ENGINE ASSEMBLY EM-241
[VK45DE]
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Revision: 2005 July 2005 FX
Preparation
1. Release fuel pressure. Refer to EC-789, "FUEL PRESSURE RELEASE" .
2. Drain engine coolant from radiator. Refer to CO-37, "
Changing Engine Coolant" .
CAUTION:
Perform this step when engine is cold.
Do not spill engine coolant on drive belts.
3. Disconnect both battery terminal. Refer to SC-4, "
BATTERY" .
4. Remove crankshaft position sensor (POS) from transmission. CAUTION:
Handle carefully to avoid dropping and shocks.
Do not disassemble.
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.
5. Remove the following parts:
Hood assembly; Refer to BL-13, "HOOD" .
Engine cover; Refer to EM-172, "ENGINE ROOM COVER" .
Front and rear engine undercover
Air duct (inlet), air duct and air cleaner case assembly; Refer to EM-176, "AIR CLEANER AND AIR
DUCT" .
Drive belts; Refer to EM-173, "DRIVE BELTS" .
Radiator and radiator hoses (upper and lower); Refer to CO-41, "RADIATOR" .
Front road wheels and tires
Engine Room LH
1. Disconnect engine room harness from the engine side and set it aside for easier work.
2. Disconnect heater hoses, and install plugs to avoid leakage of engine coolant.
3. Disconnect ground cable from exhaust manifold cover to vehicle.
4. Disconnect vacuum hose between vehicle and engine and set it aside.
5. Discharge refrigerant from A/C circuit. Refer to ATC-138, "
REFRIGERANT LINES" .
6. Remove A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope. Refer to AT C -
140, "Components" .
Engine Room RH
1. Disconnect fuel feed hose and EVAP hose. Refer to EM-192, "FUEL INJECTOR AND FUEL TUBE" .
CAUTION:
Fit plugs onto disconnected hose to prevent fuel leak.
2. Disconnect engine room harness from the engine side and set it aside for easier work.
3. Disconnect ground cable from exhaust manifold cover to vehicle.
4. Disconnect vacuum hose between vehicle and engine and set it aside.
5. Disconnect reservoir tank of power steering oil pump from engine, and move it aside for easier work. CAUTION:
When temporarily securing, keep reservoir tank upright to avoid a fluid leak.
Vehicle Underbody
1. Remove front cross bar. Refer to FSU-6, "FRONT SUSPENSION ASSEMBLY" .
2. Disconnect power steering oil pump from engine. Move it from its location and secure with a rope for eas- ier work. Refer to PS-33, "
Removal and Installation (VK45DE Models)" .
3. Remove A/T fluid cooler tube. Refer to AT- 2 7 0 , "
TRANSMISSION ASSEMBLY" .
4. Remove exhaust front tube and center muffler with power tool. Refer to EX-3, "
EXHAUST SYSTEM" .
5. Remove RH and LH transverse link mounting bolts and nuts. Refer to FSU-14, "
TRANSVERSE LINK" .
6. Disconnect stabilizer connecting rod lower. Refer to FSU-6, "
FRONT SUSPENSION ASSEMBLY" .
7. Remove A/T control rod at control device assembly side. Then temporarily secure it on transmission, so that it does not sag. Refer to AT- 2 3 3 , "
SHIFT CONTROL SYSTEM" .
CYLINDER BLOCK EM-247
[VK45DE]
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Revision: 2005 July 2005 FX
–Rocker cover; Refer to EM-197, "ROCKER COVER" .
–Other removable brackets
NOTE:
The figure shows an example of widely use engine stand that
can hold mating surface of transmission with drive plate and rear
plate removed.
CAUTION:
Before removing the hanging chains, make sure the engine
stand is stable and there is no risk of overturning.
4. Drain engine oil. Refer to LU-27, "
Changing Engine Oil" .
5. Drain engine coolant from inside engine by removing water drain plugs “B” as shown in the figure.
6. Remove the following parts and related parts (The parts listed in step 3 are not included here.)
Oil pan and oil strainer; Refer to EM-185, "OIL PAN AND OIL STRAINER" .
Crankshaft pulley, front cover and timing chain; Refer to EM-200, "TIMING CHAIN" .
Camshaft; Refer to EM-212, "CAMSHAFT" .
Cylinder head; Refer to EM-229, "CYLINDER HEAD" .
7. Remove knock sensor. CAUTION:
Carefully handle sensor, avoiding shocks.
8. Remove piston and connecting rod assembly as follows:
Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer
to EM-262, "
CONNECTING ROD SIDE CLEARANCE" .
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod bearing cap.
c. Using hammer handle or similar tool, push piston and connect- ing 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.
9. Remove connecting rod bearings from connecting rod and connecting rod bearing cap. CAUTION:
Identify installation positions, and store them without mixing them up.
PBIC0085E
PBIC1265E
PBIC0086E
GI-52
TERMINOLOGY
Revision: 2005 July 2005 FX
TERMINOLOGYPFP:00011
SAE J1930 Terminology List AAS000EO
All emission related terms used in this publication in accordance with SAE J1930 are listed. Accordingly, new
terms, new acronyms/abbreviations and old terms are listed in the following chart.
NEW TERM NEW ACRONYM /
ABBREVIATION OLD TERM
Air cleaner ACL Air cleaner
Barometric pressure BARO ***
Barometric pressure sensor-BCDD BAROS-BCDD BCDD
Camshaft position CMP ***
Camshaft position sensor CMPS Crank angle sensor
Canister *** Canister
Carburetor CARB Carburetor
Charge air cooler CAC Intercooler
Closed loop CL Closed loop
Closed throttle position switch CTP switch Idle switch
Clutch pedal position switch CPP switch Clutch switch
Continuous fuel injection system CFI system ***
Continuous trap oxidizer system CTOX system ***
Crankshaft position CKP ***
Crankshaft position sensor CKPS ***
Data link connector DLC ***
Data link connector for CONSULT-II DLC for CONSULT-II Diagnostic connector for CONSULT-II
Diagnostic test mode DTM Diagnostic mode
Diagnostic test mode selector DTM selector Diagnostic mode selector
Diagnostic test mode I DTM I Mode I
Diagnostic test mode II DTM II Mode II
Diagnostic trouble code DTC Malfunction code
Direct fuel injection system DFI system ***
Distributor ignition system DI system Ignition timing control
Early fuel evaporation-mixture heater EFE-mixture heater Mixture heater
Early fuel evaporation system EFE system Mixture heater control
Electrically erasable programmable read
only memory EEPROM ***
Electronic ignition system EI system Ignition timing control
Engine control EC ***
Engine control module ECM ECCS control unit
Engine coolant temperature ECT Engine temperature
Engine coolant temperature sensor ECTS Engine temperature sensor
Engine modification EM ***
Engine speed RPM Engine speed
Erasable programmable read only memory EPROM ***
Evaporative emission canister EVAP canister Canister
Evaporative emission system EVAP system Canister control solenoid valve
Exhaust gas recirculation valve EGR valve EGR valve
IDX-3
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ALPHABETICAL INDEX
BRK/SW - Wiring diagram ...............
EC-615, EC-1298
Bulb specifications ............................................ LT-203
Bumper, front ....................................................... EI-14
Bumper, rear ........................................................ EI-17
C
Camshaft inspection(VK45DE) ........................ EM-213
Camshaft inspection(VQ35DE) ......................... EM-86
Camshaft position sensor (PHASE) EC-307, EC-1043
Camshaft(VK45DE) ......................................... EM-212
Camshaft(VQ35DE) ........................................... EM-84
CAN .................................................................... DI-29
CAN - Wiring diagram ......... EC-172, EC-863, LAN-49,
LAN-87
, LAN-128, LAN-173, LAN-221, LAN-262,
LAN-306
, LAN-353, LAN-402, LAN-436
CAN (Controller Area Network) . BL-24, BL-59, BL-98,
BL-191
, GW-22, GW-88, RF-13, SE-16
CAN communication EC-171, EC-862, AT-32, AT-106,
TF-13
, TF-32, WT-9, BRC-11, BL-24, BL-59, BL-98,
BL-191
, GW-22, GW-88, RF-13, SE-16, DI-84, WW-9
Canister-See EVAP canister ............... EC-42, EC-733
Center bearing assembly (propeller shaft) ........ PR-13
Center bearing disassembly (propeller shaft) .... PR-12
CHARGE - Wiring diagram ................................ SC-24
Charging system ................................................ SC-23
Chassis and body maintenance ........................ MA-29
CHIME - Wiring diagram ..................................... DI-63
CIGAR - Wiring diagram .................................. WW-55
Cigarette lighter ............................................... WW-55
Cigarette lighter illumination ............................. LT-158
Circuit breaker ................................................... PG-17
Clock ................................................................. DI-112
CLOCK - Wiring diagram .................................. DI-112
Closed loop control .............................. EC-32, EC-723
Collision diagnosis ........................................... SRS-46
Combination lamp, rear, removal and installation ........
LT-149
Combination meter ............................................... DI-5
Combination meter removal and installation - See
Instrument panel .................................................. IP-11
COMM - Wiring diagram .................................. AV-114
COMPAS - Wiring diagram ................................. DI-40
Compass ............................................................ DI-38
Component Location (auto A/C) ...................... ATC-43
Compression pressure(VK45DE) .................... EM-229
Compression pressure(VQ35DE) .................... EM-100
Compressor clutch removal and installation .. ATC-144
Compressor special service tool ...................... ATC-17
Condenser ..................................................... ATC-155
Connecting rod bearing clearance(VK45DE) .. EM-269
Connecting rod bushing clearance .................. EM-142
Connecting rod bushing clearance(VK45DE) .. EM-264
Connecting rod(VK45DE) ................................ EM-264
Connecting rod(VQ35DE) ................................ EM-140
Console box - See Instrument panel ................... IP-10
CONSULT for VDC ......................................... BRC-25
CONSULT-II Reference value (A/T) .................. AT-90
Control units (terminal arrangement) ................. PG-76
Control valve (A/T) ............................................. AT-37
Controller Area Network (CAN) . BL-24, BL-59, BL-98,
BL-191
, GW-22, GW-88, RF-13, SE-16
Converter housing installation ........... AT-272, AT-276
COOL/F - Wiring diagram ................ EC-471, EC-1217
Coolant replacement(VQ35DE) ........................ MA-15
Cooling circuit (engine)(VK45DE) ..................... CO-35
Cooling circuit (engine)(VQ35DE) ...................... CO-9
Cooling fan motor ............................ EC-478, EC-1224
Cooling fan(VK45DE) ....................................... CO-49
Cooling fan(VQ35DE) ....................................... CO-21
Cowl top .............................................................. EI-23
Cowl top cover .................................................... EI-23
Crankcase ventilation system - See Positive crankcase
ventilation ............................................. EC-51
, EC-742
Crankshaft position sensor (POS) ... EC-300, EC-1036
Crankshaft(VK45DE) ...................................... EM-246
Crankshaft(VQ35DE) ...................................... EM-140
Crash zone sensor .......................................... SRS-42
Cylinder block boring(VK45DE) ...................... EM-267
Cylinder block(VK45DE) ................................. EM-245
Cylinder block(VQ35DE) ................................. EM-122
Cylinder head bolt tightening(VK45DE) .......... EM-231
Cylinder head bolt tightening(VQ35DE) .......... EM-103
Cylinder head(VK45DE) ................................. EM-229
Cylinder head(VQ35DE) ................................. EM-100
D
D/LOCK - Wiring diagram ....................... BL-26
, BL-32
Daytime light system ........................................... LT-39
Daytime running light - See Daytime light system LT-39
Diagnosis sensor unit ..................................... SRS-45
Diagnostic trouble code (DTC) for OBD system EC-15,
EC-707
Direct clutch solenoid valve ............... AT-158, AT-160
Display and amp.assembly ............... ATC-51, ATC-63
Door glass ........................................... GW-76, GW-80
Door glass Fitting Adjustment(Front) ................ GW-78
Door glass Fitting Adjustment(Rear) ................. GW-83
Door lock .......................................................... BL-157
Door mirror ...................................................... GW-114
Door trim ............................................................. EI-34
Door, front ........................................... BL-153, GW-76
Door, rear ............................................ BL-153, GW-80
Drive belt inspection ......................................... MA-22
Drive belt inspection(VQ35DE) ......................... MA-14
Drive belt(VK45DE) ........................................ EM-173
Drive belt(VQ35DE) .......................................... EM-15
Drive shaft ......................................................... MA-38
Drive shaft (rear) ............................................... RAX-9
Driver air bag .................................................. SRS-35
DTRL - Wiring diagram ....................................... LT-42
Duct and grilles .............................................. ATC-134
E
ECM power supply EC-164
, EC-413, EC-855, EC-1137
ECM/PW - Wiring diagram ............... EC-414, EC-1138
IDX-4
ALPHABETICAL INDEX
ECTS - Wiring diagram ...................... EC-210, EC-916
Electric sunroof .................................................. RF-10
Electric throttle control actuator ........ EC-424, EC-426,
EC-1148
, EC-1150
Electric throttle control actuator (VK45DE) ..... EM-178
Electric throttle control actuator (VQ35DE) ....... EM-19
Electrical load signal circuit .............. EC-679, EC-1369
Electrical unit ..................................................... PG-76
Electrical units location ...................................... PG-70
Electronic ignition (EI) system ............. EC-33, EC-724
Engine control module (ECM) .......... EC-402, EC-1134
Engine control system diagram ....................... EC-721
Engine control system diagram and chart ......... EC-30
Engine coolant temperature sensor (ECTS) ... EC-208,
EC-220
, EC-914, EC-927
Engine coolant(VK45DE) .................................. CO-37
Engine coolant(VQ35DE) ................................. CO-11
Engine oil filter replacement ............................. MA-26
Engine oil filter replacement(VQ35DE) ............. MA-19
Engine oil precautions .......................................... GI-8
Engine oil replacement(VQ35DE) ..................... MA-18
Engine oil(VK45DE) ........................................... LU-25
Engine oil(VQ35DE) ............................................ LU-7
Engine removal(VK45DE) ............................... EM-240
Engine removal(VQ35DE) .............................. EM-112
Engine room cover(VK45DE) ......................... EM-172
ETC1 - Wiring diagram .................... EC-427, EC-1151
ETC2 - Wiring diagram .................... EC-434, EC-1158
ETC3 - Wiring diagram .................... EC-438, EC-1162
EVAP canister ...................................... EC-42, EC-733
EVAP canister purge volume control solenoid valve ....
EC-336
, EC-1069, EC-1233
EVAP canister vent control valve ...... EC-343, EC-568,
EC-1076
, EC-1241
EVAP control system (small leak) diagnosis .. EC-327,
EC-367
, EC-1061, EC-1108
EVAP control system pressure sensor ........... EC-350,
EC-353
, EC-359, EC-1083, EC-1086, EC-1092
EVAP control system purge flow monitoring diagnosis
EC-322
, EC-1056
EVAP vapor lines inspection ................. MA-21, MA-28
Evaporative emission (EVAP) system . EC-39, EC-730
Evaporator ..................................................... ATC-156
Exhaust manifold(VK45DE) ............................ EM-182
Exhaust manifold(VQ35DE) .............................. EM-26
Exhaust system ................................................... EX-3
Exhaust system inspection ..................... EX-3, MA-29
Expansion valve ............................................. ATC-157
F
F/FOG - Wiring diagram ..................................... LT-81
F/PUMP - Wiring diagram ................ EC-669, EC-1359
Final drive pre-inspection .................. FFD-20, RFD-17
Final drive removal and installation .. FFD-12, FFD-14,
RFD-14
Floor trim ............................................................. EI-39
Flow charts ......................................................... GI-27
Fluid temperature sensor (A/T) ........................ AT-136
Fluorescent leak detector ............................. ATC-158
Fog lamp, front ................................................... LT-79
Front axle ............................................ FAX-4, FAX-10
Front brake solenoid valve ................. AT-154, AT-156
Front bumper ...................................................... EI-14
Front door ............................. BL-153, BL-157, GW-76
Front fog lamp .................................................... LT-79
Front passenger air bag .................................. SRS-39
Front seat belt ...................................................... SB-3
Front seat belt pre-tensioner ..... SB-2, SRS-3, SRS-44
Front suspension .............................................. FSU-6
Front washer ...................................................... WW-4
Front wiper ......................................................... WW-4
FTTS - Wiring diagram .... EC-269, EC-274, EC-1006,
EC-1011
Fuel cut control (at no load high engine speed) EC-34,
EC-725
Fuel filter replacement ......................................... FL-4
Fuel gauge ............................................................ DI-5
Fuel injection system (Bank 1) .......... EC-986, EC-995
Fuel injection system (Bank 2) .......... EC-986, EC-995
Fuel injector and fuel tube(VK45DE) .............. EM-192
Fuel injector and fuel tube(VQ35DE) ................ EM-45
Fuel level sensor EC-385, EC-387, EC-389, EC-1117,
EC-1119
, EC-1121
Fuel line inspection .................................. FL-3, MA-25
Fuel line inspection(VQ35DE) .......................... MA-17
Fuel precautions .......................................... GI-6, GI-7
Fuel pressure check ........................... EC-99, EC-789
Fuel pressure release ......................... EC-99, EC-789
Fuel pump ....................................... EC-668, EC-1358
Fuel pump and gauge .......................................... FL-4
Fuel system ......................................................... FL-3
Fuel tank ............................................................ FL-10
Fuel tank temperature sensor .......... EC-267, EC-273,
EC-1004
, EC-1010
Fuel tank vacuum relief valve ............. EC-42, EC-733
FUELB1 - Wiring diagram .. EC-250, EC-260, EC-988,
EC-997
FUELB2 - Wiring diagram .. EC-251, EC-261, EC-989,
EC-998
Fuse .................................................................. PG-17
Fuse and fusible link box .................................. PG-83
Fusible link ........................................................ PG-17
G
Gauges ................................................................. DI-5
Glass ...................................... GW-11, GW-76, GW-80
Glove box lamp ................................... LT-156, LT-202
Grille - See Exterior ............................................ EI-22
Ground distribution ........................................... PG-31
H
H/AIM - Wiring diagram ..................................... LT-75
H/LAMP - Wiring diagram .................................. LT-11
Harness connector ............................................ PG-74
Harness layout .................................................. PG-46
CAN COMMUNICATION LAN-31
[CAN]
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LAN
Revision: 2005 July 2005 FX
Ty pe 2
Ty pe 9
Input/Output Signal Chart
T: Transmit R: Receive
PKIB4202E
PKIC3676E
Signals ECM TCM Dis-
play unit BCM St e e r-
ing
angle
sensor LDW
cam-
era unit Unified
meter and
A/C
amp. ABS
actua-
tor and elec-
tric unit (con-trol
unit) Driver
seat
control unit IPDM
E/R
Engine speed signal T R R R R
Engine status signal T R
Engine coolant temperature sig-
nal TR
A/T self-diagnosis signal R T
Accelerator pedal position signal T R R
Closed throttle position signal T R
Wide open throttle position signal T R
Battery voltage signal T R
Key switch signal T R
CAN COMMUNICATION LAN-39
[CAN]
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LAN
Revision: 2005 July 2005 FX
Type 10
Input/Output Signal Chart
T: Transmit R: Receive
PKIC3677E
Signals ECM TCM Dis-
play unit AWD
con- trol
unit BCM Steer-
ing
angle
sensor LDW
cam- era
unit Uni-
fied
meter and
A/C
amp. ABS
actua- tor
and
elec- tric
unit
(con- trol
unit) Driver
seat
con- trol
unit IPDM
E/R
A/T self-diagnosis signal R T
Stop lamp switch signal R R T
Battery voltage signal T R
Key switch signal T R
Ignition switch signal T R R
P range signal T R R
Closed throttle position signal T R
Wide open throttle position sig-
nal TR
Engine speed signal T R R R R R
Engine status signal T R
Engine coolant temperature sig-
nal TR
Accelerator pedal position sig-
nal TR R R
Fuel consumption monitor sig-
nal TR
RT
Turbine revolution signal R T
Output shaft revolution signal R T R
A/C switch signal R T
A/C compressor request signal T R
A/C compressor feedback sig-
nal TR
Blower fan motor switch signal R T
ENGINE MAINTENANCE (VK45DE ENGINE) MA-25
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Revision: 2005 July 2005 FX
2. Remove air relief plug on heater hose.
3. Fill thermostat housing with water until water spills from the air relief hole, then close air relief plug. Fill
thermostat housing and reservoir tank with water and reinstall radiator cap.
4. Run engine and warm it up to normal operating temperature.
5. Rev engine two or three times under no-load.
6. Stop engine and wait until it cools down.
7. Drain water from the system. Refer to MA-23, "
DRAINING ENGINE COOLANT" .
8. Repeat steps 1 through 7 until clear water begins to drain from radiator.
Checking Fuel LinesALS000GS
Inspect fuel lines, fuel filler cap and fuel tank for improper attach-
ment, leaks, cracks, damage, loose connections, chafing or deterio-
ration.
If necessary, repair or replace damaged parts.
Changing Air Cleaner FilterALS000GT
VISCOUS PAPER TYPE
The viscous paper type filter does not need cleaning between replacement intervals. Refer to MA-7,
"PERIODIC MAINTENANCE" .
1. Remove air duct (inlet), air cleaner case and mass air flow sensor assembly. Refer to EM-176, "
AIR
CLEANER AND AIR DUCT" .
2. Remove air cleaner filter from air cleaner case.
Changing Engine OilALS000H7
WARNING:
Be careful not to burn yourself, as engine oil may be hot.
Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct
skin contact with used engine oil. If skin contact is made, wash thoroughly with soap or hand
cleaner as soon as possible.
1. Remove front engine undercover with power tool.
2. Warm up engine, put vehicle horizontally and check for engine oil leakage from engine components. Refer to LU-25, "
ENGINE OIL LEAKAGE" .
3. Stop engine and wait for 15 minutes.
PBIC1530E
SMA803A