Engine Mechanical: Removal & Installation Infiniti FX45 I

PRECAUTIONS FOR REMOVAL AND DISASSEMBLY

1. When instructed to use special service tools, use specified tools. Always be careful to work safely, avoid forceful or uninstructed operations.
2. Exercise maximum care to avoid damage to mating or sliding surfaces.
3. Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
4. Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly.
5. When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used where noted in the step.

PRECAUTIONS FOR ASSEMBLY AND INSTALLATION

1. Use torque wrench to tighten bolts or nuts to specification.
2. When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified.
3. Replace with new gasket, packing, oil seal or O-ring.
4. Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for any restriction and blockage.
5. Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well.
6. Release air within route when refilling after draining engine coolant.
7. After repairing, start engine and increase engine speed to check engine coolant, fuel, oil, and exhaust systems for leakage.

Removal

1. Major parts and inspection points under each cover are as follows; (numbered as in see scheme 12 ). Upper side of engine assembly and power steering reservoir tank Relay and battery Engine assembly front side, drive belts and cooling fan

Installation

Install in the reverse order of removal.

Scheme 74

1. Remove air duct (inlet) when inspecting drive belt for alternator, water pump and A/C compressor.
2. Remove front engine undercover with power tool when inspecting power steering oil pump belt.
3. Make sure that indicator (single line notch) of each auto tensioner is within the allowable working range (between three line notches). NOTE: Check auto tensioner indication when engine is cold. When new drive belt is installed, the range should be "A". The indicator notch is located on the moving side of auto tensioner for alternator, water pump and A/C compressor belt, while it is found on the fixed side for power steering oil pump belt.
4. Visually check entire belt for wear, damage or cracks.
5. If the indicator is out of allowable working range or belt is damaged, replace belt.

Note the following, and install in the reverse order of removal.

Scheme 75

1. Remove air duct (inlet). Refer to «AIR CLEANER AND AIR DUCT»(ref-158963-S32645370962005020300000) .
2. Front engine undercover with power tool.
3. Remove drive belts. Refer to «REMOVAL AND INSTALLATION»(ref-158963-S40577865552005020300000) . Keep auto tensioner pulley arm locked after belt is removed.
4. Remove auto tensioner and idler pulley with power tool. Keep auto tensioner pulley arm locked to install or remove auto tensioner.

Install in the reverse order of removal.

Scheme 76

1. Remove engine cover with power tool. Refer to «ENGINE ROOM COVER»(ref-158963-S06074735262005020300000) .
2. Disconnect harness connector from mass air flow sensor.
3. Disconnect vacuum hose and PCV hose.
4. Remove air duct (inlet), air cleaner case and mass air flow sensor assembly, air duct and resonator assembly disconnecting their joints. Add marks as necessary for easier installation.
5. Remove mass air flow sensor from air cleaner case. CAUTION: Handle mass air flow sensor with following cares. Do not shock it. Do not disassemble it. Do not touch its sensor.

Note the following, and install in the reverse order of removal.

1. Align marks. Attach each joint. Screw clamps firmly.

1. Remove air duct (inlet), air cleaner case and mass air flow sensor assembly.
2. Remove air cleaner filter from cleaner case.

Install in the reverse order of removal.

Scheme 77

Scheme 78

Scheme 79

Scheme 80

1. Remove engine cover with power tool. Refer to «ENGINE ROOM COVER»(ref-158963-S06074735262005020300000) .
2. Release fuel pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-151810-S21305829172003010800000) .
3. Drain engine coolant. Refer to «DRAINING ENGINE COOLANT»(ref-172394-S36492838212005022800000) .
4. Remove air duct (inlet), air cleaner case and mass air flow sensor assembly, air duct and resonator assembly. Refer to «AIR CLEANER AND AIR DUCT»(ref-158963-S32645370962005020300000) .
5. Disconnect fuel feed hose quick connector on engine side. Refer to «FUEL INJECTOR AND FUEL TUBE»(ref-158963-S14867697182005020300000) .
6. Remove fuel damper and fuel hose assembly. Refer to «FUEL INJECTOR AND FUEL TUBE»(ref-158963-S14867697182005020300000) . CAUTION: While hoses are disconnected, plug them to prevent fuel from draining. Do not separate fuel damper and fuel hose.
7. Remove or disconnect harnesses, brackets, vacuum hose, vacuum gallery and PCV hose and tube from intake manifold (upper).
8. Remove electric throttle control actuator as follows: Disconnect harness connector. Loosen mounting bolts diagonally. CAUTION: Handle carefully to avoid any shock to electric throttle control actuator. Do not disassemble.
9. Disconnect water hoses from water gallery.
10. Remove intake manifold adaptor and water gallery.
11. Loosen bolts in reverse order as shown in figure to remove intake manifold (upper) with power tool.
12. Remove vacuum tank from intake manifold (lower).
13. Remove fuel injector and fuel tube assembly. Refer to «FUEL INJECTOR AND FUEL TUBE»(ref-158963-S14867697182005020300000) .
14. Loosen bolts in reverse order as shown in figure to remove intake manifold (lower) with power tool.
15. Remove intake manifold gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

Scheme 81

1. Check the surface distortion of both the intake manifold (upper and lower) mating surfaces with straightedge and feeler gauge. Limit: 0.1 mm (0.004 in)
2. If it exceeds the limit, replace intake manifolds (lower and/or upper).

Note the following, and install in the reverse order of removal.

Scheme 82

Scheme 83

Scheme 84

1. Remove engine cover with power tool. Refer to «ENGINE ROOM COVER»(ref-158963-S06074735262005020300000) .
2. Remove front and rear engine undercovers with power tool.
3. Remove air duct (inlet), air cleaner case and mass air flow sensor assembly, air duct and resonator assembly. Refer to «AIR CLEANER AND AIR DUCT»(ref-158963-S32645370962005020300000) .
4. Remove front cross bar. Refer to «REMOVAL & INSTALLATION»(ref-166182-S14780889182004091500000) .
5. Drain engine coolant from radiator. Refer to «DRAINING ENGINE COOLANT»(ref-172394-S36492838212005022800000) . CAUTION: Perform this step when engine is cold. Do not spill engine coolant on drive belts.
6. Remove radiator. Refer to «REMOVAL AND INSTALLATION»(ref-172394-S31028763572005022800000) .
7. Remove drive belts. Refer to «CHECKING DRIVE BELTS»(ref-158963-S22589808982005020300000) .
8. Remove heated oxygen sensors as follows: Disconnect harness connector of each heated oxygen sensors. Remove heated oxygen sensor 1 and 2 on both bank with heated oxygen sensor wrench (SST). CAUTION: Be careful not to damage heated oxygen sensor. Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; replace with a new one.
9. Remove exhaust mounting bracket between three way catalysts (right and left bank) and transmission. Refer to EXHAUST SYSTEM .
10. Disconnect A/C piping from A/C compressor, then remove A/C compressor with power tool. Refer to «COMPONENTS»(ref-171325-S14788335622005020800000) .
11. Remove alternator and bracket. Refer to «GENERATOR»(ref-166067-S04166173422004091000000) .
12. Remove exhaust front tube with power tool. Refer to EXHAUST SYSTEM .
13. Remove steering lower joint at power steering gear assembly side, and release steering lower shaft. Refer to «POWER STEERING GEAR AND LINKAGE»(ref-172959-S14613131402005030800000) .
14. Remove three way catalysts (right and left bank).
15. Remove exhaust manifold covers. (right and left bank)
16. Loosen nuts in reverse order as shown in the figure to remove exhaust manifold. NOTE: Disregard the numerical order No. 9 to No. 12 in removal.
17. Remove exhaust manifold gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

Scheme 85

1. Check the surface distortion of each exhaust manifold flange mating surface with straightedge and feeler gauge. Limit: 0.3 mm (0.012 in)
2. If it exceeds the limit, replace exhaust manifold.

Note the following, and install in the reverse order of removal.

Scheme 86

Scheme 87

1. Remove front tire.
2. Remove hood assembly. Refer to HOOD .
3. Remove engine cover with power tool. Refer to «ENGINE ROOM COVER»(ref-158963-S06074735262005020300000) .
4. Remove front and rear engine undercovers with power tool.
5. Drain engine oil. Refer to CHANGING ENGINE OIL .
6. Drain engine coolant. Refer to «DRAINING ENGINE COOLANT»(ref-172394-S36492838212005022800000) . CAUTION: Perform this step when engine is cold. Do not spill engine coolant on drive belts.
7. Remove drive belts. Refer to «DRIVE BELTS»(ref-158963-S21592309282005020300000) .
8. Remove auto tensioner of power steering oil pump belt. Refer to «DRIVE BELT AUTO TENSIONER AND IDLER PULLEY»(ref-158963-S27340166892005020300000) .
9. Remove power steering oil pump with piping connected, and temporarily secure it aside with ropes or equivalent. Refer to «POWER STEERING OIL PUMP»(ref-172959-S34549476252005030800000) .
10. Remove A/C compressor with piping connected, and temporarily secure it aside with ropes or equivalent. Refer to «COMPONENTS»(ref-171325-S14788335622005020800000) .
11. Remove A/C compressor fitting bolts, and install A/C compressor temporarily on vehicle side with ropes or equivalent.
12. Remove harness of lower side of oil pan.
13. Remove crankshaft position sensor (POS) from transmission. CAUTION: Handle carefully to avoid dropping and shocks. Do not disassemble it. Do not allow metal powder to adhere to magnetic part at sensor tip. Do not place sensors in a location where they are exposed to magnetism.
14. Install engine slinger and hang engine assembly to secure position. Refer to «ENGINE ASSEMBLY»(ref-158963-S21545795282005020300000) .
15. Remove front suspension member with power tool. Refer to «FRONT SUSPENSION MEMBER»(ref-166182-S01650036442004091500000) .
16. Remove front final drive assembly. Refer to FRONT FINAL DRIVE ASSEMBLY .
17. Remove oil filter. Refer to OIL FILTER .
18. Disconnect oil cooler water hoses, and remove oil cooler water pipe and oil cooler. Refer to OIL COOLER .
19. Remove oil pan as the follows: Remove rear plate cover. Remove transmission joint bolts which pierce oil pan. Refer to «REMOVAL AND INSTALLATION (AWD MODELS)»(ref-171001-S14766714062005012500000) . Loosen oil pan bolts with power tool in reverse order as shown in the figure. NOTE: Disregard the numerical order No. 11 and No. 17 in removal. Insert seal cutter (SST) between oil pan and cylinder block. Slide seal cutter by tapping on the side of seal cutter with hammer. Remove oil pan. CAUTION: Be careful not to damage the mating surface. Do not insert flat-blade screwdriver, this will damage the mating surface. Remove O-rings from bottom of oil pump and front cover.
20. As necessary, pull axle pipe from oil pan. Hold pipes and pull them out to front drive shaft (left) installing side.
21. Remove oil strainer.

Install in the reverse order of removal.

Scheme 88

Scheme 89

1. Remove engine cover with power tool. Refer to «ENGINE ROOM COVER»(ref-158963-S06074735262005020300000) .
2. Remove ignition coil. Refer to «IGNITION COIL»(ref-158963-S35156859472005020300000) .
3. Remove spark plug with spark plug wrench (commercial service tool).

Install in the reverse order of removal.

REMOVAL AND INSTALLATION

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

1. Remove engine cover with power tool. Refer to «ENGINE ROOM COVER»(ref-158963-S06074735262005020300000) .
2. Release fuel pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-151810-S21305829172003010800000) .
3. Disconnect fuel feed hose on engine side as follows: (Except to confirm whether or not there is quick connector cap, perform same procedure for the side of centralized under-floor piping as well.) Remove quick connector cap from quick connector connection. (engine side only) Disconnect quick connector from fuel feed damper as the following: CAUTION: Disconnect quick connector by using quick connector release [SST: J-45488], not by picking out retainer tabs (centralized under-floor piping side). With the sleeve side of quick connector release facing quick connector, install quick connector release onto fuel tube. Insert quick connector release into quick connector until sleeve contacts and goes no further. Hold quick connector release on that position. CAUTION: Inserting quick connector release hard will not disconnect quick connector. Hold quick connector release where it contacts and goes no further. Draw and pull out quick connector straight from fuel damper. CAUTION: Pull quick connector holding "A" position as shown in the figure. Do not pull with lateral force applied. O-ring inside quick connector may be damaged. Prepare container and cloth beforehand as fuel will leak out. Avoid fire and sparks. Keep parts away from heat source. Especially, be careful when welding is performed around them. Do not expose parts to battery electrolyte or other acids. Do not bend or twist connection between quick connector and fuel feed hose during installation/removal. To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar.
4. Disconnect fuel damper and fuel hose assembly from fuel tubes (RH and LH). CAUTION: While hoses are disconnected, plug them to prevent fuel from draining. Do not separate fuel damper and fuel hose.
5. Remove intake manifold (upper) with power tool. Refer to «INTAKE MANIFOLD»(ref-158963-S18903985172005020300000) .
6. Disconnect harness connector from fuel injector.
7. Loosen mounting bolts in reverse order as shown in figure, and remove fuel tube and fuel injector assembly. CAUTION: Do not tilt it, or remaining fuel in pipes may flow out from pipes.
8. Remove spacers on intake manifold (lower).
9. Remove fuel injector from fuel tube as follows: Open and remove clip. Remove fuel injector from fuel tube by pulling straight. CAUTION: Be careful with remaining fuel that may go out from fuel tube. Be careful not to damage injector nozzles during removal. Do not bump or drop fuel injectors. Do not disassemble fuel injectors.
10. Remove fuel damper (RH) and fuel feed damper.

Scheme 97

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Scheme 99

Scheme 100

1. Install fuel damper (RH) and fuel feed damper. When handling O-rings, be careful of the following caution: CAUTION: Handle O-ring with bare hands. Do not wear gloves. Lubricate O-ring with new engine oil. Do not clean O-ring with solvent. Make sure that O-ring and its mating part are free of foreign material. When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it quickly into fuel tube. Insert O-ring straight into fuel tube. Do not decenter or twist it. Insert fuel damper (RH) and fuel feed damper straight into fuel tube (RH). Tighten mounting bolts evenly in turn. After tightening mounting bolts, make sure that there is no gap between flange and fuel tube (RH).
2. Install O-rings to fuel injector paying attention to the following caution. CAUTION: Upper and lower O-rings are different. Be careful not to confuse them. Fuel tube side: Black Nozzle side: Green Handle O-ring with bare hands. Never wear gloves. Lubricate O-ring with new engine oil. Do not clean O-ring with solvent. Make sure that O-ring and its mating part are free of foreign material. When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it quickly into fuel tube. Insert O-ring straight into fuel tube. Do not decenter or twist it.
3. Install fuel injector to fuel tube as follows: Insert clip into clip mounting groove on fuel injector. Insert clip so that lug "A" of fuel injector matches notch "A" of the clip. CAUTION: Do not reuse clip. Replace it with a new one. Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring. Insert fuel injector into fuel tube with clip attached. Insert it while matching it to the axial center. Insert fuel injector so that lug "B" of fuel tube matches notch "B" of the clip. Make sure that fuel tube flange is securely fixed in flange fixing groove on clip. Make sure that installation is complete by checking that fuel injector does not rotate or come off. Make sure that protrusions of fuel injectors are aligned with cutouts of clips after installation.
4. Install spacers on intake manifold (lower).
5. Install fuel tube and fuel injector assembly to intake manifold. CAUTION: Be careful not to let tip of injector nozzle come in contact with other parts. Tighten mounting bolts in two steps in numerical order as shown in the figure. 1st step: 10.1 N.m (1.0 kg-m, 7 ft-lb) 2nd step: 23.5 N.m (2.4 kg-m, 17 ft-lb)
6. Connect fuel feed hose on engine side as the following: (Excepting to confirm whether or not there is quick connector cap, perform same procedure for the side of centralized under-floor piping as well.) Make sure no foreign substances are deposited in and around fuel tube and quick connector, and no damage on them. Thinly apply new engine oil around fuel tube from tip end to spool end. Align center to insert quick connector straight into fuel tube. Insert fuel tube into quick connector until top spool is completely inside quick connector, and 2nd level spool exposes right below quick connector. Hold "A" position as shown in the figure when inserting fuel tube into quick connector. CAUTION: Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick connector. Insert until you hear a "click" sound and actually feel the engagement. To avoid misidentification of engagement with a similar sound, be sure to perform the next step. Pull quick connector by hand holding "A" position. Make sure it is completely engaged (connected) so that it does not come out from fuel tube. Install quick connector cap on quick connector connection. (on engine side only). Install fuel feed hose to hose clamps.
7. Install in the reverse order of removal after this step.

Valve Guide Replacement

When valve guide is removed, replace with oversized [0.2 mm (0.008 in)] valve guide.

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

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 suitable tool. CAUTION: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
3. Using valve guide reamer (commercial service tool), ream cylinder head valve guide hole. Valve guide hole diameter (for service parts): Intake and exhaust : 10.175 - 10.196 mm (0.4006 - 0.4014 in)
4. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil.
5. Press valve guide from camshaft side to dimensions as in the figure. CAUTION: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
6. Using valve guide reamer (commercial service tool), apply reamer finish to valve guide. Standard: Intake and exhaust: 6.000 - 6.018 mm (0.2362 - 0.2369 in)

Scheme 107

1. After confirming that the dimensions of valve guides and valves are within specifications, perform this procedure.
2. Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve contact on the surface.
3. Check if the contact area band is continuous all around the circumference.
4. If not, grind to adjust valve fitting and check again. If the contacting surface still has NG conditions even after the re-check, replace valve seat.

Valve Seat Replacement

When valve seat is removed, replace with oversized [0.5 mm (0.020 in)] valve seat.

Scheme 108

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Scheme 110

Scheme 111

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. CAUTION: Prevent scratching cylinder head by excessive boring.
2. Ream cylinder head recess diameter for service valve seat. 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) 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. 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. Grind to obtain the dimensions indicated in the figure.
6. Using compound, grind to adjust valve fitting.
7. Check again for normal contact. Refer to «VALVE SEAT CONTACT»(ref-158963-S40737270262005020300000) .

Scheme 112

1. Set try square along the side of valve spring and rotate spring. Measure the maximum clearance between the top face of spring and try square. Limit : 2.0 mm (0.079 in)
2. If it exceeds the limit, replace valve spring.

Scheme 113

1. Check valve spring pressure at specified spring height. Standard: Intake and exhaust Free height: 46.35 - 46.85 mm (1.8247 - 1.8444 in) Installation height: 33.8 mm (1.331 in) Installation load: 165 - 189 N (16.8 - 19.3 kg, 37 - 42 lb) Height during valve open: 24.4 mm (0.961 in) Load with valve open: 290 - 330 N (29.6 - 33.7 kg, 65 - 74 lb)
2. If the installation load or load with valve open is out of the standard, replace valve spring.

Scheme 114

Note the following, and install in the reverse order of removal.

Scheme 115

1. Where positioning pin is used, be sure to securely insert it into the hole of mating part.
2. When installing engine mount brackets (RH and LH) to cylinder block, tighten two upper bolts (shown as "A" in the figure) first. Then tighten two lower bolts (shown as "B" in the figure).