ENGINE ASSEMBLY
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Revision: 2004 November 2004 FX35/FX45
Vehicle Underbody
1. Remove A/T fluid cooler hoses and power steering oil pump oil cooler hoses.
2. Remove exhaust front tube. Refer to EX-3, "
EXHAUST SYSTEM" .
3. Disconnect steering lower joint, and release steering shaft. Refer to PS-12, "
STEERING COLUMN" .
4. Separate transmission and propeller shaft. Refer to PR-6, "
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 FSU-6, "
FRONT SUSPENSION
ASSEMBLY" .
9. Remove lower ends of LH and RH sides struts from lower arms. Refer to FSU-6, "
FRONT SUSPENSION
ASSEMBLY" .
10. Remove LH and RH sides lower arms from suspension member. Refer to FSU-6, "
FRONT SUSPENSION
ASSEMBLY" .
11. Remove LH and RH sides front drive shafts from LH and RH sides knuckles. Refer to FA X - 1 2 , "
FRONT
DRIVE SHAFT" .
Removal Work
1. Use a manual lift table caddy (commercial service tool) or equiv-
alently 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
FSU-6, "
FRONT SUSPENSION ASSEMBLY" .
4. Carefully lower jack to remove engine, transmission, and sus-
pension 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.
Separation Work
1. Install engine slingers into front of RH bank cylinder head and
rear of left bank cylinder head.
2. Remove power steering oil pump from engine side. Refer to PS-31, "
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.
PBIC0804E
Slinger bolts:
: 28.0 N·m (2.9 kg-m, 21 ft-lb)
SBIA0474E
EM-118
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ENGINE ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
5. Remove front drive shaft LH and RH sides. Refer to FAX-12, "FRONT DRIVE SHAFT" .
6. Remove alternator. Refer to SC-23, "
CHARGING SYSTEM" .
7. Remove starter motor. Refer to SC-10, "
STARTING SYSTEM" .
8. Remove front propeller shaft from front final drive assembly side. Refer to PR-4, "
FRONT PROPELLER
SHAFT" .
9. Separate engine from transmission assembly. Refer to AT- 2 6 6 , "
TRANSMISSION ASSEMBLY" .
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 FFD-10, "
FRONT FINAL DRIVE ASSEM-
BLY" .
INSTALLATION
Note to the following, and install in the reverse order of removal.
For a location with a positioning pin, insert it securely into hole of
mating part.
For a part with a specified installation orientation, refer to com-
ponent figure in EM-115, "
AWD MODEL" .
When installing engine mounting bracket on cylinder block,
tighten two upper bolts (shown as A in figure) first. Then tighten
two lower bolts (shown as B in figure). (LH and RH sides)
Install engine mounting bracket (lower) paying attention to the
following.
–a. Temporarily tighten mounting bolts (shown as C, D and E in
figure).
–b. Tighten mounting bolts to the specified torque with following
mounting surfaces touched.
Engine mounting bracket to engine mounting bracket (lower)
(shown as C and D in figure).
Front final drive to engine mounting bracket (lower) (shown as E
in figure).
INSPECTION AFTER INSTALLATION
Before starting engine, check the levels of engine coolant, engine oil and working fluid. If less than
required quantity, fill to the specified level.
Use procedure below to check for fuel leakage.
–Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at connection points.
–Start engine. With engine speed increased, check again for fuel leakage at connection points.
Run engine to check for unusual noise and vibration.
Warm up engine thoroughly to make sure there is no leakage of engine coolant, engine oil, working fluid,
fuel and exhaust gas.
Bleed air from passages in pipes and tubes of applicable lines, such as in cooling system.
After cooling down engine, again check amounts of engine coolant, engine oil and working fluid. Refill to
specified level, if necessary.
Summary of the inspection items:
SBIA0477E
SBIA0478E
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Working fluid Level Leakage Level
EM-124
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CYLINDER BLOCK
Revision: 2004 November 2004 FX35/FX45
12. Use a seal cutter (SST) to cut away liquid gasket and remove
rear oil seal retainer.
CAUTION:
Be careful not to damage mounting surface.
If rear oil seal retainer is removed, replace it with a new
one.
NOTE:
Rear oil seal and retainer make up a single part and are
removed as an assembly.
13. Remove baffle plate from main bearing beam (2WD model).
14. Remove piston and connecting rod assembly.
Before removing piston and connecting rod assembly, check
connecting rod side clearance. Refer to EM-136, "
CONNECT-
ING ROD SIDE CLEARANCE" .
a. Position crankshaft pin corresponding to connecting rod to be
removed onto the bottom dead center.
b. Remove connecting rod cap.
c. Using a hammer handle or similar tool, push piston and connect-
ing rod assembly out to cylinder head side.
15. Remove connecting rod bearings from connecting rod and con-
necting rod cap.
CAUTION:
When removing them, note the installation position. Keep them in the correct order.
16. Remove piston rings form piston.
Use a piston ring expander (commercial service tool).
CAUTION:
When removing piston rings, be careful not to damage
piston.
Be careful not to damage piston rings by expanding
them excessively.
17. Remove piston from connecting rod as follows.
a. Using a snap ring pliers, remove snap ring.
SEM830E
EMQ0191D
PBIC0087E
PBIC0088E
CYLINDER BLOCK
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Revision: 2004 November 2004 FX35/FX45
14. Install connecting rod bearings to connecting rod and connect-
ing rod cap.
When 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 protru-
sion with the cutout of connecting rod to install.
Check the oil hole on connecting rod and that on the corre-
sponding bearing are aligned.
15. 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 cylinder bore, piston and crank-
shaft pin.
Match cylinder position with the cylinder number on connect-
ing rod to install.
Using a piston ring compressor (SST) or suitable tool, install
piston with the front mark on the piston crown facing the front
of engine.
CAUTION:
Be careful not to damage cylinder wall and crankshaft pin, resulting from an interference of con-
necting rod big end.
16. Install connecting rod cap.
Match the stamped cylinder number marks on connecting rod
with those on cap to install.
Be sure that front mark on connecting rod cap is facing front
of engine.
17. Tighten connecting rod bolt as follows.
a. Apply engine oil to the threads and seats of connecting rod
bolts.
b. Tighten bolts.
c. Then tighten all bolts “90” degrees clockwise (Angle tightening).
CAUTION:
Always use an angle wrench [SST: KV10112100 (BT8653-
A)]. Avoid tightening based on visual check alone.
After tightening bolt, make sure that the crankshaft rotates
smoothly.
Check the connecting rod side clearance. Refer to EM-136, "CONNECTING ROD SIDE CLEARANCE"
18. Install baffle plate to main bearing beam.
PBIC0266E
SEM620
PBIC0809E
: 19.6 N·m (2.0 kg-m, 14 ft-lb)
SEM953E
CYLINDER BLOCK
EM-137
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Revision: 2004 November 2004 FX35/FX45
Piston to Piston Pin Oil Clearance
(Piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)
If clearance exceeds specification, replace piston/piston pin assembly with reference to specification of
each parts.
When replacing piston/piston pin assembly, refer to EM-140, "PISTON TO CYLINDER BORE CLEAR-
ANCE" .
PISTON RING SIDE CLEARANCE
Measure side clearance of piston ring and piston ring groove
with feeler gauge.
If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit,
replace piston also.
PISTON RING END GAP
Check if inner diameter of cylinder bore is within specification.
Refer to EM-140, "
PISTON TO CYLINDER BORE CLEAR-
ANCE" .
Insert piston ring until middle of cylinder with piston, and mea-
sure gap.
If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylin-
der and use oversized piston and piston ring.Standard : 0.002 - 0.006 mm (0.0001 - 0.0002 in)
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)
SEM024AA
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)
PBIC0118E
EM-138
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CYLINDER BLOCK
Revision: 2004 November 2004 FX35/FX45
CONNECTING ROD BEND AND TORSION
Check with connecting rod aligner.
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 microme-
ter. Refer to EM-126, "
ASSEMBLY" for the tightening procedure.
CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)
Piston Pin Bushing Inner Diameter (Small End)
Measure inner diameter of bushing.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
PBIC2077E
Standard : 55.000 - 55.013 mm (2.1654 - 2.1659 in)
PBIC1641E
Standard : 22.000 - 22.012 mm (0.8661 - 0.8666 in)
PBIC0120E
CYLINDER BLOCK
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Revision: 2004 November 2004 FX35/FX45
DRIVE PLATE
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.
If anything is found, replace drive plate.
OIL JET
Check nozzle for deformation and damage.
Blow compressed air from nozzle, and check for clogs.
If it is not satisfied, clean or replace oil jet.
OIL JET RELIEF VALVE
Using a clean plastic stick, press check valve in oil jet relief
valve. Make sure that valve moves smoothly with proper reac-
tion force.
If it is not satisfied, replace oil jet relief valve.
SEM760G
EMU0468D
SERVICE DATA AND SPECIFICATIONS (SDS)
EM-147
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Revision: 2004 November 2004 FX35/FX45
DRIVE BELT
*: If belt tension gauge cannot be installed at check points shown, check drive belt tension at different location on the belt.
INTAKE MANIFOLD COLLECTOR, INTAKE MANIFOLD AND EXHAUST MANIFOLD
Unit: mm (in)
SPARK PLUG
ItemsDeflection adjustment Unit: mm (in) Tension adjustment* Unit: N (kg, lb)
Used belt
New beltUsed belt
New belt
Limit After adjustment Limit After adjustment
Alternator and
power steering
oil pump belt7 (0.28)4 - 5
(0.16 - 0.20)3.5 - 4.5
(0.138 - 0.177)294 (30, 66)730 - 818
(74.5 - 83.5,
164 - 184)838 - 926
(85.5 - 94.5,
188 - 208)
Air conditioner
compressor belt12 (0.47)9 - 10
(0.35 - 0.39)8 - 9
(0.31- 0.35)196 (20, 44)348 - 436
(35.5 - 44.5,
78 - 98)470 - 559
(4 8 - 5 7 ,
106 - 126)
Applied pushing
force98 N (10 kg, 22 lb) —
KBIA1731J
Items Limit
Surface distortionIntake manifold collector upper 0.1 (0.004)
Intake manifold collector lower 0.1 (0.004)
Intake manifold 0.1 (0.004)
Exhaust manifold 0.3 (0.012)
MakeNGK
Standard typePLFR5A-11
Hot typePLFR4A-11
Cold typePLFR6A-11
Gap (nominal)1.1 mm (0.043 in)