Engine Mechanical: Overhaul Infiniti QX80 I

VVEL Ladder Assembly

DRIVE SHAFT OPERATIONAL CHECK

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1. Hold the both ends of the drive shaft (A) and rotate it to check that it rotates smoothly. CAUTION: Turn VVEL ladder assembly upside down to prevent the drive shaft from dropping off.

CONTROL SHAFT OPERATIONAL CHECK

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1. Move control shaft (A) to the small stopper and large stopper to check that the control shaft functions smoothly. CAUTION: Turn VVEL ladder assembly upside down to prevent the drive shaft from dropping off.

LINK CHECK FOR BACK-LASH (BONDING)

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1. Check that the link and the shaft of drive shaft and control shaft are not fixed.
2. Check this by moving drive shaft and control shaft in the axial and rotation directions.
3. If there is an unusualness related to the above three items, replace VVEL ladder assembly & cylinder head assembly.

Note. VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinder head assembly.

Disassembly

1. Remove intake manifold. Refer to " «EXPLODED VIEW»(ref-618039-S29160082932014052700000) ".
2. Remove exhaust manifold. Refer to " «EXPLODED VIEW»(ref-618039-S09315994722014052700000) ".
3. Remove oil pan (lower). Refer to " «EXPLODED VIEW»(ref-618039-S12949663282014052700000) ".
4. Remove ignition coil and spark plug. Refer to " «EXPLODED VIEW»(ref-618039-S22326611972014052700000) ".
5. Remove rocker cover. Refer to " «EXPLODED VIEW»(ref-618039-S11896676402014052700000) ".
6. Remove timing chain. Refer to " «EXPLODED VIEW»(ref-618039-S01507607752014052700000) ".
7. Remove exhaust camshaft and VVEL ladder assembly. Refer to " «EXPLODED VIEW»(ref-618039-S23782643852014052700000) ".
8. Remove cylinder head. Refer to " «EXPLODED VIEW»(ref-618039-S11126209662014052700000) ".

Assembly

Assemble in the reverse order of disassembly.

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1. Remove transmission assembly. Refer to " «2WD: EXPLODED VIEW»(ref-618051-S37351552972014052700000) " (2WD models) or " «4WD: EXPLODED VIEW»(ref-618051-S21180294812014052700000) " (AWD models).
2. Before removing the drive plate, put a match mark (A) on the crankshaft and drive plate for alignment during installation.
3. Remove drive plate as par the following procedure. Set the ring gear stopper [SST: KV10120100 (J-47245)] (A) as shown in the figure below. Loosen the bolts diagonally, and then pull drive plate with both hands to remove it. CAUTION: Never disassemble them. Never place them with signal plate facing down. When handling signal plate, take care not to damage or scratch them. Handle signal plate in a manner that prevents them from becoming magnetized. Take care not to damage the periphery of the sensing area. Any dropped drive plate shall not be used. (The drive plate to which the sensing area shall not be placed on the floor.) Never touch drive plate with bare hands. Always use urethane coating gloves or skin gloves when removing these parts. Never use torn glove.
4. Remove pilot converter (1) using the pilot bushing puller (commercial service tool) (A), if necessary.

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1. Install pilot converter to the crankshaft using suitable tool, if removed. With a drift of the following outer diameter, press-fit as far as it will go. Pilot converter: Approx. 35 mm (1.38 in) Press-fit pilot converter with its chamfered side facing crankshafts shown in the figure below.
2. Install drive plate in the reverse order of removal. Install drive plate (4) and reinforcement plate (3) as shown in the figure below. When installing drive plate to crankshaft (1), be sure to correctly align crankshaft side dowel pin and drive plate side dowel pin hole. CAUTION: If these are not aligned correctly, engine runs roughly and "MIL" illuminates. Holding ring gear with the ring gear stopper [SST: KV10120100 (J-47245)]. Tighten the mounting bolts crosswise over several times.

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Scheme 177

1. Check drive plate and signal plate (A) for deformation or damage. CAUTION: Never 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 damage is found, replace drive plate.
3. Measure the deflection of drive plate contact surface to torque converter with a dial indicator (A).
4. Measure the deflection at the area (B). Limit: 0.35 mm (0.0138 in) or less.
5. If measured value is out of the standard, replace drive plate.

Scheme 178

Refer to " COMPONENTS " for symbol marks in the figure.

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1. Remove the following parts: Oil pans (lower and upper): Refer to " «EXPLODED VIEW»(ref-618039-S12949663282014052700000) " and " «EXPLODED VIEW»(ref-618039-S05361728722014052700000) ". Front cover and timing chain: Refer to " «EXPLODED VIEW»(ref-618039-S01507607752014052700000) ". Cylinder head: Refer to " «EXPLODED VIEW»(ref-618039-S11126209662014052700000) ".
2. Remove knock sensor. CAUTION: Carefully handle knock sensor avoiding shocks.
3. Remove oil filter (for VVEL ladder assembly) from cylinder block, if necessary. Refer to " «EXPLODED VIEW»(ref-618039-S11126209662014052700000) ".
4. Remove piston and connecting rod assembly as per the following: Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to " «INSPECTION»(ref-618039-S28368704222014052700000) ". CAUTION: Be careful not to drop connecting rod bearing, and to scratch the surface. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center. Loosen mounting bolts, and remove connecting rod bearing cap. Using a hammer handle (A) or similar tool, push piston and connecting rod assembly out to the cylinder head side. CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
5. Remove connecting rod bearings from connecting rod and connecting rod bearing cap. CAUTION: Be careful not to drop connecting rod bearing, and to scratch the surface. Identify installation positions, and store them without mixing them up.
6. Remove piston rings from piston. Before removing piston rings, check the piston ring side clearance. Refer to " «INSPECTION»(ref-618039-S28368704222014052700000) ". Use a piston ring expander (commercial service tool) (A). CAUTION: When removing piston rings, be careful not to damage piston. Be careful not to damage piston rings by expanding them excessively.
7. Remove piston from connecting rod as per the following: Using snap ring pliers (A), remove snap rings. Heat piston to 60 to 70°C (140 to 158°F) with an industrial use dryer (A) or an equivalent. Push out piston pin using a stick that has an outer diameter of approximately 20 mm (0.79 in).
8. Remove rear oil seal and rear oil seal retainer assembly from cylinder block. Insert screwdriver or similar tool between rear end of crankshaft counter weight and rear oil seal retainer, and separate liquid gasket to remove. CAUTION: Be careful not to damage the mating surfaces.
9. Using screwdriver or similar tool, and lever off rear oil seal from rear oil seal retainer.
10. Remove main bearing cap as per the following: Before loosening cylinder block bolts, measure the crankshaft end play. Refer to " «INSPECTION»(ref-618039-S28368704222014052700000) ". Loosen side bolts starting from No. 30 to 21 to remove. Loosen main bearing cap sub bolts starting from No. 20 to 11 to remove. Loosen main bearing cap bolts starting from No. 10 to 1 to remove. Remove the main bearing cap. Insert bolts (1) into bolt holes, and then remove main bearing cap (2) by lifting up and shaking forward and backward. CAUTION: Be careful not to damage the mounting surface.
11. Remove crankshaft.
12. Remove main bearings and thrust bearings from main bearing cap and cylinder block. CAUTION: Be careful not to drop main bearing, and to scratch the surface. Identify installation positions, and store them without mixing them up.
13. Remove oil jet.

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1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to remove any foreign material. CAUTION: Use goggles to protect your eyes.
2. Install each plug to cylinder block as shown in the figure below. Refer to " «COMPONENTS»(ref-618029-S35771567592014052700000) " for symbols in the figure. Tighten each plug as specified below. Part Tightening torque Plug (2) 78.0 N.m (8.0 kg-m, 58 ft-lb) Water drain plug (3) 19.6 N.m (2.0 kg-m, 14 ft-lb) Plug (4) 53.9 N.m (5.5 kg-m, 40 ft-lb) Replace washers (1), (5) with new ones. CAUTION: Do not reuse washers. Apply sealant to the thread of water drain plug (3). Use Genuine RTV silicone sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-618029-S36441413172014052700000) ". Apply sealant to the thread of plug (4). Use high strength thread locking sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-618029-S36441413172014052700000) ".
3. Install main bearings and thrust bearings as per the following: CAUTION: Be careful not to drop main bearing, and to scratch the surface. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and main bearing caps. Install thrust bearings (2) to both sides of the No. 3 journal housing on cylinder block (1). Install thrust bearings with the oil groove (A) facing crankshaft arm (outside). Install main bearings paying attention to the direction. Main bearing with oil hole (B) and groove (C) goes on cylinder block. The one without them goes on main bearing cap. Before installing main bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it. When installing, align main bearing stopper protrusion to cutout of cylinder block and main bearing. Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.
4. Install crankshaft to cylinder block. While turning crankshaft by hand, check that it turns smoothly.
5. Install main bearing caps as per the following: Align the identification number to the journal position to install. Install it with the front mark (indicated by stamping) facing the front of engine. Using plastic hammer or similar tool, tap them lightly to seat them on the installation position. NOTE: Main bearing cap cannot be replaced as a single parts, because it is machined together with cylinder block.
6. Install each main bearing cap bolts as per the following: CAUTION: If main bearing cap bolts and sub bolts are re-used, check their outer diameters before installation. Refer to " «INSPECTION»(ref-618039-S28368704222014052700000) ". Apply new engine oil to threads and seat surfaces of main bearing cap bolts and sub bolts. Tighten all bolts in order of (No. 1 - 30) temporarily. Tighten main bearing cap bolts (M12) in order of No. 1 - 10. Torque Value: 39.2 N.m (4.0 kg-m, 29 ft-lb) Tighten main bearing cap sub bolts (M9) in order of No. 11 - 20. Torque Value: 29.4 N.m (3.0 kg-m, 22 ft-lb) Tighten main bearing cap bolts (M12) in order of No. 1 - 10 (clockwise). Angle tightening: 40 degrees CAUTION: Use the angle wrench [SST: KV10112100 (BT8653-A)] (A) to check tightening angle. Never make judgment by visual inspection. Tighten main bearing cap sub bolts (M9) in order of No. 11 - 20. (clockwise) Angle tightening: 30 degrees Tighten side bolts (M10) in order of No. 21 - 30. Torque Value: 49.0 N.m (5.0 kg-m, 36 ft-lb) After installing bolts, check that crankshaft can be rotated smoothly by hand. Check the crankshaft end play. Refer to " «CYLINDER BLOCK»(ref-618039-S23374632392014052700000) ".
7. Install rear oil seal retainer. Apply a continuous bead of liquid gasket with tube presser (commercial service tool) to rear oil seal retainer as shown in the figure below. Use Genuine RTV silicone sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-618029-S36441413172014052700000) ".
8. Install rear oil seal on rear oil seal retainer. Apply new engine oil to both oil seal lip (A) and dust seal lip (B). Install it so that each seal lip is oriented as shown in the figure below. CAUTION: Be careful not to scratch or make burrs on circumference of oil seal. Press in rear oil seal (1) to the position as shown in the figure below. Using a suitable drift [outer diameter: 101 mm (3.98 in)]. Check the garter spring is in position and seal lips are not inverted.
9. Install piston to connecting rod as per the following: Assemble so that the front mark (A) on the piston head and the cylinder number (D) on connecting rod are positioned as shown in the figure below. Using snap ring pliers, install new snap ring to the groove of piston rear side. Insert it fully into groove to install. Install piston to connecting rod. Using an industrial use dryer or similar tool, heat piston until piston pin can be pushed in by hand without excess force [approximately 60 to 70°C (140 to 158°F)]. From the front to the rear, insert piston pin into piston and connecting rod. Install new snap ring to the groove of the piston front side. Insert it fully into groove to install. After installing, check that connecting rod moves smoothly.
10. Using a piston ring expander (commercial service tool) (A), install piston rings. CAUTION: When installing piston rings, be careful not to damage piston. Be careful not to damage piston rings by expending them excessively. If there is stamped mark on ring, mount it with marked side up. Stamped mark: Top ring (A): 1 K Second ring (B): 2 K Position each ring with the gap as shown in the figure below referring to the piston front mark (D). Check the piston ring side clearance. Refer to " «INSPECTION»(ref-618039-S28368704222014052700000) ".
11. Install connecting rod bearings to connecting rod and connecting rod bearing cap. CAUTION: Be careful not to drop connecting rod bearing, and to scratch the surface. Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it. When installing, align connecting rod bearing stopper protrusion (B) with cutout (A) of connecting rods and connecting rod bearing caps to install. Ensure the oil hole (C) on connecting rod and that on the corresponding bearing are aligned.
12. Install piston and connecting rod assembly to crankshaft. Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center. Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal. Match the cylinder position with the cylinder number on connecting rod to install. Be sure that front mark on piston crown is facing the front of the engine. Using a piston ring compressor [SST: EM03470000 (J-8037)] (A) or suitable tool, install piston with the front mark on the piston crown facing the front of the engine. CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
13. Install connecting rod bearing cap. Match the stamped cylinder number marks on connecting rod with those on connecting rod bearing cap to install. Be sure that front mark (H) on connecting rod bearing cap is facing the front of the engine.
14. Tighten connecting rod bolts as per the following: Inspect the outer diameter of connecting rod bolt. Refer to " «INSPECTION»(ref-618039-S28368704222014052700000) ". Apply engine oil to the threads and seats of connecting rod bolts. Tighten connecting rod bolts. Torque Value: 29.4 N.m (3.0 kg-m, 21.7 ft-lb) Completely loosen connecting rod bolts. Torque Value: 0 N.m (0 kg-m, 0 ft-lb) Tighten connecting rod bolts. Torque Value: 19.6 N.m (2.0 kg-m, 14.5 ft-lb) Tighten connecting rod bolts. (clockwise) Angle tightening: 90 degrees CAUTION: Always use the angle wrench [SST: KV10112100 (BT8653-A)]. Never make judgment by visual inspection. After tightening connecting rod bolts, check that crankshaft rotates smoothly. Check the connecting rod side clearance. Refer to " «INSPECTION»(ref-618039-S28368704222014052700000) ".
15. Install knock sensors (1). Install knock sensors in the direction shown in the figure below. After installing knock sensor, connect harness connector, and lay it out to front of the engine. CAUTION: Never tighten mounting bolts while holding connector. If any impact by dropping is applied to knock sensor, replace it with new one. NOTE: Check that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor. Check that knock sensor does not interfere with other parts.
16. Install oil filter (for VVEL ladder assembly).
17. Assemble in the reverse order of disassembly.

Scheme 202

1. Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with a dial indicator (A). Standard and limit: Refer to " «CYLINDER BLOCK»(ref-618039-S23374632392014052700000) ".
2. If the measured value exceeds the limit, replace thrust bearings, and measure again. If it still exceeds the limit, replace crankshaft also.

Scheme 203

1. Measure the side clearance between connecting rod and crankshaft arm with a feeler gauge (A). Standard and limit: Refer to " «CYLINDER BLOCK»(ref-618039-S23374632392014052700000) ".
2. If the measured value exceeds the limit, replace connecting rod, and measure again. If it still exceeds the limit, replace crankshaft also.