Engine Mechanical: Other Infiniti FX35 I

PRECAUTIONS NECESSARY FOR STEERING WHEEL ROTATION AFTER BATTERY DISCONNECT

Note. This Procedure is applied only to models with Intelligent Key system and NVIS/IVIS (NISSAN/INFINITI VEHICLE IMMOBILIZER SYSTEM - NATS). Remove and install all control units after disconnecting both battery cables with the ignition knob in the "LOCK" position. Always use CONSULT-II to perform self-diagnosis as a part of each function inspection after finishing work. If DTC is detected, perform trouble diagnosis according to self-diagnostic results.

For models equipped with the Intelligent Key system and NVIS/IVIS, an electrically controlled steering lock mechanism is adopted on the key cylinder.

For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and steering wheel rotation will become impossible.

If steering wheel rotation is required when battery power is interrupted, follow the procedure below before starting the repair operation.

PRECAUTIONS FOR DISCONNECTING FUEL PIPING

1. Before starting work, make sure no fire or spark producing items are in the work area.
2. Release fuel pressure before disconnecting and disassembly.
3. After disconnecting pipes, plug openings to stop fuel leakage.

SPECIAL SERVICE TOOLS

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Scheme 274

Scheme 275

Scheme 276

Scheme 277

Scheme 278

Scheme 279

Scheme 280

Note. Use (Scheme 281) to help you find the cause of the symptom. Locate the area where noise occurs. Confirm the type of noise. Specify the operating condition of engine. Check specified noise source.

If necessary, repair or replace these parts.

Scheme 281

CHECKING DRIVE BELTS

Scheme 282

1. Inspect belts for cracks, fraying, wear and oil. If necessary, replace.
2. Inspect drive belt deflection or tension at a point on belt midway between pulleys. Inspection should be done only when engine is cold, or over 30 minutes after engine is stopped. Measure belt tension with belt tension gauge (Commercial service tool: BT3373-F or equivalent) at points marked shown in the figure. When measuring deflection, apply 98 N (10 kg, 22 lb) at the marked point. Adjust if belt deflection exceeds the limit or if belt tension is not within specifications. CAUTION: When checking belt deflection or tension immediately after installation, first adjust it to the specified value. Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflection between pulleys. Tighten idler pulley lock nut by hand and measure deflection or tension without looseness.

Scheme 283

Air Conditioner Compressor Belt

1. Remove front engine undercover with power tool.
2. Loosen idler pulley lock nut (C) and adjust tension by turning adjusting bolt (D). see scheme 15 For specified belt tension, refer to «CHECKING DRIVE BELTS»(ref-158850-S16142496872005020300000).
3. Tighten nut (C). 34.8 N.m (3.5 kg-m, 26 ft-lb)

Intake Manifold Collector (Lower)

Tighten in numerical order as shown in the figure.

Note. Tighten mounting bolts to secure gasket (lower), intake manifold collector (lower), gasket (upper), and intake manifold collector cover.

Scheme 284

Scheme 285

1. If stud bolts were removed, install them and tighten to the specified torque below. 5.9 N.m (0.6 kg-m, 52 in-lb)
2. Shank length under bolt head varies with bolt location. Install bolts while referring to numbers shown and in (Scheme 285). (Bolt length does not include pilot portion.) Bolt M6 x 25 mm (0.98 in): 7, 8, 10, 11, 13, 14, 15, 16, 18 M6 x 45 mm (1.77 in): 2, 4, 5 M6 x 60 mm (2.36 in): 1, 3, 6, 9 M6 Nut: 12, 17
3. Tighten in numerical order as shown in the figure.

Water Hose

1. Insert hose by 27 to 32 mm (1.06 to 1.26 in) from connector end.
2. Clamp hose at location of 3 to 7 mm (0.12 to 0.28 in) from hose end.

Scheme 286

1. Install gasket with three protrusions for installation check facing any direction other than upward.
2. Tighten in numerical order (Scheme 286)
3. Perform the "Throttle Valve Closed Position Learning" when harness connector of electric throttle control actuator is disconnected. Refer to THROTTLE VALVE CLOSED POSITION LEARNING.
4. Perform the "Idle Air Volume Learning" and "Throttle Valve Closed Position Learning" when electric throttle control actuator is replaced. Refer to IDLE AIR VOLUME LEARNING.

Scheme 287

Scheme 288

1. Release fuel pressure. Refer to FUEL PRESSURE RELEASE .
2. Remove intake manifold collector (upper and lower). Refer to «INTAKE MANIFOLD COLLECTOR»(ref-158850-S25261397642005020300000) .
3. Remove fuel tube and fuel injector assembly. Refer to «FUEL INJECTOR AND FUEL TUBE»(ref-158850-S33821907532005020300000) .
4. Loosen bolts and nuts in reverse order of illustration to remove intake manifold with power tool.
5. Remove intake manifold gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

Scheme 289

1. Check the surface distortion of the intake manifold mating surface with straightedge and feeler gauge. Limit : 0.1 mm (0.04 in)
2. If it exceeds the limit, replace intake manifold.

Air Fuel Ratio Sensor and Heated Oxygen Sensor

Scheme 290

Check on Fuel Leakage

1. After installing fuel tubes, make sure there is no fuel leakage at connections in the following steps. a) Apply fuel pressure to fuel lines with turning ignition switch "ON" (with engine stopped). Then check for fuel leaks at connections. b) Start engine and rev it up and check for fuel leaks at connections. NOTE: Use mirrors for checking on invisible points.

Scheme 291

Scheme 292

1. Remove intake manifold collector (upper and lower). Refer to «INTAKE MANIFOLD COLLECTOR»(ref-158850-S25261397642005020300000) .
2. Remove ignition coil. Refer to «IGNITION COIL»(ref-158850-S36818243042005020300000) .
3. Remove PCV hoses from rocker covers.
4. Loosen bolts in the reverse order shown in the figure (with power tool).
5. Use scraper to remove all traces of liquid gasket from cylinder head and camshaft bracket.

Scheme 293

Scheme 294

1. Apply liquid gasket of 3.0 mm (0.12 in) diameter to position shown in the figure (both edges of No. 1 camshaft bracket) (on both banks). First, apply it to engine longitudinal direction [5.0 mm (0.197 in) + 5.0 mm (0.197 in) side in figure]. Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS.
2. Install rocker cover. Check if rocker cover gasket is dropped from installation groove of rocker cover.
3. Tighten bolts two steps separately in order numbers in illustration. 1st step: 1.96 N.m (0.20 kg-m, 17 in-lb) 2nd step: 8.33 N.m (0.85 kg-m, 74 in-lb)
4. Install PCV hose. Insert PCV hose by 25 to 30 mm (0.98 to 1.18 in) from connector end. When installing, be careful not to twist or come in contact with other parts. Install PCV hose between right and left rocker covers with its identification paint facing upward (right rocker cover side). (Scheme 291)
5. Install in the reverse order of removal after this step.

Timing Chain

Check for cracks and any excessive wear at link plates and roller links of timing chain. Replace timing chain as necessary.

Scheme 295

Outer Diameter of Camshaft Journal

Measure outer diameter of camshaft journal.

Scheme 296

1. Standard outer diameter: No. 1 : 25.935 - 25.955 mm (1.0211 - 1.0218 in) No. 2, 3, 4 : 23.445 - 23.465 mm (0.9230 - 0.9238 in)

Scheme 297

1. Tighten camshaft bracket bolt with specified torque. Refer to «INSTALLATION»(ref-158850-S41067908182005020300000) .
2. Using inside micrometer, measure inner diameter "A" of camshaft bracket. Standard inner diameter: No. 1 : 26.000 - 26.021 mm (1.0236 - 1.0244 in) No. 2, 3, 4 : 23.500 - 23.521 mm (0.9252 - 0.9260 in)

Calculation of Camshaft Journal Oil Clearance

(Journal oil clearance) = (inner diameter of camshaft bracket) - (outer diameter of camshaft journal).

1. Standard: No. 1 : 0.045 - 0.086 mm (0.0018 - 0.0034 in) No. 2, 3, 4 : 0.035 - 0.076 mm (0.0014 - 0.0030 in)
2. Limit : 0.15 mm (0.0059 in)

If it exceeds the limit, replace either or both camshaft and cylinder head.

Note. Camshaft brackets cannot be replaced as a single part, because it is machined together with cylinder head. Replace whole cylinder head assembly.

Scheme 298

Scheme 299

1. Install dial indicator in thrust direction on front end of camshaft. Measure end play of dial indicator when camshaft is moved forward/backward (in direction to axis). Standard : 0.115 - 0.188 mm (0.0045 - 0.0074 in) Limit : 0.24 mm (0.0094 in)
2. Measure the following parts if out of the limit. Dimension "A" for camshaft No. 1 journal Standard : 27.500 - 27.548 mm (1.0827 - 1.0846 in) Dimension "B" for cylinder head No. 1 journal Standard : 27.360 - 27.385 mm (1.0772 - 1.0781 in)
3. Refer to the standards above, and then replace camshaft and/or cylinder head.

Scheme 300

1. Put V-block on precise flat table, and support No. 2 and No. 4 journal of camshaft. CAUTION: Do not support journal No. 1 (on the side of camshaft sprocket) because it has a different diameter from the other three locations.
2. Measure camshaft sprocket runout with dial indicator. (Total indicator reading) Limit : 0.15 mm (0.0059 in)

1. If it exceeds the limit, replace camshaft sprocket.

Valve Lifter

Check if surface of valve lifter has any wear or cracks.

Scheme 301

1. If anything above is found, replace valve lifter.

Outer Diameter of Valve Lifter

Measure outer diameter at 1/2 height of valve lifter with micrometer since valve lifter is in barrel shape.

Scheme 302

1. Valve lifter outer diameter (Intake and exhaust): 33.977 - 33.987 mm (1.3377 - 1.3381 in)

Valve Lifter Hole Diameter

Using inside micrometer, measure diameter of valve lifter hole of cylinder head.

Scheme 303

1. Standard (Intake and exhaust): 34.000 - 34.016 mm (1.3386 - 1.3392 in)

Calculation of Valve Lifter Clearance

(Valve lifter clearance) = (hole diameter of valve lifter) - (outer diameter of valve lifter).

1. Standard (Intake and exhaust): 0.013 - 0.039 mm (0.0005 - 0.0015 in)

If it exceeds the standard, referring to each standard of valve lifter outer diameter and valve lifter hole diameter, replace either or both valve lifter and cylinder head.

Scheme 304

Scheme 305

Scheme 306

Scheme 307

Scheme 308

Scheme 309

Scheme 310

Scheme 311

Scheme 312

Scheme 313

1. Install secondary chain tensioners on both sides of cylinder head. Install chain tensioner with its stopper pin attached. Install tensioner with sliding part facing downward on rightside cylinder head, and with sliding part facing upward on left-side cylinder head. Install new O-ring as shown.
2. Install valve lifter. Install it in the original position.
3. Install camshafts. Install camshaft with dowel pin attached to its front end face on exhaust side. Follow your identification marks made during removal, or follow the identification marks that are present on new camshafts for proper placement and direction. Install camshaft so that dowel pin hole and dowel pin on front end face are positioned as shown in figure. (No. 1 cylinder TDC on its compression stroke) NOTE: Large- and small-pin holes are located on front end face of intake camshaft, at intervals of 180°. Face small dia. side pin hole upward (in cylinder head upper face direction).
4. Install camshaft brackets. Remove foreign material completely from camshaft bracket backside and from cylinder head installation face. Install camshaft bracket in original position and direction as shown in figure. Install No. 2 to 4 camshaft brackets aligning stamp marks as shown. NOTE: There are no identification marks indicating left and right for No. 1 camshaft bracket. Apply liquid gasket to mating surface of No. 1 camshaft bracket as shown on right and left banks. Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS .
5. Tighten camshaft brackets in the following steps, in numerical order as shown. Tighten No. 7 to 10, then tighten No. 1 to 6 in order as shown. 1.96 N.m (0.20 kg-m, 1 ft-lb) Tighten all bolts in numerical order as shown. 5.88 N.m (0.60 kg-m, 4 ft-lb) Tighten all bolts in the numerical order as shown. 10.4 N.m (1.1 kg-m, 8 ft-lb) CAUTION: After tightening mounting bolts of No. 1 camshaft brackets, be sure to wipe off excessive liquid gasket from the parts list below. Mating surface of rocker cover Mating surface of rear timing chain case
6. Measure difference in levels between front end faces of No. 1 camshaft bracket and cylinder head. Standard : -0.14 to 0.14 mm (-0.0055 to 0.0055 in) If measurement is outside the specified range, re-install camshaft and camshaft bracket.
7. Inspect and adjust valve clearance. Refer to «VALVE CLEARANCE»(ref-158850-S00775506132005020300000) .
8. Install in the reverse order of removal after this step.

Cylinder Head Distortion

Note. When performing this inspection, cylinder block distortion should be also checking. Refer to CYLINDER BLOCK DISTORTION .

Scheme 314

1. Using scraper, wipe off oil, scale, gasket, sealant and carbon deposits from surface of cylinder head. CAUTION: Do not allow gasket fragments to enter engine oil or engine coolant passages.
2. At each of several locations on bottom surface of cylinder head, measure distortion in six directions. Limit: 0.1 mm (0.004 in) If it exceeds the limit, replace cylinder head.

Scheme 315

Scheme 316

Scheme 317

Scheme 318

1. Install cylinder head gasket.
2. Turn crankshaft until No. 1 piston is set at TDC on the compression stroke. Crankshaft key should line up with the right bank cylinder center line as shown.
3. Install cylinder head following steps below to tighten cylinder head bolts in the order shown in figure. Tighten all bolts. 8.1 N.m (10 kg-m, 72 ft-lb) Completely loosen. 0 N.m (0kg-m, O ft-lb) CAUTION: In step "b", loosen bolts in the reverse order of that indicated in (Scheme 316). Tighten all bolts. 39.2 N.m (4.0 kg-m, 29 ft-lb) Turn all bolts "90" degrees clockwise (angle tightening). Turn all bolts "90" degrees clockwise again [target: 90 degrees (angle tightening)]. CAUTION: Check and confirm the tightening angle by using angle wrench (SST) and cylinder head bolt wrench (commercial service tool). Avoid judgment by visual inspection without SST. Check tightening angle indicated on angle wrench (SST) indicator plate.
4. After installing cylinder head, measure distance between front end faces of cylinder block and cylinder head (left and right banks). Standard: 14.1 - 14.9 mm (0.555-0.587 in) If measurement is outside the specified range, re-install cylinder head.
5. Perform steps in reverse order of removal for the following operations.

Scheme 319

Scheme 320

Scheme 321

1. Remove spark plug with spark plug wrench (commercial service tool).
2. Remove valve lifter. Mark position on valve lifter for assembly.
3. Remove valve collet. Compress valve spring with valve spring compressor, attachment and adapter (SST). Remove valve collet with magnet hand. CAUTION: When working, take care not to damage valve lifter holes.
4. Remove valve spring retainer and valve spring.
5. Push valve stem to combustion chamber side, and remove valve. Inspect valve guide clearance before removal. Refer to «VALVE GUIDE CLEARANCE»(ref-158850-S34697962652005020300000) . Mark position on valve for assembly.
6. Remove valve oil seals using valve oil seal puller (SST).
7. Remove valve spring seat.
8. If valve seat must be replaced, refer to «VALVE SEAT CONTACT»(ref-158850-S04693421692005020300000) .
9. If valve guide must be replaced, refer to «VALVE GUIDE CLEARANCE»(ref-158850-S34697962652005020300000) .
10. Remove spark plug tube, as necessary. Using a pair of pliers, pull spark plug tube out of cylinder head. CAUTION: Take care not to damage cylinder head. Once removed, a spark plug tube will be deformed and cannot be reused. Do not remove it unless absolutely necessary.

Scheme 322

Scheme 323

Scheme 324

Scheme 325

1. When valve guide is removed, install it. Refer to «VALVE GUIDE CLEARANCE»(ref-158850-S34697962652005020300000).
2. When valve seat is removed, install it. Refer to «VALVE SEAT CONTACT»(ref-158850-S04693421692005020300000).
3. Install valve oil seals. Install with valve oil seal drift (SST) to match dimension in illustration. Height "H" (Without valve spring seat installed) Intake and exhaust: 14.3 - 14.9 mm (0.563 - 0.587 in)
4. Install valve spring seat.
5. Install the valves. Larger diameter valves are for intake side.
6. Install valve spring (uneven pitch type). Install smaller pitch end (paint mark) to cylinder head side (valve spring seat side).
7. Install valve spring retainer.
8. Install valve collet. Compress valve spring with valve spring compressor, attachment and adapter (SST). Install valve collet with magnet hand. CAUTION: When working, take care not to damage valve lifter holes. Tap valve stem edge lightly with plastic hammer after installation to check its installed condition.
9. Install valve lifter.
10. Install spark plug tube. Press-fit spark plug tube following procedure below. Remove old liquid gasket adhering to cylinder-head mounting hole. Apply liquid gasket to area within approximately 12 mm (0.47 in) from edge of spark plug tube press-fit side. Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS. Using a drift, press-fit spark plug tube so that its height "H" is as specified in (Scheme 325). Standard press-fit height "H": 38.55 - 38.65 mm (1.5177 - 1.5217 in) CAUTION: When press-fitting, take care not to deform spark plug tube. After press-fitting, wipe off liquid gasket protruding onto cylinder-head upper face.
11. Install spark plug.

Scheme 326

1. Check dimensions of each valve. For dimensions (Scheme 385)
2. If dimensions are out of the standard, replace valve.

Valve Stem Diameter

Measure inner diameter of valve guide with inside micrometer.

Scheme 327

1. Standard Intake: 5.965 - 5.980 mm (0.2348 - 0.2354 in) Exhaust: 5.955 - 5.970 mm (0.2344 - 0.2350 in)

Valve Guide Inner Diameter

Measure inner diameter of valve guide with inside micrometer.

1. Standard Intake and: 6.000 - 6.018 mm (0.2362 - 0.2369 in) Exhaust

Valve Guide Clearance

1. (Valve guide clearance) = (Valve guide inner diameter) - (Valve stem diameter). Valve guide clearance: Standard Intake: 0.020 - 0.053 mm (0.0008 - 0.0021 in) Exhaust: 0.030 - 0.063 mm (0.0012 - 0.0025 in) Limit Intake: 0.08 mm (0.003 in) Exhaust: 0.09 mm (0.004 in)
2. If it exceeds the limit, replace valve guide and / or valve.

Outline

At first, remove engine and transmission assembly with suspension member downward. The separate engine from transmission.

Preparation

1. Release fuel pressure. Refer to FUEL PRESSURE RELEASE .
2. Disconnect both battery terminals.
3. Remove engine cover (Refer to «INTAKE MANIFOLD COLLECTOR»(ref-158850-S25261397642005020300000) battery cover and LH/RH sides front tire.
4. Remove front and rear engine undercover and front cross bar with power tool.
5. Drain engine coolant from radiator drain plug. Refer to CHANGING ENGINE COOLANT .
6. Remove cowl top cover RH. Refer to COWL TOP .
7. Remove air duct and air cleaner case assembly. Refer to «AIR CLEANER AND AIR DUCT»(ref-158850-S12244247462005020300000) .
8. Remove radiator upper and lower hoses. Refer to RADIATOR .

Scheme 328

1. Disconnect heater hose from vehicle-side, and fit a plug onto hose end to prevent engine coolant leak.
2. Disconnect grounding wire (between vehicle to left bank cylinder head).
3. Disconnect battery positive cable at vehicle side and temporarily fasten it on engine.
4. Disconnect engine room harness connectors shown in the figure
5. Disconnect A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope.
6. Disconnect two body ground cables.
7. Disconnect brake booster vacuum hose.
8. Disconnect fuel feed hose and EVAP hose. CAUTION: Fit plugs onto disconnected hoses to prevent fuel leak.
9. Remove power steering oil pump reservoir tank and piping from vehicle, and temporarily secure them on engine. Refer to POWER STEERING OIL PUMP . CAUTION: When temporarily securing, keep them upright to avoid a fluid leak.

Scheme 329

1. Follow procedure below to disconnect engine room harness connectors at passenger room side, and temporarily secure them on engine. Remove passenger-side kicking plate dash side finisher, and glove box. Refer to BODY SIDE TRIM and INSTRUMENT PANEL ASSEMBLY . Disconnect engine room harness connectors at unit sides ECM and other. Disengage intermediate fixing point. Pull out engine room harnesses to engine room side, and temporarily secure them on engine. CAUTION: When pulling out harnesses, take care not to damage harnesses and connectors. After temporarily securing, cover connectors with vinyl or similar material to protect against foreign material adhesion.

Vehicle Underbody

1. Remove A/T fluid cooler hoses and power steering oil pump oil cooler hoses.
2. Remove exhaust front tube. Refer to EXHAUST SYSTEM .
3. Disconnect steering lower joint, and release steering shaft. Refer to STEERING COLUMN .
4. Separate transmission and propeller shaft. Refer to REAR PROPELLER SHAFT .
5. Disengage shift control linkage at selector lever side. Then, temporarily secure it on transmission, so that it does not sag.
6. Remove rear plate cover from upper oil pan. Then, remove bolts fixing drive plate to torque converter.
7. Remove bolts fixing transmission to lower rear side of upper oil pan.
8. Remove front stabilizer. Refer to «REMOVAL & INSTALLATION»(ref-166182-S14780889182004091500000) .
9. Remove LH and RH sides tie-rod ends from steering knuckle. Refer to «REMOVAL & INSTALLATION»(ref-166182-S14780889182004091500000) .
10. Remove lower ends of LH and RH sides struts from lower arms. Refer to «REMOVAL & INSTALLATION»(ref-166182-S14780889182004091500000) .
11. Remove LH and RH sides lower arms from suspension member. Refer to «REMOVAL & INSTALLATION»(ref-166182-S14780889182004091500000) .

At first, remove engine and transmission assembly with suspension member downward. Then separate engine from transmission.

1. Release fuel pressure. Refer to FUEL PRESSURE RELEASE .
2. Disconnect both battery terminals.
3. Remove engine cover (Refer to «INTAKE MANIFOLD COLLECTOR»(ref-158850-S25261397642005020300000) , battery cover and LH/RH sides front tire.
4. Remove front and rear engine undercover and front cross bar with power tool.
5. Drain engine coolant from radiator drain plug. Refer to CHANGING ENGINE COOLANT .
6. Remove cowl top cover RH. Refer to COWL TOP .
7. Remove air duct and air cleaner case assembly. Refer to «AIR CLEANER AND AIR DUCT»(ref-158850-S12244247462005020300000) .
8. Remove radiator upper and lower hoses. Refer to RADIATOR .

Scheme 330

1. Disconnect heater hose from vehicle-side, and fit a plug onto hose end to prevent engine coolant leak.
2. Disconnect grounding wire (between vehicle to left bank cylinder head).
3. Disconnect battery positive cable at vehicle side and temporarily fasten it on engine.
4. Disconnect engine room harness connectors shown in the figure.
5. Disconnect A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope.
6. Disconnect two body ground cables.
7. Disconnect brake booster vacuum hose.
8. Disconnect fuel feed hose and EVAP hose. CAUTION: Fit plugs onto disconnected hoses to prevent fuel leak.
9. Remove power steering oil pump reservoir tank and piping from vehicle, and temporarily secure them on engine. Refer to POWER STEERING OIL PUMP . CAUTION: When temporarily securing, keep them upright to avoid a fluid leak.

Scheme 331

1. Follow procedure below to disconnect engine room harness connectors at passenger room side, and temporarily secure them on engine. Remove passenger-side kicking plate, dash side finisher, and glove box. Refer to BODY SIDE TRIM and INSTRUMENT PANEL ASSEMBLY . Disconnect engine room harness connectors at unit sides ECM and other. Disengage intermediate fixing point. Pull out engine room harnesses to engine room side, and temporarily secure them on engine. CAUTION: When pulling out harnesses, take care not to damage harnesses and connectors. After temporarily securing, cover connectors with vinyl or similar material to protect against foreign material adhesion.

1. Remove A/T fluid cooler hoses and power steering oil pump oil cooler hoses.
2. Remove exhaust front tube. Refer to EXHAUST SYSTEM .
3. Disconnect steering lower joint, and release steering shaft. Refer to STEERING COLUMN .
4. Separate transmission and propeller shaft. Refer to REAR PROPELLER SHAFT .
5. Disengage shift control linkage at selector lever side. Then, temporarily secure it on transmission, so that it does not sag.
6. Remove rear plate cover from upper oil pan. Then, remove bolts fixing drive plate to torque converter.
7. Remove bolts fixing transmission to lower rear side of upper oil pan.
8. Remove LH and RH sides tie-rod ends from steering knuckle. Refer to «REMOVAL & INSTALLATION»(ref-166182-S14780889182004091500000) .
9. Remove lower ends of LH and RH sides struts from lower arms. Refer to «REMOVAL & INSTALLATION»(ref-166182-S14780889182004091500000) .
10. Remove LH and RH sides lower arms from suspension member. Refer to «REMOVAL & INSTALLATION»(ref-166182-S14780889182004091500000) .
11. Remove LH and RH sides front drive shafts from LH and RH sides knuckles. Refer to «REMOVAL, OVERHAUL & INSTALLATION»(ref-165270-S16927743042004082400000) .

Scheme 332

1. Use a manual lift table caddy (commercial service tool) or equivalently rigid tool such as a 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.
2. Remove rear member mounting bolt.
3. Remove suspension member mounting bolt and nut. Refer to «REMOVAL & INSTALLATION»(ref-166182-S14780889182004091500000) .
4. Carefully lower jack to remove engine, transmission, and suspension member assembly. When performing work, observe the following: CAUTION: Confirm there is no interference with vehicle. Make sure all connection points have been disconnected. 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 lift.

Scheme 333

1. Install engine slingers into front of RH bank cylinder head and rear of left bank cylinder head. Slinger bolts: 28.0 N.m (2.9 kg-m, 21 ft-lb)
2. Remove power steering oil pump from engine side. Refer to POWER STEERING OIL PUMP .
3. Remove engine mounting insulator RR under side nut with power tool.
4. Lift with hoist and separate engine and transmission assembly from suspension member. CAUTION: Before and during this lifting, always check if any harnesses are left connected. Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
5. Remove front drive shaft LH and RH sides. Refer to «REMOVAL, OVERHAUL & INSTALLATION»(ref-165270-S16927743042004082400000) .
6. Remove alternator. Refer to «GENERATOR»(ref-166067-S04166173422004091000000) .
7. Remove starter motor. Refer to «REMOVAL & INSTALLATION»(ref-167750-S19717379932004102000000) .
8. Remove front propeller shaft from front final drive assembly side. Refer to FRONT PROPELLER SHAFT .
9. Separate engine from transmission assembly. Refer to «REMOVAL & INSTALLATION»(ref-171001) .
10. Remove engine mounting insulator FR and engine mounting bracket with power tool.
11. Remove front final drive assembly from oil pan (upper). Refer to FRONT FINAL DRIVE ASSEMBLY .

When New Cylinder Block is Used

Check cylinder bore grade ("1", "2", or "3") on rear side of cylinder block, and select a 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.)

Scheme 334

Scheme 335

1. Measure the cylinder block bore inner diameter.
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner diameter of the "Piston Selection Table".
3. Select piston of the same grade.

Scheme 336

Note. Piston is available together with piston pin as an assembly. Piston pin (piston pin bore) 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.

When New Connecting Rod and Crankshaft are Used

Check pin diameter grade number ("0", "1", or "2") stamped in front of crankshaft, and select connecting rod bearing of same grade number.

Note. There is no grading for connecting rod big end inner diameter.

Scheme 337

Scheme 338

1. Measure dimensions of the big end inner diameter of connecting rod and outer diameter of crankshaft pin individually.
2. Confirm the big end inner diameter of connecting rod is within the standard value.
3. Apply the measured dimension to the "Connecting Rod Bearing Selection Table".
4. Determine the grade of crankshaft pin diameter grade by comparing the measurement with the values under the crankshaft pin outer diameter of (Scheme 339).
5. Select connecting rod bearing of the same grade.

Undersize Bearings Usage Guide

1. When the specified oil clearance is not obtained with standard size connecting rod bearings, use undersize (US) bearings.
2. When using undersize bearing, measure the bearing inner diameter with bearing installed, and grind crankshaft pin so that the oil clearance satisfies the standard.

Scheme 339

Scheme 340

Scheme 341

Scheme 342

1. «MAIN BEARING SELECTION TABLE»(ref-158850-S33745774602005020300000) rows correspond to bearing housing grade on rear left side of cylinder block.
2. Apply journal diameter grade stamped on crankshaft front side to column in (Scheme 344).
3. Find sign (main bearing grade) at crossing of row and column in (Scheme 344).

When Cylinder Block and Crankshaft are Reused

1. Measure inner diameter of cylinder block main bearing housing and outer diameter of crankshaft journal.
2. Find measured dimension in "Cylinder block bearing housing inner diameter" row of (Scheme 344).
3. Find the measured dimension in "Crankshaft main journal diameter" column in (Scheme 344).
4. Select main bearing grade at the point where selected row and column meet in (Scheme 344).

Scheme 343

Scheme 344

Scheme 345

1. Use undersize (US) bearing when oil clearance with standard size main bearing is not within specification.
2. When using undersize (US) bearing, measure the bearing inner diameter with bearing installed, and grind journal until oil clearance falls within specification.

Scheme 346

Scheme 347

1. Using a dial gauge, measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward. Standard: 0.10-0.25 mm (0.0039-0.0098 in) Limit: 0.30 mm (0.0118 in)
2. If the measured value exceeds the limit, replace thrust bearings, and measure again. If it still exceeds the limit, replace crankshaft also.

Scheme 348

1. Measure side clearance between connecting rod and crankshaft arm with feeler gauge. Standard: 0.20-0.35 mm (0.0079-0.0138 in) Limit: 0.-40 mm (0.0157 in)
2. If the measured value exceeds the limit, replace connecting rod, and measure again. If it still exceeds the limit, replace crankshaft also.

Piston Pin Hole Diameter

Measure the hole diameter of piston pin hole with an inside micrometer.

Scheme 349

1. Standard: 21.993-22.005 mm (0.8669-0.8663 in)

Piston to Piston Pin Oil Clearance

(Piston pin oil clearance) = (Piston pin hole diameter) - (Piston pin outer diameter)

1. Standard: 0.002-0.006 mm (0.0001-0.0002 in)

1. If clearance exceeds specification, replace piston/piston pin assembly with reference to specification of each parts.
2. When replacing piston/piston pin assembly, refer to «PISTON TO CYLINDER BORE CLEARANCE»(ref-158850-S37951274562005020300000) .

Scheme 350

1. Measure side clearance of piston ring and piston ring groove with feeler gauge. Standard: Top ring: 0.045-0.080 mm (0.0018-0.0031 in) 2nd ring: 0.030-0.070 mm (0.0012-0.0028 in) Oil ring: 0.065-0.135 mm (0.0026-0.0053 in) Limit: Top ring: 0.11 mm (0.0043 in) 2nd ring: 0.10 mm (0.004 in)
2. If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, replace piston also.

Scheme 351

1. Check if inner diameter of cylinder bore is within specification. Refer to «PISTON TO CYLINDER BORE CLEARANCE»(ref-158850-S37951274562005020300000) .
2. Insert piston ring until middle of cylinder with piston, and measure gap. Standard: Top ring: 0.23-0.33 mm (0.0091-0.0130 in) 2nd ring: 0.33-0.48 mm (0.0130-0.0189 in) Oil ring: 0.20-0.50 mm (0.0079-0.0197 in) Limit: Top ring: 0.54 mm (0.0213 in) 2nd ring: 0.80 mm (0.0315 in) Oil ring: 0.95 mm (0.0374 in)
3. If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylinder and use oversized piston and piston ring.

Scheme 352

1. Check with connecting rod aligner. Bend: Limit: 0.15 mm (0.0059 in) per 100 mm (3.94 in) length Torsion: Limit: 0.30 mm (0.0118 in) per 100 mm (3.94 in) length
2. If it exceeds the limit, replace connecting rod assembly.

Connecting Rod Bearing Housing Diameter (Big End)

Install connecting rod cap without connecting rod bearing installed. After tightening connecting rod bolt to the specified torque, measure the connecting rod big end inner diameter using an inside micrometer. Refer to ASSEMBLY for the tightening procedure.

Scheme 353

1. Standard: 55.000-55.013 mm (2.1654-2.1659 in)

Piston Pin Bushing Inner Diameter (Small End)

Measure inner diameter of bushing.

Scheme 354

1. Standard: 22.000-22.012 mm (0.8661-0.8666 in)

Connecting Rod Bushing Oil Clearance (Small End)

(Connecting rod bushing oil clearance)=(Piston pin bushing inner diameter)-(Piston pin outer diameter)

1. Standard: 0.005-0.017 mm (0.0002-0.0007 in)
2. Limit: 0.030 mm (0.0012 in)

Scheme 355

1. If the measured value exceeds the standard, replace connecting rod assembly and/or piston and piston pin assembly.
2. If replacing piston and piston pin assembly, refer to «PISTON TO CYLINDER BORE CLEARANCE»(ref-158850-S37951274562005020300000) .
3. If replacing connecting rod assembly, refer to «CONNECTING ROD BEARING OIL CLEARANCE»(ref-158850-S26374236722005020300000) .

Factory Installed Parts Grading

Service parts apply only to grade "0".

Scheme 356

Scheme 357

Scheme 358

1. Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or other contamination. CAUTION: Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.
2. Measure the distortion on the block upper face at some different points in 6 directions. Limit: 0.10 mm (0.0039 in)
3. If out of the distortion limit, replace cylinder block.

Scheme 359

1. Install main bearing caps and main bearing beam with main bearings removed, and tighten mounting bolts to the specified torque. Refer to «ASSEMBLY»(ref-158850-S27450952092005020300000) for the tightening procedure.
2. Using a bore gauge, measure the inner diameter of the main bearing housing. Standard: 63.993-64.017 mm (2.5194-2.5203 in)
3. If out of the standard, replace cylinder block and main bearing caps as assembly.

Note. Cylinder block cannot be replaced as single part, because it is machined together with main bearing caps.

Scheme 360

Scheme 361

1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper at 6 different points on each cylinder. ("X" and "Y" directions at "A", "B" and "C") ("Y" is in longitudinal direction of engine) Standard inner diameter: 95.500-95.530 mm (3.7598-3.7610 in) Wear limit: 0.20 mm (0.0079 in) Out-of-round (Difference between "X" and "Y"): Limit: 0.015 mm (0.0006 in) Taper (Difference between "A" and "C"): Limit: 0.010 mm (0.0004 in)
2. If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, hone or re-bore the inner wall.
3. An oversize piston is provided. When using an oversize piston, re-bore cylinder so that the clearance of the piston-to-cylinder bore satisfies the standard.

1. Oversize (Service): 0.20 mm (0.0079 in)

Piston Skirt Diameter

Measure piston skirt diameter using micrometer.

Scheme 362

1. Measure point: Distance from the top 41.0 mm (1.614 in)
2. Standard: 95.480-95.510 mm (3.7590-3.7602 in)

Piston-to-Cylinder Bore Clearance

1. Calculate by piston skirt diameter and cylinder bore inner diameter (direction "X", position "B"). (Clearance)=(Cylinder bore inner diameter)-(Piston skirt diameter). Standard: 0.010-0.030 mm (0.0004-0.0012 in) Limit: 0.08 mm (0.0031 in)
2. If it exceeds the limit, replace piston/piston pin assembly. refer to «HOW TO SELECT PISTON»(ref-158850-S06084640132005020300000) .

Re-boring Cylinder Bore

1. Cylinder bore size is determined by adding piston-to-cylinder bore clearance to piston diameter "A". Re-bored size calculation:"D"="A"+"B"-"C" Where, "D": Bored diameter "A": Piston diameter as measured "B": Piston-to-cylinder bore clearance (standard value) "C": Honing allowance 0.02 mm (0.0008 in)
2. Install main bearing caps and main bearing beam, and tighten to the specified torque. Otherwise, cylinder bores may be distorted in final assembly.
3. Cut cylinder bores. NOTE: When any cylinder needs boring, all other cylinders must also be bored. Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a time.
4. Hone cylinders to obtain specified piston-to-cylinder bore clearance.
5. Measure finished cylinder bore for out-of-round and taper.

Note. Measurement should be done after cylinder bore cools down.

Crankshaft Main Journal Diameter

1. Measure outer diameter of crankshaft main journals with micrometer. Standard: 59.951-59.975 mm (2.3603-2.3612 in) dia .
2. Out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to «MAIN BEARING OIL CLEARANCE»(ref-158850-S30746295982005020300000) .

Scheme 363

1. Measure outer diameter of crankshaft pin journal with micrometer. Standard: 51.956 - 51.974 mm (2.0455 - 2.0462 in) dia.
2. If out of the standard, measure the connecting rod bearing oil clearance. Then use undersized bearing. Refer to «CONNECTING ROD BEARING OIL CLEARANCE»(ref-158850-S26374236722005020300000) .

Scheme 364

1. Using a micrometer, measure the dimensions at "4" different points shown in the figure on each journal and pin.
2. Out-of-round is indicated by the difference in dimensions between "X" and "Y" at "A" and "B".
3. Taper is indicated by the difference in dimension between "A" and "B" at "X" and "Y". Limit Taper (Difference between "A" and "B"): 0.002 mm (0.0001 in) Out-of-round (Difference between "X" and "Y"): 0.002 mm (0.0001 in)
4. If the measured value exceeds the limit, correct or replace crankshaft.
5. If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select the main bearing and/or connecting rod bearing. Refer to «MAIN BEARING OIL CLEARANCE»(ref-158850-S30746295982005020300000) and/or «CONNECTING ROD BEARING OIL CLEARANCE»(ref-158850-S26374236722005020300000) .

Scheme 365

1. Place a V-block on a precise flat table to support journals on the both end of crankshaft.
2. Place a dial gauge straight up on No. 3 journal.
3. While rotating crankshaft, read the movement of the pointer on the dial gauge. (Total indicator reading) Standard: Less than 0.025 mm (0.0010 in) Limit: 0.10 mm (0.0039 in)
4. If it exceeds the limit, replace crankshaft.

Scheme 366

1. Install connecting rod bearings to connecting rod and connecting rod bearing cap, and tighten connecting rod bolts to the specified torque. Using a inside micrometer measure the inner diameter of connecting rod bearing. Refer to «ASSEMBLY»(ref-158850-S27450952092005020300000) for the tightening procedure. (Oil clearance) = (Connecting rod bearing inner diameter) - (Crankshaft pin diameter) Standard: 0.034 -0.059 mm (0.0013 -0.0023 in) (actual clearance) Limit: 0.070 mm (0.0028 in)
2. If clearance cannot be adjusted within the standard, grind crankshaft pin and use undersized bearing. Refer to «HOW TO SELECT CONNECTING ROD BEARING»(ref-158850-S21388404602005020300000) .

Scheme 367

1. Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.
2. Cut a plastigage slightly shorter than bearing width, and place it in crankshaft axial direction, avoiding oil holes.
3. Install connecting rod bearings to connecting rod and connecting rod bearing cap, and tighten connecting rod bolts to the specified torque. Refer to «ASSEMBLY»(ref-158850-S27450952092005020300000) for the tightening procedure. CAUTION: Never rotate crankshaft.
4. Remove connecting rod cap and bearings, and using the scale on the plastigage bag, measure the plastigage width.

Note. The procedure when the measured value exceeds the limit is same as that described in the "Method by Calculation".

Scheme 368

1. Install main bearings to cylinder block and main bearing cap. Measure the main bearing inner diameter with bearing cap bolt tightened with main bearing beam to the specified torque. Refer to «ASSEMBLY»(ref-158850-S27450952092005020300000) for the tightening procedure. (Oil clearance) = (Main bearing inner diameter) - (Crankshaft main journal diameter) Standard: 0.035 -0.045 mm (0.0014 -0.0018 in) (actual clearance) Limit: 0.065 mm (0.0026 in)
2. If the measured value exceeds the limit, select main bearings referring to the main bearing inner diameter and crankshaft journal outer diameter, so that the oil clearance satisfies the standard. Refer to «HOW TO SELECT MAIN BEARING»(ref-158850-S12298240912005020300000) .

Scheme 369

1. Remove engine oil and dust on crankshaft journal and the surfaces of each bearing completely.
2. Cut a plastigage slightly shorter than bearing width, and place it in crankshaft axial direction, avoiding oil holes.
3. Install main bearing to cylinder block and main bearing cap, and tighten main bearing bolts with main bearing beam to the specified torque. Refer to «ASSEMBLY»(ref-158850-S27450952092005020300000) for the tightening procedure. CAUTION: Never rotate crankshaft.
4. Remove bearing cap and bearings, and using the scale on the plastigage bag, measure the plastigage width. NOTE: The procedure when the measured value exceeds the limit is same as that described in the "Method by Calculation".

Scheme 370

1. When main bearing cap is removed after being tightened to the specified torque with main bearings installed, the tip end of bearing must protrude. Refer to «ASSEMBLY»(ref-158850-S27450952092005020300000) for the tightening procedure. Standard: There must be crush height.
2. If the standard is not met, replace main bearings.

Scheme 371

1. When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings installed, the tip end of bearing must protrude. Refer to «ASSEMBLY»(ref-158850-S27450952092005020300000) for the tightening procedure. Standard: There must be crush height.
2. If the standard is not met, replace connecting rod bearings.

Main Bearing Cap Bolt Outer Diameter

1. Measure outer diameters ("d1", "d2") at two positions shown in the figure.
2. Measure "d2" at a point within block "A". Limit: 0.11 mm (0.0051 in)
3. When the value of "d1" - "d2" exceeds the limit (a large difference in dimensions), replace bolt with a new one.

Scheme 372

1. Measure outer diameter "d" at position shown in the figure.
2. If reduction appears in a position other than "d", regard it as "d". Standard: 7.90 - 8.00 mm (0.3110 - 0.3150 in) Limit: 7.75 mm (0.3051 in)
3. When "d" exceeds the limit (when it becomes thinner), replace bolt with a new one.

Scheme 373

1. Check drive plate and signal plate for deformation or damage. CAUTION: Do not disassemble drive plate. Never place drive plate with signal plate facing down. When handling signal plate, take care not to damage or scratch it. Handle signal plate in a manner that prevents it from becoming magnetized
2. If anything is found, replace drive plate.

Oil Jet

1. Check nozzle for deformation and damage.
2. Blow compressed air from nozzle, and check for clogs.
3. If it is not satisfied, clean or replace oil jet.

Scheme 374

1. Using a clean plastic stick, press check valve in oil jet relief valve. Make sure that valve moves smoothly with proper reaction force.
2. If it is not satisfied, replace oil jet relief valve.

STANDARD AND LIMIT

General Specifications Cylinder arrangement V-6 Displacement cm 3 (cu in) 3,498 (213.45) Bore and stroke mm (in) 95.5 x 81.4 (3.76 x 3.205) Valve arrangement DOHC Firing order 1-2-3-4-5-6 Number of piston rings Compression 2 Oil 1 Number of main bearings 4 Compression ratio 10.3 Compression pressure kPa (kg/cm 2 , psi)/300 rpm Standard 1,275 (13.0,185) Minimum 981 (10.0,142) Differential limit between cylinders 98 (1.0,14) Cylinder number Valve timing (Intake valve timing control - "OFF") Unit: degree a b c d e f 240 238 -6 64 8 52

Scheme 375

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Scheme 380

Scheme 381

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Scheme 400