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2004 - Engine Mechanical - Coupe: Specifications Infiniti G35 III

Mechanical 25 illustrations ~484 words

PARTS REQUIRING ANGLE TIGHTENING

  1. Use angle wrench [SST: KV10112100 (BT8653-A)] for the final tightening of the following engine parts: Cylinder head bolts Main bearing cap bolts Connecting rod cap bolts Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular tightening)
  2. Do not use a torque value for final tightening.
  3. The torque value for these parts are for a preliminary step.
  4. Ensure thread and seat surfaces are clean and coated with engine oil.

Scheme 1

Scheme 1: Removal Of Liquid Gasket Sealing
Scheme 1: Removal Of Liquid Gasket Sealing
  1. After removing the mounting bolts and nuts, separate the mating surface using a seal cutter (SST) and remove the old liquid gasket sealing. CAUTION: Be careful not to damage the mating surfaces.
  2. In areas where seal cutter (SST) is difficult to use, use a plastic hammer to lightly tap (1) seal cutter where liquid gasket is applied. Use plastic hammer to slide seal cutter (2) by tapping on the side. CAUTION: If for some unavoidable reason a tool such as flat-bladed screwdriver is used, be careful not to damage the mating surfaces.

Scheme 2

Scheme 2: Liquid Gasket Application Procedure
Scheme 2: Liquid Gasket Application Procedure

Scheme 3

Scheme 3
Scheme 3
  1. Using a scraper, remove the old liquid gasket adhering to the gasket application surface and the mating surface. Remove the liquid gasket completely from the groove of the gasket application surface, mounting bolts, and bolt holes.
  2. Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove adhering moisture, grease and foreign material.
  3. Attach the liquid gasket tube to the tube presser [SST: WS39930000 ( - )]. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-179413-S29795405052005070700000) .
  4. Apply liquid gasket without breaks to the specified location with the specified dimensions.

Scheme 4

Scheme 4
Scheme 4
  1. If there is a groove for the liquid gasket application, apply gasket to the groove.
  2. As for bolt holes, normally apply liquid gasket inside the holes. Occasionally, it should be applied outside the holes. Make sure to read the text of this manual.
  3. Within five minutes of liquid gasket application, install the mating component.
  4. If liquid gasket protrudes, wipe it off immediately.
  5. Do not retighten mounting bolts and nuts after the installation.
  6. After 30 minutes or more have passed from the installation fill engine oil and engine coolant.
CAUTIONIf there are specific instructions in this manual, observe them.

ENGINE SPECIFICATIONS

ApplicationSpecification
Displacement213.45 Cu. In. (3.5L)
Bore3.760 In. (95.5 mm)
Stroke3.205 In. (81.4 mm)
Compression Pressure142-185 psi (10.0-13.0 kg/cm 2 )
Compression Ratio10.3:1
Fuel SystemSFI

GENERAL SPECIFICATIONS

ValveIn. (mm)
Exhaust.011-.015 (.29-.37)
Intake.010-.013 (.26-.34)

VALVE CLEARANCE SPECIFICATIONS

ApplicationIn. (mm)
Crankshaft
End Play
Standard.0039-.0098 (.10-.25)
Service Limit.0118 (.30)
Runout.0039 (.10)
Main Bearings
Journal Diameter (1)
Grade No. A2.3612-2.3612 (59.974-59.975)
Grade No. B2.3611-2.3612 (59.973-59.974)
Grade No. C2.3611-2.3611 (59.972-59.973)
Grade No. D2.3611-2.3611 (59.971-59.972)
Grade No. E2.3610-2.3611 (59.970-59.971)
Grade No. F2.3610-2.3610 (59.969-59.970)
Grade No. G2.3610-2.3609 (59.968-59.969)
Grade No. H2.3609-2.3609 (59.967-59.968)
Grade No. J2.3609-2.3609 (59.966-59.967)
Grade No. K2.3608-2.3609 (59.965-59.966)
Grade No. L2.3608-2.3608 (59.964-59.965)
Grade No. M2.3607-2.3608 (59.963-59.964)
Grade No. N2.3607-2.3607 (59.962-59.963)
Grade No. P2.3607-2.3607 (59.961-59.962)
Grade No. R2.3606-2.3607 (59.960-59.961)
Grade No. S2.3606-2.3606 (59.959-59.960)
Grade No. T2.3605-2.3606 (59.958-59.959)
Grade No. U2.3605-2.3605 (59.957-59.958)
Grade No. V2.3605-2.3605 (59.956-59.957)
Grade No. W2.3604-2.3605 (59.955-59.956)
Grade No. X2.3604-2.3604 (59.954-59.955)
Grade No. Y2.3603-2.3604 (59.953-59.954)
Grade No. 42.3603-2.3603 (59.952-59.953)
Grade No. 72.3603-2.3603 (59.951-59.952)
Journal Out-Of-Round.0001 (.002)
Journal Taper.0001 (.002)
Oil Clearance
Standard.0014-.0018 (.035-.045)
Service Limit.0026 (.065)
Connecting Rod Bearings
Journal Diameter (1)
Grade No. 02.0460-2.0462 (51.968-51.974)
Grade No. 12.0457-2.0460 (51.962-51968)
Grade No. 22.0455-2.0457 (51.956-51.962)
Journal Out-Of-Round.0001 (.002)
Journal Taper.0001 (.002)
Oil Clearance
Standard.0013-.0023 (.034-.059)
Service Limit.0028 (.070)
(1) To locate engine component grade marks (Scheme 8)- (Scheme 11).
(1)To locate engine component grade marks (Scheme 8)- (Scheme 11).

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS

Grade Number (3)ID ColorThickness - In. (mm)
0Black.0787-.0789 (2.000-2.003)
1Brown.0789-.0790 (2.003-2.006)
2Green.0790-.0791 (2.006-2.009)
3Yellow.0791-.0792 (2.009-2.012)
4Blue.0792-.0793 (2.012-2.015)
5Pink.0793-.0794 (2.015-2.018)
6Purple.0794-.0796 (2.018-2.021)
7White.0796-.0797 (2.021-2.024)
(1) Width for all bearings is.783-.791 In. (19.9-20.1 mm). (2) Grade is the same for lower and upper bearings. (3) To locate engine component grade marks (Scheme 8)- (Scheme 11).
(1)Width for all bearings is .783-.791 In. (19.9-20.1 mm).
(2)Grade is the same for lower and upper bearings.
(3)To locate engine component grade marks (Scheme 8)- (Scheme 11).

MAIN BEARING SPECIFICATIONS (MATCHED SET) (1) (2)

Grade Number (3)ID ColorThickness - In. (mm)
01
LowerBlack.0787-.0789 (2.000-2.003)
UpperBrown.0789-.0790 (2.003-2.006)
12
LowerBrown.0789-.0790 (2.003-2.006)
UpperGreen.0790-.0791 (2.006-2.009)
23
LowerGreen.0790-.0791 (2.006-2.009)
UpperYellow.0791-.0792 (2.009-2.012)
34
LowerYellow.0791-.0792 (2.009-2.012)
UpperBlue.0792-.0793 (2.012-2.015)
45
LowerBlue.0792-.0793 (2.012-2.015)
UpperPink.0793-.0794 (2.015-2.018)
56
LowerPink.0793-.0794 (2.015-2.018)
UpperPurple.0794-.0796 (2.018-2.021)
67
LowerPurple.0794-.0796 (2.018-2.021)
UpperWhite.0796-.0797 (2.021-2.024)
(1) Width for all bearings is.783-.791 In. (19.9-20.1 mm). (2) Grade is different for lower and upper bearings. (3) To locate engine component grade marks (Scheme 8)- (Scheme 11).
(1)Width for all bearings is .783-.791 In. (19.9-20.1 mm).
(2)Grade is different for lower and upper bearings.
(3)To locate engine component grade marks (Scheme 8)- (Scheme 11).

MAIN BEARING SPECIFICATIONS (MISMATCHED SET) (1) (2)

ApplicationIn. (mm)
Bore Diameter
Pin Bore
Grade No. 0.8661-.8664 (22.000-22.006)
Grade No. 1.8664-.8666 (22.006-22.012)
Crankpin Bore2.1654-2.1659 (55.000-55.013)
Center-To-Center Length5.8110-5.8149 (144.15-144.25)
Maximum Bend Per 3.94 In. (100 mm).006 (.15)
Maximum Twist Per 3.94 In. (100 mm).012 (.30)
Side Play
Standard.0079-.0138 (.20-.35)
Service Limit.0157 (.40)

CONNECTING RODS

Grade NumberID ColorThickness - In. (mm)
0Black.0591-.0592 (1.500-1.503)
1Brown.0592-.0593 (1.503-1.506)
2Green.0593-.0594 (1.506-1.509)

CONNECTING ROD BEARING SPECIFICATIONS

ApplicationIn. (mm)
Pistons
Clearance.0004-.0012 (.010-.030)
Diameter (1)
Grade No. 13.7590-3.7594 (95.480-95.490)
Grade No. 23.7594-3.7598 (95.490-95.500)
Grade No. 33.7598-3.7602 (95.000-95.510)
.008 In. (.20 mm) Oversize3.7669-3.7681 (95.680-95.710)
Piston Pin Hole
Diameter
Grade No. 0.8659-.8661 (21.993-21.999)
Grade No. 1.8661-.8663 (21.999-22.005)
Pins
Diameter
Grade No. 01.8657-.8659 (21.989-21.995)
Grade No. 02.8659-.8662 (21.995-22.001)
Piston Interference Fit.0001-.0002 (.002-.006)
Rod Bushing Clearance
Standard.0002-.0007 (.005-.017)
Service Limit.0012 (.030)
Rings
No. 1
End Gap.0091-.0130 (.23-.33)
Limit.0213 (.54)
Side Clearance.0018-.0031 (.040-.080)
Limit.0043 (.11)
No. 2
End Gap.0130-.0189 (.33-.48)
Limit.0315 (.80)
Side Clearance.0012-.0028 (.030-.070)
Limit.004 (.10)
No. 3 (Oil Control)
End Gap.0079-.0197 (.20-.50)
Limit.0374 (.95)
Side Clearance.0026-.0053 (.065-.135)
(1) To locate engine component grade marks (Scheme 8)- (Scheme 11).
(1)To locate engine component grade marks (Scheme 8)- (Scheme 11).

PISTONS, PINS & RINGS

ApplicationIn. (mm)
Cylinder Bore
Standard Diameter (1)
Grade No. 13.7598-3.7602 (95.500-95.510)
Grade No. 23.7602-3.7606 (95.510-95.520)
Grade No. 33.7606-3.7610 (95.520-95.530)
Main Journal Inner Diameter Grade (Without Bearing)
Journal Diameter (1)
Grade No. A2.5194-2.5194 (63.993-63.994)
Grade No. B2.5194-2.5195 (63.994-63.995)
Grade No. C2.5195-2.5195 (63.995-63.996)
Grade No. D2.5195-2.5196 (63.996-63.997)
Grade No. E2.5196-2.5196 (63.997-63.998)
Grade No. F2.5196-2.5196 (63.998-63.999)
Grade No. G2.5196-2.5197 (63.999-64.000)
Grade No. H2.5197-2.5197 (64.000-64.001)
Grade No. J2.5197-2.5198 (64.001-64.002)
Grade No. K2.5198-2.5198 (64.002-64.003)
Grade No. L2.5198-2.5198 (64.003-64.004)
Grade No. M2.5198-2.5199 (64.004-64.005)
Grade No. N2.5199-2.5199 (64.005-64.006)
Grade No. P2.5199-2.5200 (64.006-64.007)
Grade No. R2.5200-2.5200 (64.007-64.008)
Grade No. S2.5200-2.5200 (64.008-64.009)
Grade No. T2.5200-2.5201 (64.009-64.010)
Grade No. U2.5201-2.5201 (64.010-64.011)
Grade No. V2.5201-2.5202 (64.011-64.012)
Grade No. W2.5202-2.5202 (64.012-64.013)
Grade No. X2.5202-2.5202 (64.013-64.014)
Grade No. Y2.5202-2.5203 (64.014-64.015)
Grade No. 42.5203-2.5203 (64.015-64.016)
Grade No. 72.5203-2.5203 (64.016-64.017)
Maximum Taper.0006 (.015)
Maximum Out-Of-Round.0006 (.015)
Maximum Deck Warpage (2).004 (.10)
(1) To locate engine component grade marks (Scheme 8)- (Scheme 11). (2) Maximum resurfacing limit of cylinder block and cylinder head combined is.008 in. (.20).
(1)To locate engine component grade marks (Scheme 8)- (Scheme 11).
(2)Maximum resurfacing limit of cylinder block and cylinder head combined is .008 in. (.20).

CYLINDER BLOCK

ApplicationClearance - In. (mm)
Body-To-Outer Rotor.0045-.0102 (.114-.260)
Inner Rotor-To-Outer Rotor TipLess Than .0071 (.180)
Housing-To-Inner Rotor (1).0012-.0028 (.030-.070)
Housing-To-Outer Rotor (1).0020-.0043 (.050-.110)
Inner Rotor Shoulder-To-Housing.0018-.0036 (.045-.091)
(1) Lay straightedge across gears and housing. Insert feeler gauge between straightedge and gear.
(1)Lay straightedge across gears and housing. Insert feeler gauge between straightedge and gear.

OIL PUMP SPECIFICATIONS

ApplicationIn. (mm)
Intake Valves
Face Angle45 Degrees 15 Min.-45 Degrees 45 Min.
Head Diameter1.4567-1.4685 (37.00-37.30)
Valve Margin
Standard.043 (1.1)
LimitMore Than .020 (.50)
Valve Length3.794 (96.37)
Stem Diameter.2348-.2354 (5.965-5.980)
Valve Tip Maximum Refinish.008 (.20)
Exhaust Valves
Face Angle45 Degrees 15 Min.-45 Degrees 45 Min.
Head Diameter1.228-1.240 (31.20-31.50)
Valve Margin
Standard.051 (1.3)
LimitMore Than .020 (.50)
Valve Length3.697 (93.90)
Stem Diameter.2344-.2350 (5.955-5.970)
Valve Tip Maximum Refinish.008 (.20)
Valve Springs
Free Length1.7961 (45.62)
Out-Of-Square.083 (2.10)
Lbs. @ In. (kg @ mm)
Pressure
Standard Installed41.4-46.8 @ 1.457 (18.8-21.2 @ 37.0)
Valve Open91.5-103.2 @ 1.095 (41.5-46.8 @ 27.8)

VALVES & VALVE SPRINGS

ApplicationIn. (mm)
Cylinder Head Height (1)4.972-4.980 (126.30-126.50)
Maximum Warpage (2).004 (.10)
Valve Seats
Seat Angle45 Degrees
Seat Width
Exhaust.051-.059 (1.29-1.51)
Intake.043-.052 (1.09-1.31)
Seat Bore (Oversize)
Exhaust1.2873-1.2880 (32.700-32.716)
Intake1.5157-1.5164 (38.500-38.516)
Valve Guides
Cylinder Head Valve Guide Bore I.D.
Standard.3927-.3935 (9.975-9.996)
Service Limit.4006-.4014 (10.175-10.196)
Valve Guide I.D..2362-.2369 (6.000-6.018)
Valve Guide Installed Height.496-.504 (12.60-12.80)
Valve Stem-To-Guide Oil Clearance
Exhaust
Standard.0012-.0025 (.030-.063)
Service Limit.0035 (.09)
Intake
Standard.0008-.0021 (.020-.053)
Service Limit.003 (.08)
(1) Measure from cylinder head cover surface to head gasket surface. (2) Maximum resurfacing limit of cylinder block and cylinder head combined is .008 (.20).
(1)Measure from cylinder head cover surface to head gasket surface.
(2)Maximum resurfacing limit of cylinder block and cylinder head combined is .008 (.20).

CYLINDER HEAD

ApplicationIn. (mm)
Bore Diameter
No. 11.0236-1.0244 (26.000-26.021)
No. 2, 3 & 4.9252-.9260 (23.500-.23.521)
End Play
Standard.0045-.0074 (.115-.188)
Service Limit.0094 (.24)
Journal Diameter
No. 11.0211-1.0218 (25.935-25.955)
No. 2, 3 & 4.9230-.9238 (23.445-23.465)
Camshaft RunoutLess Than .0020 (.050)
Sprocket RunoutLess Than .006 (.15)
Lobe Height
Standard1.7663-1.7738 (44.865-45.055)
Service Limit.008 (.20)
Oil Clearance
Standard
Journal No. 1.0018-.0034 (.045-.086)
Journal No. 2, 3, & 4.0014-.0030 (.035-.076)
Service Limit.0059 (.150)

CAMSHAFT

ApplicationIn. (mm)
Bore Diameter1.3386-1.3392 (34.000-34.016)
Lifter Diameter1.3377-1.3381 (33.977-33.987)
Oil Clearance.0005-.0015 (.013-.039)

VALVE LIFTERS

TORQUE SPECIFICATIONS

ApplicationFt. Lbs. (N.m)
Camshaft Sprocket Bolts
Exhaust87-94 (118-128)
Intake72-79 (98-107)
Connecting Rod Nut (1)
Step 114-15 (19-21)
Step 2Tighten Additional 90-95 Degrees
Crankshaft Pulley Bolt
Step 129-36 (39-49)
Step 2Tighten Additional 60-66 Degrees
Cylinder Head Bolt (2) (3)
Step 172 (98)
Step 2Loosen Bolts
Step 325-32 (34-44)
Step 4Tighten Additional 90-95 Degrees
Step 5Tighten Additional 90-95 Degrees
Drain Plug22-29 (29-39)
Engine Mount
Mount-To-Bracket Nut32-40 (43-55)
Mount-To-Engine Bolt32-40 (43-55)
Right & Left Mount-To-Suspension Nut65-72 (87-98)
Transaxle Mount-To-Transaxle Bolt32-40 (43-55)
Transaxle Mount-To-Crossmember Bolt32-40 (43-55)
Exhaust Manifold Nut (4)21-23 (28-32)
Flywheel/Flexplate Bolt61-69 (83-93)
Fuel Tube Assembly
Step 1(5)
Step 216-19 (19-26)
Idler Pulley Bracket Bolt20 (27)
Ignition Coil Bolt15-22 (20-29)
Intake Manifold (6)
Step 1(7)
Step 220-23 (26-31)
Main Bearing Cap Bolt (8) (9)
Step 124-28 (32-38)
Step 2Tighten Additional 90-95 Degrees
Oil Cooler Connector32-40 (44-54)
Oil Drain Plug22-29 (30-39)
Oil Filter11-15 (15-20)
Oil Pan (10)
Lower Pan Bolts(11)
Upper Pan Bolts12-14 (16-19)
Oil Pump Pick-Up Tube-To-Oil Pump Bolt15-16 (20-22)
Oil Pump Regulator Valve Cap29-50 (39-69)
Oxygen Sensor30-36 (40-50)
Slack Guide12 (16)
Spark Plug15-21 (20-29)
3 Way Catalyst-To-Manifold Bolt
Bank 145-58 (61-78)
Bank 222-25 (29-34)
Transmission-To-Engine Bolt (12)
Automatic
Bolts 1-552-58 (70-79)
Bolts 6-923-29 (31-40)
Manual
Bolts 1-652-58 (70-79)
Bolts 7-1023-30 (31-40)
INCH Lbs. (N.m)
Camshaft Bearing Cap Bolts (13)
Step 118 (2)
Step 252 (6)
Step 3 (Tighten Caps No. 1-6)80-104 (9.0-11.8)
Step 4 (Tighten Caps No. 7-10)74-91 (8.3-10.3)
CVTC Cover89-106 (10-12)
Front Timing Chain Case Bolt (14)
8 mm Bolt(16)
6 mm Bolt106-124 (12-14)
Intake Manifold Collector Bolt106-124 (12-14)
IVTC Valve Cover Bolt97 (11)
Oil Baffle Plate22-28 (2.4-3.1)
Oil Pump Cover Bolt
Long Bolt57-66 (6.5-7.5)
Short Bolt53-69 (6-8)
Rear Oil Seal Retainer Bolt71-80 (8-9)
Rear Timing Chain Case Bolt (15)
6 mm Bolt106-124 (12-14)
8 mm Bolt(16)
Rocker Cover Bolt (17)
Step 19-27 (1-3)
Step 261-80 (7-9)
Timing Chain Tensioner Bolt62-80 (7-9)
Water Pump Bolt71-97 (8-11)
(1) Measure bolts prior to installation for proper length. If bolts exceed specification, replace bolt. (Scheme 12) (2) Measure bolts prior to installation for proper length. If bolts exceed specification, replace bolt. (Scheme 13) (3) Tighten bolts to specification in sequence. (Scheme 14) (4) Tighten bolts to specification in sequence. (Scheme 15) (5) Tighten to 80-97 INCH lbs. (9-11 N.m) (6) Tighten bolts to specification in sequence. (Scheme 16) (7) Tighten to 44-86 INCH lbs. (5-10 N.m). (8) Tighten to specification in sequence. (Scheme 17)(9) Measure bolts prior to installation for proper length. If bolts exceed specification, replace bolt. (Scheme 18) (10) Tighten bolts to specification in sequence. (Scheme 19)and (Scheme 20). (11) Tighten to 80-97 INCH lbs. (9-11 N.m). (12) Tighten to specification in sequence. (Scheme 21) (13) Tighten to specification in sequence. (Scheme 22) (14) Tighten to specification in sequence. (Scheme 23) (15) Tighten to specification in sequence. (Scheme 24) (16) Tighten to 19-23 ft. lbs. (26-31 N.m) (17) Tighten to specification in sequence. (Scheme 25)
(1)Measure bolts prior to installation for proper length. If bolts exceed specification, replace bolt. (Scheme 12)
(2)Measure bolts prior to installation for proper length. If bolts exceed specification, replace bolt. (Scheme 13)
(3)Tighten bolts to specification in sequence. (Scheme 14)
(4)Tighten bolts to specification in sequence. (Scheme 15)
(5)Tighten to 80-97 INCH lbs. (9-11 N.m)
(6)Tighten bolts to specification in sequence. (Scheme 16)
(7)Tighten to 44-86 INCH lbs. (5-10 N.m).
(8)Tighten to specification in sequence. (Scheme 17)
(9)Measure bolts prior to installation for proper length. If bolts exceed specification, replace bolt. (Scheme 18)
(10)Tighten bolts to specification in sequence. (Scheme 19)and (Scheme 20).
(11)Tighten to 80-97 INCH lbs. (9-11 N.m).
(12)Tighten to specification in sequence. (Scheme 21)
(13)Tighten to specification in sequence. (Scheme 22)
(14)Tighten to specification in sequence. (Scheme 23)
(15)Tighten to specification in sequence. (Scheme 24)
(16)Tighten to 19-23 ft. lbs. (26-31 N.m)
(17)Tighten to specification in sequence. (Scheme 25)

TORQUE SPECIFICATIONS

Scheme 5

Scheme 5: DRIVE BELT
Scheme 5: DRIVE BELT

Scheme 6

Scheme 6: INTAKE MANIFOLD COLLECTOR, INTAKE MANIFOLD AND EXHAUST MANIFOLD
Scheme 6: INTAKE MANIFOLD COLLECTOR, INTAKE MANIFOLD AND EXHAUST MANIFOLD

Scheme 7

Scheme 7: SPARK PLUG
Scheme 7: SPARK PLUG

Scheme 8

Scheme 8: ENGINE SPECIFICATIONS
Scheme 8: ENGINE SPECIFICATIONS

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25

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