DATA AND SPECIFICATIONS (SDS) ....724
Fuel Pressure .......................................................724
Idle Speed and Ignition Timing .............................724
Calculated Load Value ..........................................724
Mass Air Flow Sensor ...........................................724
Intake Air Temperature Sensor .............................724
Engine Coolant Temperature Sensor ...................724
Fuel Tank Temperature Sensor ............................724
Crankshaft Position Sensor (POS) .......................724
Camshaft Position Sensor (PHASE) ....................724
A/F Sensor 1 Heater ............................................ .724
Heated Oxygen Sensor 2 Heater .........................725
Throttle Control Motor ...........................................725
Fuel Injector ..........................................................725
Fuel Pump ............................................................725
VK45DE
INDEX FOR DTC .....................................................726
DTC No. Index ......................................................726
Alphabetical Index ................................................730
PRECAUTIONS .......................................................734
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” ...............................................................734
Precautions for Procedures without Cowl Top Cover .734
On Board Diagnostic (OBD) System of Engine and
A/T ........................................................................734
Precaution ............................................................735
PREPARATION .......................................................738
Special Service Tools ...........................................738
Commercial Service Tools ....................................739
ENGINE CONTROL SYSTEM ................................740
System Diagram ...................................................740
Multiport Fuel Injection (MFI) System ...................741
Electronic Ignition (EI) System .............................743
Fuel Cut Control (At No Load and High Engine
Speed) ..................................................................744
AIR CONDITIONING CUT CONTROL ....................745
Input/Output Signal Chart .....................................745
System Description ...............................................745AUTOMATIC SPEED CONTROL DEVICE (ASCD) .746
System Description ...............................................746
Component Description ........................................747
CAN COMMUNICATION .........................................748
System Description ...............................................748
EVAPORATIVE EMISSION SYSTEM .....................749
Description ............................................................749
Component Inspection ..........................................752
Removal and Installation .......................................753
How to Detect Fuel Vapor Leakage ......................753
ON BOARD REFUELING VAPOR RECOVERY
(ORVR) ....................................................................756
System Description ...............................................756
Diagnostic Procedure ............................................757
Component Inspection ..........................................759
POSITIVE CRANKCASE VENTILATION ................761
Description ............................................................761
Component Inspection ..........................................761
IVIS (INFINITI VEHICLE IMMOBILIZER SYSTEM-
NATS) ......................................................................763
Description ............................................................763
ON BOARD DIAGNOSTIC (OBD) SYSTEM ...........764
Introduction ..........................................................
.764
Two Trip Detection Logic .......................................764
Emission-Related Diagnostic Information .............765
Malfunction Indicator Lamp (MIL) .........................780
OBD System Operation Chart ...............................782
BASIC SERVICE PROCEDURE .............................788
Basic Inspection ....................................................788
Idle Speed and Ignition Timing Check ..................793
Idle Mixture Ratio Adjustment ...............................795
VIN Registration ....................................................806
Accelerator Pedal Released Position Learning .....806
Throttle Valve Closed Position Learning ...............806
Idle Air Volume Learning .......................................807
Fuel Pressure Check ............................................809
TROUBLE DIAGNOSIS ..........................................811
Trouble Diagnosis Introduction .............................811
DTC Inspection Priority Chart ...............................817
Fail-Safe Chart ......................................................819
Symptom Matrix Chart ..........................................820
Engine Control Component Parts Location ...........824
Vacuum Hose Drawing .........................................833
Circuit Diagram .....................................................834
ECM Harness Connector Terminal Layout ............836
ECM Terminals and Reference Value ...................836
CONSULT-II Function (ENGINE) ..........................846
Generic Scan Tool (GST) Function .......................859
CONSULT-II Reference Value in Data Monitor .....862
Major Sensor Reference Graph in Data Monitor
Mode .....................................................................866
TROUBLE DIAGNOSIS - SPECIFICATION VALUE .868
Description ............................................................868
Testing Condition ..................................................868
Inspection Procedure ...........................................
.868
Diagnostic Procedure ............................................869
TROUBLE DIAGNOSIS FOR INTERMITTENT INCI-
Page 3008 of 5621
PRECAUTIONS
EI-3
C
D
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F
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MA
B
EI
Revision: 2006 January2006 M35/M45
PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
NIS00245
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WAR NING :
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for Procedures without Cowl Top CoverNIS00246
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
Precautions for WorkNIS00247
After removing and installing the opening/closing parts, be sure to carry out fitting adjustments to check
their operation.
Check the lubrication level, damage, and wear of each part. If necessary, grease or replace it.
PIIB3706J
Page 3013 of 5621
EI-8
SQUEAK AND RATTLE TROUBLE DIAGNOSES
Revision: 2006 January2006 M35/M45
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. Sunvisor 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 underhood 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.
Page 3065 of 5621
EM-2Revision: 2006 January2006 M35/M45 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 .................................................... 72
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 ......................................................
............ 98
Removal and Installation of Valve Oil Seal ............. 98
REMOVAL ........................................................
... 98
INSTALLATION .................................................... 98
Removal and Installation of Front Oil Seal ............. 99
REMOVAL ........................................................
... 99
INSTALLATION .................................................... 99
Removal and Installation of Rear Oil Seal .............. 99
REMOVAL ........................................................
... 99
INSTALLATION ..................................................100
CYLINDER HEAD .................................................. .101
On-Vehicle Service ...............................................101
CHECKING COMPRESSION PRESSURE .......101
Components .........................................................102Removal and Installation .......................................102
REMOVAL ..........................................................102
INSPECTION AFTER REMOVAL ......................103
INSTALLATION ..................................................104
INSPECTION AFTER INSTALLATION ..............105
Disassembly and Assembly ..................................106
COMPONENTS .................................................106
DISASSEMBLY ..................................................106
ASSEMBLY ........................................................107
Inspection after Disassembly ................................108
VALVE DIMENSIONS ........................................108
VALVE GUIDE CLEARANCE ............................108
VALVE GUIDE REPLACEMENT .......................109
VALVE SEAT CONTACT ....................................110
VALVE SEAT REPLACEMENT ..........................110
VALVE SPRING SQUARENESS ....................... 111
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD ..............................112
ENGINE ASSEMBLY ...............................................113
Components (2WD Models) ..................................113
Removal and Installation (2WD Models) ...............113
REMOVAL ..........................................................114
INSTALLATION ..................................................116
INSPECTION AFTER INSTALLATION ..............117
Components (AWD Models) .................................118
Removal and Installation (AWD Models) ..............118
REMOVAL ..........................................................119
INSTALLATION ..................................................121
INSPECTION AFTER INSTALLATION ..............122
CYLINDER BLOCK .................................................123
Components ..........................................................123
Disassembly and Assembly ..................................124
DISASSEMBLY ..................................................124
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 3067 of 5621
EM-4Revision: 2006 January2006 M35/M45 ROCKER COVER ...................................................199
Components .........................................................199
Removal and Installation ......................................199
REMOVAL ........................................................
.199
INSTALLATION ..................................................201
TIMING CHAIN ........................................................203
Components .........................................................203
Removal and Installation ......................................204
REMOVAL ........................................................
.204
INSPECTION AFTER REMOVAL ......................208
INSTALLATION ..................................................208
INSPECTION AFTER INSTALLATION ..............214
CAMSHAFT .............................................................215
Components .........................................................215
Removal and Installation ......................................215
REMOVAL ........................................................
.215
INSPECTION AFTER REMOVAL ......................216
INSTALLATION ..................................................219
INSPECTION AFTER INSTALLATION ..............221
INSPECTION AFTER INSTALLATION ..............222
Valve Clearance ....................................................222
INSPECTION .....................................................222
ADJUSTMENT ..................................................225
OIL SEAL ................................................................229
Removal and Installation of Valve Oil Seal ...........229
REMOVAL ........................................................
.229
INSTALLATION ..................................................229
Removal and Installation of Front Oil Seal ...........230
REMOVAL ........................................................
.230
INSTALLATION ..................................................230
Removal and Installation of Rear Oil Seal ............231
REMOVAL ........................................................
.231
INSTALLATION ..................................................231
CYLINDER HEAD .................................................. .233
On-Vehicle Service ...............................................233
CHECKING COMPRESSION PRESSURE .......233
Components .........................................................234
Removal and Installation ......................................234
REMOVAL ........................................................
.234
INSPECTION AFTER REMOVAL ......................235
INSTALLATION ..................................................235
Disassembly and Assembly ..................................237
COMPONENTS .................................................237
DISASSEMBLY .................................................237
ASSEMBLY ......................................................
.238
Inspection after Disassembly ................................239
VALVE DIMENSIONS ........................................239
VALVE GUIDE CLEARANCE ............................240
VALVE GUIDE REPLACEMENT .......................240
VALVE SEAT CONTACT ...................................242
VALVE SEAT REPLACEMENT .........................242
VALVE SPRING SQUARENESS .......................243
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD .............................243ENGINE ASSEMBLY ...............................................244
Components ..........................................................244
Removal and Installation .......................................244
REMOVAL ..........................................................245
INSTALLATION ..................................................247
INSPECTION AFTER INSTALLATION ..............247
CYLINDER BLOCK .................................................249
Components ..........................................................249
Disassembly and Assembly ..................................250
DISASSEMBLY ..................................................250
ASSEMBLY ........................................................254
How to Select Piston and Bearing ........................259
DESCRIPTION ..................................................259
HOW TO SELECT PISTON ...............................260
HOW TO SELECT CONNECTING ROD BEAR-
ING .....................................................................261
HOW TO SELECT MAIN BEARING ..................262
Inspection after Disassembly ................................266
CRANKSHAFT END PLAY ................................266
CONNECTING ROD SIDE CLEARANCE .........266
PISTON TO PISTON PIN OIL CLEARANCE .....266
PISTON RING SIDE CLEARANCE ...................267
PISTON RING END GAP ..................................267
CONNECTING ROD BEND AND TORSION .....268
CONNECTING ROD BIG END DIAMETER ......268
CONNECTING ROD BUSHING OIL CLEAR-
ANCE .................................................................268
CYLINDER BLOCK DISTORTION ....................269
MAIN BEARING HOUSING INNER DIAMETER .270
PISTON TO CYLINDER BORE CLEARANCE ..270
CRANKSHAFT MAIN JOURNAL DIAMETER ...271
CRANKSHAFT PIN JOURNAL DIAMETER ......272
CRANKSHAFT OUT-OF-ROUND AND TAPER .272
CRANKSHAFT RUNOUT ..................................272
CONNECTING ROD BEARING OIL CLEAR-
ANCE .................................................................273
MAIN BEARING OIL CLEARANCE ...................274
CRUSH HEIGHT OF MAIN BEARING ..............275
CRUSH HEIGHT OF CONNECTING ROD
BEARING ...........................................................275
DRIVE PLATE ....................................................275
SERVICE DATA AND SPECIFICATIONS (SDS) ....276
Standard and Limit ................................................276
GENERAL SPECIFICATIONS ...........................276
DRIVE BELTS ....................................................276
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD .................................................................276
SPARK PLUG ....................................................277
CAMSHAFT AND CAMSHAFT BEARING .........277
CYLINDER HEAD ..............................................279
CYLINDER BLOCK ............................................282
PISTON, PISTON RING AND PISTON PIN ......283
CONNECTING ROD ..........................................284
CRANKSHAFT ...................................................285
MAIN BEARING .................................................287
CONNECTING ROD BEARING .........................288
Page 3387 of 5621
FFD-10
FRONT OIL SEAL
Revision: 2006 January2006 M35/M45
INSTALLATION
1. Apply multi-purpose grease to front oil seal lips.
2. Using the drifts, install front oil seal as shown in figure.
CAUTION:
Do not reuse oil seal.
When installing, do not incline oil seal.
3. Align the matching mark (B) of drive pinion with the matching
mark (A) of companion flange, and then install the companion
flange (1).
4. Apply anti-corrosion oil to the thread and seat of new drive pin-
ion lock nut, and temporarily tighten drive pinion lock nut to drive
pinion.
CAUTION:
Do not reuse drive pinion lock nut.
5. Tighten to drive pinion lock nut, while adjust total preload torque.
CAUTION:
Adjust to the lower limit of the drive pinion lock nut tight-
ening torque first.
After adjustment, rotate drive pinion back and forth 2 to 3
times to check for unusual noise, rotation malfunction,
and other malfunctions.
If measured value is out of the specification, remove final
drive assembly and disassemble drive pinion parts to check
and adjust each part. Refer to FFD-13, "
Removal and Installa-
tion" and FFD-15, "Disassembly and Assembly" .
6. Install front propeller shaft. Refer to PR-5, "
Removal and Installation" .
7. Install side shaft assembly.
8. Install front drive shaft both. Refer to FA X - 11 , "
Removal and Installation" .
9. Refill gear oil to the final drive and check oil level. Refer to FFD-8, "
FILLING" .
10. Check the final drive for oil leakage. Refer to FFD-8, "
OIL LEAKAGE AND OIL LEVEL" . Tool number A: ST33400001 (J-26082)
B: KV38102510 ( — )
PDIA0786J
PDIA0783J
Tool number A: ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque:
127.4 - 245.0 Nꞏm (13.0 - 25.0 kg-m, 94 - 181 ft-lb)
Total preload torque:
1.56 - 2.65 Nꞏm (0.16 - 0.27 kg-m, 14 - 23 in-lb)
PDIA0969E
Page 3407 of 5621
FFD-30
FRONT FINAL DRIVE ASSEMBLY
Revision: 2006 January2006 M35/M45
10. Install companion flange (1).
NOTE:
When reusing drive pinion, align the matching mark (B) of drive
pinion with the matching mark (A) of companion flange, and then
install companion flange (1).
11. Apply anti-corrosion oil to the thread and seat of new drive pin-
ion lock nut, and temporarily tighten drive pinion lock nut to drive
pinion.
CAUTION:
Do not reuse drive pinion lock nut.
12. Tighten to drive pinion lock nut, while adjust pinion bearing pre-
load torque.
CAUTION:
Adjust to the lower limit of the drive pinion lock nut tight-
ening torque first.
After adjustment, rotate drive pinion back and forth 2 to 3
times to check for unusual noise, rotation malfunction,
and other malfunctions.
13. Install differential case assembly. Refer to FFD-30, "
Differential
Assembly" .
CAUTION:
Do not install carrier cover yet.
14. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion
flange runout. Refer to FFD-17, "
Drive Gear Runout" , FFD-17, "Tooth Contact" , FFD-19, "Backlash" ,
FFD-19, "
Companion Flange Runout" .
Recheck above items. Readjust the above description, if necessary.
15. Check total preload torque. Refer to FFD-16, "
Total Preload Torque" .
16. Install carrier cover. Refer to FFD-30, "
Differential Assembly" .
Differential Assembly
1. Install side gear thrust washers with the same thickness as the
ones installed prior to disassembly or reinstall the old ones on
the side gears.
PDIA0799J
Tool number A: ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque:
127.4 - 245.0 Nꞏm (13.0 - 25.0 kg-m, 94 - 181 ft-lb)
Pinion bearing preload:
0.78 - 1.57 Nꞏm (0.08 - 0.16 kg-m, 7 - 13 in-lb)
PDIA0802J
SDIA0193J