2004 INFINITI FX35 Engine

CYLINDER BLOCK
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Revision: 2004 November 2004 FX35/FX45
22. Install knock sensor.

Install knock sensor so that connector faces front of engine.

After installing knock sensor, connect harness connector, and
lay it out to rear of engine.
CAUTION:

Do not tighten mounting bolts while holding connector.

If any impact by dropping is applied to knock sensor,
replace it with new one.
NOTE:

Make sure that there is no foreign material on the cylinder
block mating surface and the back surface of knock sensor.

Make sure that knock sensor does not interfere with other parts.
23. Install followings in reverse order of removal.
How to Select Piston and Bearing ABS00FPI
DESCRIPTION
*For the service parts, the grade for fitting cannot be selected between a piston pin and a connecting rod.
(Only 0 grade is available.) The information at the shipment from the plant is described as a reference.

The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.

For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.

For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
HOW TO SELECT PISTON
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.)
PBIC0810E
Selection points Selection parts Selection items Selection methods
Between cylinder block and
crankshaftMain bearingMain bearing grade
(bearing thickness)Determined by match of cylin-
der block bearing housing
grade (inner diameter of hous-
ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Between crankshaft and con-
necting rodConnecting rod bearingConnecting rod bearing grade
(bearing thickness)Combining service grades for
connecting rod big end inner
diameter and crankshaft pin
outer diameter determine con-
necting rod bearing selection.
Between cylinder block and pis-
tonPiston and piston pin assembly
(Piston is available together
with piston pin as an assembly.)Piston grade
(piston outer diameter)Piston grade = cylinder bore
grade (inner diameter of bore)
*Between piston and connect-
ing rod———
PBIC0811E

CYLINDER BLOCK
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Revision: 2004 November 2004 FX35/FX45
Piston Pin Outer Diameter
Measure outer diameter of piston pin.
Connecting Rod Bushing Oil Clearance (Small End)
(Connecting rod bushing oil clearance) = (Piston pin bushing inner diameter) – (Piston pin outer diameter)

If the measured value exceeds the standard, replace connecting rod assembly and/or piston and piston
pin assembly.

If replacing piston and piston pin assembly, refer to EM-140, "PISTON TO CYLINDER BORE CLEAR-
ANCE" .

If replacing connecting rod assembly, refer to EM-142, "CON-
NECTING ROD BEARING OIL CLEARANCE" .
Factory installed parts grading:
Service parts apply only to grade “0”.
Unit: mm (in)
*: After installing in connecting rod
CYLINDER BLOCK DISTORTION

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.Standard : 21.989 - 22.001 mm (0.8657 - 0.8662 in)
PBIC0117E
Standard : 0.005 - 0.017 mm (0.0002 - 0.0007 in)
Limit : 0.030 mm (0.0012 in)
PBIC0809E
Grade 0 1
Piston pin bushing inner
diameter* 22.000 - 22.006
(0.8661 - 0.8664) 22.006 - 22.012
(0.8664 - 0.8666)
Piston pin hole diameter 21.993 - 21.999
(0.8659 - 0.8661) 21.999 - 22. 005
(0.8661 - 0.8663)
Piston pin outer diameter 21.989 - 21.995
(0.8657- 0.8659) 21.995 - 22.001
(0.8659 - 0.8662)
PBIC0812E

EM-140
[VQ35DE]
CYLINDER BLOCK
Revision: 2004 November 2004 FX35/FX45

Measure the distortion on the block upper face at some different
points in 6 directions.

If out of the distortion limit, replace cylinder block.
MAIN BEARING HOUSING INNER DIAMETER

Install main bearing caps and main bearing beam with main
bearings removed, and tighten mounting bolts to the specified
torque. Refer to EM-126, "
ASSEMBLY" for the tightening proce-
dure.

Using a bore gauge, measure the inner diameter of the main
bearing housing.

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.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter

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)

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.

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.
CAUTION:
When using oversize piston, use it for all cylinders with
oversize piston rings.

When using an oversize piston, use it for all cylinders with over-
size piston rings.Limit : 0.10 mm (0.0039 in)
SEM123C
Standard : 63.993 - 64.017 mm (2.5194 - 2.5203 in)
PBIC1643E
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)
Oversize (Service) : 0.20 mm (0.0079 in)
PBIC0923E
SEM843E

CYLINDER BLOCK
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Revision: 2004 November 2004 FX35/FX45

If clearance cannot be adjusted within the standard, grind crankshaft pin and use undersized bearing.
Refer to EM-132, "
HOW TO SELECT CONNECTING ROD BEARING" .
Method of Using Plastigage

Remove engine oil and dust on crankshaft pin and the surfaces
of each bearing completely.

Cut a plastigage slightly shorter than bearing width, and place it
in crankshaft axial direction, avoiding oil holes.

Install connecting rod bearings to connecting rod and connect-
ing rod bearing cap, and tighten connecting rod bolts to the
specified torque. Refer to EM-126, "
ASSEMBLY" for the tighten-
ing procedure.
CAUTION:
Never rotate crankshaft.

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”.
MAIN BEARING OIL CLEARANCE
Method by Calculation

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 EM-126, "
ASSEMBLY" for the tightening procedure.
(Oil clearance) = (Main bearing inner diameter) – (Crankshaft main
journal diameter)

If the measured value exceeds the limit, select main bearings
referring to the main bearing inner diameter and crankshaft jour-
nal outer diameter, so that the oil clearance satisfies the standard. Refer to EM-133, "
HOW TO SELECT
MAIN BEARING" .
Method of Using Plastigage

Remove engine oil and dust on crankshaft journal and the sur-
faces of each bearing completely.

Cut a plastigage slightly shorter than bearing width, and place it
in crankshaft axial direction, avoiding oil holes.

Install main bearing to cylinder block and main bearing cap, and
tighten main bearing bolts with main bearing beam to the speci-
fied torque. Refer to EM-126, "
ASSEMBLY" for the tightening
procedure.
CAUTION:
Never rotate crankshaft.

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”.
PBIC1149E
Standard : 0.035 - 0.045 mm (0.0014 - 0.0018 in)
(actual clearance)
Limit : 0.065 mm (0.0026 in)
PBIC1644E
PBIC1149E

PRECAUTIONS
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Revision: 2004 November 2004 FX35/FX45
[VK45DE]PRECAUTIONSPFP:00001
Precautions Necessary for Steering Wheel Rotation After Battery DisconnectABS00DAO
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.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the
steering lock will be released.
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT-II.
Precautions for Drain Engine CoolantABS006HV
Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingABS006HW

Before starting work, make sure no fire or spark producing items are in the work area.

Release fuel pressure before disconnecting and disassembly.

After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and DisassemblyABS006HX

When instructed to use special service tools, use specified tools. Always be careful to work safely, avoid
forceful or uninstructed operations.

Exercise maximum care to avoid damage to mating or sliding surfaces.

Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.

Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly.

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 Inspection, Repair and ReplacementABS006HY
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and InstallationABS006HZ

Use torque wrench to tighten bolts or nuts to specification.

EM-160
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PRECAUTIONS
Revision: 2004 November 2004 FX35/FX45

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 speci-
fied, do exactly as specified.

Replace with new gasket, packing, oil seal or O-ring.

Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.

Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.

Release air within route when refilling after draining engine coolant.

After repairing, start engine and increase engine speed to check engine coolant, fuel, oil, and exhaust
systems for leakage.
Parts Requiring Angle TighteningABS006I0

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 nuts
–Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle
tightening)

Do not use a torque value for final tightening.

The torque value for these parts are for a preliminary step.

Ensure thread and seat surfaces are clean and coated with engine oil.
Precautions for Liquid GasketABS006I1
REMOVAL OF LIQUID GASKET SEALING

After removing mounting bolts and nuts, separate the mating
surface using seal cutter (SST) and remove old liquid gasket
sealing.
CAUTION:
Be careful not to damage the mating surfaces.

In areas where seal cutter (SST) is difficult to use, use plastic
hammer to lightly tap the areas where liquid gasket is applied.
CAUTION:
If for some unavoidable reason tool such as a flat-blade
screwdriver is used, be careful not to damage the mating
surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using scraper, remove old liquid gasket adhering to the liquid
gasket application surface and the mating surface.

Remove liquid gasket completely from the groove of the liquid
gasket application surface, mounting bolts, and bolt holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
PBIC0002E
PBIC0003E

PRECAUTIONS
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Revision: 2004 November 2004 FX35/FX45
3. Attach liquid gasket tube to tube presser [SST: WS39930000
(—)].
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-48, "
RECOMMENDED CHEMICAL PRODUCTS AND
SEALANTS" .
4. Apply liquid gasket without breaks to the specified location with the specified dimensions.

If there is a groove for the liquid gasket application, apply liquid gasket to the groove.

As for the 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.

Within five minutes of liquid gasket application, install the mat-
ing component.

If liquid gasket protrudes, wipe it off immediately.

Do not retighten after the installation.

Wait 30 minutes or more after installation before refilling
engine with engine oil and engine coolant.
CAUTION:
If there are specific instructions in this manual, observe
them.
EMA0622D
SEM159F

EM-164
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PREPARATION
Revision: 2004 November 2004 FX35/FX45
Commercial Service ToolsABS006I3
—
(J-45476)
Ring gear stopperRemoving and installing crankshaft pulley
—
(J-45488)
Quick connector releaseRemoving fuel tube quick connectors in
engine room
(Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210) Tool number
(Kent-Moore No.)
Tool nameDescription
PBIC1655E
PBIC0198E
(Kent-Moore No.)
Tool nameDescription
Power toolLoosening bolts and nuts
Spark plug wrench Removing and installing spark plug
Manual lift table caddy Removing and installing engine
(J24239-01)
Cylinder head bolt wrenchLoosening and tightening cylinder head bolt,
and use with angle wrench [SST:
KV10112100 (BT8653-A)]
a: 13 (0.51) dia.
b: 12 (0.47)
c: 10 (0.39)
Unit: mm (in)
PBIC0190E
S-NT047
ZZA1210D
NT583