EM-122
[VQ35DE]
ENGINE ASSEMBLY
Revision: 2006 July 2007 FX35/FX45
Do not allow engine mounting insulator to be damage and careful no engine oil gets on it.
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 component figure in EM-118, "Components
(AWD Models)" .
When installing engine mounting bracket (RH and LH) on cylin-
der block, tighten two upper bolts (shown as “A” in the figure)
first. Then tighten two lower bolts (shown as “B” in the figure).
Install engine mounting bracket (RH) (lower) as follows:
–Temporarily tighten mounting bolts (shown as “C”, “D” and “E” in
the figure).
–Tighten mounting bolts to the specified torque with following
mounting surfaces touched.
Engine mounting bracket (RH) to engine mounting bracket (RH) (lower) (shown as “C” and “D” in figure).
Front final drive to engine mounting bracket (RH) (lower) (shown as “E” in figure).
Make sure all engine mounting insulators are seated properly,
then tighten mounting nuts.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-12, "
RECOMMENDED FLUIDS AND LUBRICANTS" .
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 fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.
Bleed air from lines and hoses of applicable lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
* Transmission/transaxle/CVT fluid. power steering fluid, brake fluid, etc.
PBIC3042E
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING EM-171
[VK45DE]
C
D E
F
G H
I
J
K L
M A
EM
Revision: 2006 July 2007 FX35/FX45
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting — Engine NoiseNBS003HK
PBIC2865E
EM-172
[VK45DE]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Revision: 2006 July 2007 FX35/FX45
Use the Chart Below to Help You Find the Cause of the Symptom.NBS003HL
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
A: Closely related B: Related C: Sometimes related —: Not related Location
of noise Type of
noise Operating condition of engine
Source of noise Check item Refer-
ence page
Before
warm- up After
warm- up When
start- ing When
idling When
racing While
driving
Top of
engine
Rocker
cover
Cylinder
head Ticking or
clicking C A — A B — Tappet noise Valve clearance
EM-222
Rattle C A — A B C Camshaft
bearing noise Camshaft journal oil
clearance
Camshaft runout EM-217EM-216
Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil pan Slap or
knock —A—B B— Piston pin
noise Piston to piston pin oil
clearance
Connecting rod bush-
ing oil clearance EM-265
EM-267
Slap or
rap A——B B A Piston slap
noise Piston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsion EM-269EM-266
EM-266
EM-267
Knock A B C B B B
Connecting
rod bearing
noise Connecting rod bush-
ing oil clearance
Connecting rod bear-
ing oil clearance EM-267EM-272
Knock A B — A B C
Main bearing
noise Main bearing oil clear-
ance
Crankshaft runout EM-273EM-271
Front of
engine
front cover Tapping or
ticking AA—BBB Timing chain
and chain
tensioner
noise Timing chain cracks
and wear
Timing chain tensioner
operation EM-208
EM-203
Front of
engine Squeak-
ing or fizz-
ing AB—B—C Drive belts
(Sticking or
slipping) Drive belts deflection
EM-174CreakingA BAB A B Drive belts
(Slipping) Idler pulley bearing
operation
Squall
Creak AB—BAB Water pump
noise Water pump operation CO-51,
"WATER
PUMP"
EM-214
[VK45DE]
TIMING CHAIN
Revision: 2006 July 2007 FX35/FX45
f. Further tighten by 90 degrees. (Angle tightening)
Check the tightening angle by referencing to the notches. The
angle between two notches is 90 degrees.
15. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to confirm it turns smoothly.
16. Install in the reverse order of removal after this step. NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in guide may gen-
erate a pounding noise during and just after engine start. However, this does not indicate an unusualness.
Noise will stop after hydraulic pressure rises.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The followings are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-12, "
RECOMMENDED FLUIDS AND LUBRICANTS"
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 fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.
Bleed air from lines and hoses of applicable lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
* Transmission/transaxle/CVT fluid. power steering fluid, brake fluid, etc.
PBIC2346E
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
CAMSHAFT EM-227
[VK45DE]
C
D E
F
G H
I
J
K L
M A
EM
Revision: 2006 July 2007 FX35/FX45
Thickness of new adjusting shim can be identified by stamp
marks on the reverse side (inside the cylinder).
8. Install new adjusting shim using suitable tool.
Install with the surface on which the thickness is
stamped facing down.
9. Remove lifter stopper as follows:
a. Except exhaust side of No. 7 and 8 cylinder;
i. Perform same procedure for removal, place camshaft pliers (SST).
ii. Remove lifter stopper (SST).
iii. Remove camshaft pliers.
b. Exhaust side of No. 7 and 8 cylinder.
Rotate crankshaft slowly 180 degrees clockwise. then remove lifter stopper.
10. Manually turn crankshaft pulley a few turns.
11. Make sure that the valve clearance is within the standard. Refer to EM-222, "
INSPECTION" .
12. Install all removed parts in the reverse order of removal. Refer to EM-219, "
INSTALLATION" .
13. Warm up the engine, and check for unusual noise and vibration.
SEM873E
PBIC1568E
PBIC1569E
EM-246
[VK45DE]
ENGINE ASSEMBLY
Revision: 2006 July 2007 FX35/FX45
Separation Work
1. Change engine slinger installing to cylinder head (right bank).
NOTE:
In order to keep secure position when hoisting engine.
2. Remove engine mounting insulators (RH and LH) under side nut with power tool.
3. Lift with hoist and separate engine and transmission assembly from front suspension member. CAUTION:
Before and during this lifting, always make sure that any harnesses are left connected.
Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
4. Remove alternator. Refer to SC-24, "
CHARGING SYSTEM" .
5. Remove starter motor. Refer to SC-11, "
STARTING SYSTEM" .
6. Separate engine from transmission assembly. Refer to AT- 2 6 9 , "
Removal and Installation (AWD Models)"
.
7. Remove front final drive from engine. Refer to FFD-13, "
FRONT FINAL DRIVE ASSEMBLY" .
8. Remove engine mounting insulators (RH and LH) and brackets (RH and LH) from engine with power tool.
9. Remove engine rear member and engine mounting insulator (rear) from transmission.
INSTALLATION
Note the following, and install in the reverse order of removal.
Do not allow engine mounting insulator to be damage and careful no engine oil gets on it.
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 component figure in EM-243, "Removal and
Installation" .
When installing engine mounting brackets (RH and LH) on cylin-
der block, tighten two upper bolts (shown as “A” in the figure)
first. Then tighten two lower bolts (shown as “B” in the figure).
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The followings are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-12, "
RECOMMENDED FLUIDS AND LUBRICANTS" .
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 fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant. Slinger bolts:
: 33.4 N·m (3.4 kg-m, 25 ft-lb)
PBIC2447E
PBIC2365E
EXHAUST SYSTEM EX-5
C
D E
F
G H
I
J
K L
M A
EX
Revision: 2006 July 2007 FX35/FX45
Tighten main muffler mounting bracket bolts in numerical order
as shown in the figure.
CAUTION:
Always replace exhaust tube gaskets with new ones when reassembling.
If heat insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the heat
insulator, remove them.
When installing heat insulator avoid large gaps or interference between heat insulator and each
exhaust pipe.
Remove deposits from the sealing surface of each connection. Connect them securely to avoid
gases leakage.
Temporarily tighten mounting nuts on the exhaust manifold side and mounting bolts on the vehi-
cle side. Check each part for unusual interference, and then tighten them to the specified torque.
When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/
left directions.
INSPECTION AFTER INSTALLATION
Make sure clearance between tail tube and bumper is even.
With engine running, check exhaust tube joints for gas leakage and unusual noises.
Check to ensure that mounting brackets and mounting rubbers are installed properly and free from undue
stress. Improper installation could result in excessive noise and vibration.
PBIC1049E
FAX-1
FRONT AXLE
D DRIVELINE/AXLE
CONTENTS
C E F
G H
I
J
K L
M
SECTION
A
B
FA X
Revision: 2006 July 2007 FX35/FX45
FRONT AXLE
2WD
PREPARATION ........................................................... 2
Special Service Tools .......................................... ..... 2
Commercial Service Tools ................................... ..... 2
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ........................................... ..... 3
NVH Troubleshooting Chart ................................ ..... 3
FRONT WHEEL HUB AND KNUCKLE ................. ..... 4
On-Vehicle Inspection ......................................... ..... 4
WHEEL BEARING INSPECTION .................... ..... 4
Removal and Installation ..................................... ..... 4
COMPONENTS ............................................... ..... 4
REMOVAL ........................................................ ..... 4
INSPECTION AFTER REMOVAL .................... ..... 5
INSTALLATION ................................................ ..... 5
SERVICE DATA AND SPECIFICATIONS (SDS) ... ..... 6
Wheel Bearing ..................................................... ..... 6
AWD
PRECAUTIONS ..................................................... ..... 7
Caution ................................................................ ..... 7
PREPARATION ...................................................... ..... 8
Special Service Tools .......................................... ..... 8
Commercial Service Tools ................................... ..... 8
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ........................................... ..... 9
NVH Troubleshooting Chart ................................ ..... 9
FRONT WHEEL HUB AND KNUCKLE ................. ... 10
On-Vehicle Inspection ......................................... ... 10 WHEEL BEARING INSPECTION ....................
... 10
Removal and Installation ..................................... ... 10
COMPONENTS ................................................ ... 10
REMOVAL ........................................................ ... 10
INSPECTION AFTER REMOVAL .................... ... 11
INSTALLATION ................................................ ... 11
FRONT DRIVE SHAFT .......................................... ... 12
On-Vehicle Inspection .......................................... ... 12
DRIVE SHAFT BOOT REPLACEMENT ........... ... 12
Removal and Installation (Left Side) .................... ... 15
COMPONENTS ................................................ ... 15
REMOVAL ........................................................ ... 15
INSPECTION AFTER REMOVAL .................... ... 15
INSTALLATION ................................................ ... 15
Removal and Installation (Right Side) ................. ... 16
COMPONENTS ................................................ ... 16
REMOVAL ........................................................ ... 16
INSPECTION AFTER REMOVAL .................... ... 16
INSTALLATION ................................................ ... 17
Disassembly and Assembly (Left Side) ............... ... 18
COMPONENTS ................................................ ... 18
DISASSEMBLY ................................................ ... 18
INSPECTION AFTER DISASSEMBLY ............. ... 19
ASSEMBLY ...................................................... ... 20
Disassembly and Assembly (Right Side) ............. ... 22
COMPONENTS ................................................ ... 22
DISASSEMBLY ................................................ ... 22
INSPECTION AFTER DISASSEMBLY ............. ... 23
ASSEMBLY ...................................................... ... 24
SERVICE DATA AND SPECIFICATIONS (SDS) ... ... 26
Wheel Bearing ..................................................... ... 26
Drive Shaft ........................................................... ... 26