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1. JPBIA0018ZZ Revision 2009 March EM 207 2009 FX35 FX50 OIL PAN UPPER lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE OIL PAN UPPER Exploded View INFOID 0000000003733445 SEC 110 150 213 fg 8 8 0 90 78 fy 8 8 0 90 78 2 5 18 0 21 6 2 2 16 0 21 6 2 2 16 l p m 8 8 0 90 78 5S JPBIA2088GB 1 Oil level gauge 2 Oil level gauge guide 3 O ring 4 Oil cooler 5 Connector bolt 6 Oil filter Drain plug washer 8 Oil pan lower 9 Oil strainer 10 Gasket 11 Oil temperature sensor 12 Oil pressure switch 13 O ring 14 Axle pipe 15 O ring 16 Rear plate cover 17 Crankshaft position sensor POS 18 O ring 19 O ring 20 Baffle plate 21 Baffle plate A Refer to LU 29 B Refer to LU 28 C Oil pump side lt Oil pan side Refer to Gl 4 Components for symbols in the figure Revision 2009 March EM 208 2009 FX35 FX50 OIL PAN UPPER lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE Disassembly and Assembly INFO1D 0000000008733446 DISASSEMBLY WARNING To avoid the danger of being scalded never drain engine oil when engine is hot EM 1 Remove oil filter Refer to LU 28 Removal and Installation 2 Remove oil cooler Refer to LU 29 Exploded View 3 Remove A C compressor and A C compressor bracket Refer to HA 94 Exploded View and EM 212 Exploded View Remove oil level gauge and oil level gauge guide Remove oil pressure switch and oil temperature sen
2. 0 33 0 48 0 0130 0 0189 0 67 0 0264 Top End gap 2nd Oil rail ring PISTON PIN Items 0 17 0 47 0 0067 0 0185 Standard 0 82 0 0323 Unit mm in Limit Piston pin outer diameter 21 989 21 995 0 8657 0 8659 Piston to piston pin oil clearance 0 002 0 006 0 0001 0 0002 Connecting rod bushing oil clearance CONNECTING ROD Items 0 005 0 017 0 0002 0 0007 Standard 0 030 0 0012 Unit mm in Limit Center distance 157 68 157 78 6 21 6 21 Bend per 100 3 94 0 15 0 0059 Torsion per 100 3 94 0 30 0 0118 Connecting rod bushing inner diameter 22 000 22 006 0 8661 0 8664 Connecting rod big end diameter Without bearing Grade No A Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No ZEereoanc roa mama wD 57 000 57 001 2 2441 2 2441 57 001 57 002 2 2441 2 2442 57 002 57 003 2 2442 2 2442 57 003 57 004 2 2442 2 2442 57 004 57 005 2 2442 2 2443 57 005 57 006 2 2443 2 2443 57 006 57 007 2 2443 2 2444 57 007 57 008 2 2444 2 2444 57 008 57 009 2 2444 2 2444 57 009 57 010 2 2444 2 2445 57 010 57 011 2 2445 2 2445 57 011 57 012 2 2445 2 2446 57 012 57 013 2 2446 2 2446 Side clearance After installing in connecting rod C
3. 17 Install pilot converter e With a drift of the following outer diameter press fit as far as it will go Pilot converter Approximately 33 mm 1 30 in PBIC2947E e Press fit pilot converter with its chamfer facing crankshaft as shown in the figure lt _ Crankshaft side JPBIA0210ZZ Revision 2009 March EM 125 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR 18 Install knock sensors A Bank 1 B Bank 2 lt Engine front e Install knock sensor so that connector faces rear of the engine e After installing knock sensor connect harness connector and lay it out to rear of the engine CAUTION e Never tighten mounting bolts while holding connector e If any impact by dropping is applied to knock sensor replace it with new one NOTE e Check that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor e Check that knock sensor does not interfere with other parts JPBIA0211ZZ 19 Note the following item assemble in the reverse order of disassembly after this step Drive plate e When installing drive plate to crankshaft 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 turns on e Install drive plate 2 and reinforcement plate 3 as shown in the figure 1 Ring gear 4 Pilot converter 5
4. A B C E H J K L M N Measure the connecting rod big end diameter Refer to EM 147 Cylinder Block Check that the connecting rod big end diameter is within the standard value Measure the crankshaft pin journal diameter Refer to EM 147 Cylinder Block Determine the grade of crankshaft pin diameter grade by corresponding to the measured dimension in Crankshaft pin journal diameter column of CONNECTING ROD BEARING SELECTION TABLE Select connecting rod bearing of the same grade alalalalala oe a aaa as Unit mm in St i se ce Se el se be se be oe be p k sie aa fied aea ood Daa eke be all eal kes 5 ALA AL AT Alalalatalatalala Crankshaft v lelalalalolo sl tll lololo i z3 til is sis isi sisisisi sis pin sound NNN NMN NMN MARE diameter A EA EA E EA EA E E A E A A Unit mm in claloa ls wlol njoalalol aualo I Ole lela ea EA Eea Ee AEA Gaa ere SWESS ENS S NI SE SE SISSE NINININI NI N N N N N N N N 10 O O 0 0 0 oOj Oj oo ooj oOojoojoA o lzlialolt ojelnjl oj laj oj j a ora al alo olola o a eae e E Mark Axle diameter ojojojajajajejajejejojoje NINI NI NI NI NI N N N N N N N wW 0 0 0 0 0 o o o o o o jo a 63974 53973 1250 21240 0 0 oo loloj i ii i aTe B 53 973 53 972 2 1249 2 1249 0 0 O 1 1 A 17 1 27 2 Cc 53 972 53 971 2 1249
5. Exhaust side e Secure the hexagonal portion of camshaft EXH using a wrench to tighten mounting bolt Refer to EM 227 Exploded View Intake side e Secure the hexagonal portion located in between journal No 1 and journal No 2 of drive shaft A using a wrench B to tighten mounting bolt Refer to EM 227 Exploded View lt 1 Engine front NOTE The figure shows an example of bank 2 JPBIA2302ZZ 3 Install timing chains as per the following a Install crankshaft sprockets for both banks e Install each crankshaft sprocket so that its flange side the larger diameter side without teeth A faces in the direction shown in the figure 1 Crankshaft sprocket bank 1 side 2 Crankshaft sprocket bank 2 side NOTE The same parts are used but facing directions are different JPBIA2114ZZ Revision 2009 March EM 219 2009 FX35 FX50 TIMING CHAIN lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE b Install timing chains Bank 2 F install min chain so that the matching mark outer groove B on camshaft sprocket is aligned with the copper link A on timing chain while the matching mark punched C on crank shaft sprocket is aligned with the yellow link D one on timing chain as shown in the figure Bank 1 G install ig chain so that the matching mark outer groove B on camshaft sprocket is aligned with the copper link A on timing chain while the matching mark notched
6. MAIN BEARING OIL CLEARANCE Method by Calculation e Install main bearings 3 to cylinder block 1 and main bearing cap 2 and tighten main bearing cap bolts to the specified torque Refer to EM 256 Disassembly and Assembly for the tightening procedure e Measure the inner diameter of main bearing with a bore gauge Oil clearance Main bearing inner diameter Crankshaft main journal diameter Standard and limit Refer to EM 291 Main Bearing e If the calculated value exceeds the limit select proper main bear ing according to main bearing inner diameter and crankshaft main JPBIA0232ZZ journal diameter to obtain the specified bearing oil clearance Refer to EM 274 Description Method of Using Plastigage e Remove engine oil and dust on crankshaft journal and the surfaces of each bearing completely e Cut a plastigage slightly shorter than the bearing width and place it in crankshaft axial direction avoiding oil holes e Install main bearing to cylinder block and main bearing cap and tighten main bearing cap bolts with main bearing cap to the specified torque Refer to EM 256 Disassembly and Assembly for the tightening proce dure CAUTION Never rotate crankshaft Revision 2009 March EM 271 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VK50VE e Remove main bearing cap and bearings and using the scale on the plastigage bag measure the plastigage width NOTE Th
7. AYANA Bearing housing grade No 2 of AECK J Bearing housing grade No 3 e GAO XD Bearing housing grade No 4 ENINN H Cylinder bore grade No 1 Cylinder bore grade No Cylinder bore grade No JPBIAO268ZZ Cylinder bore grade No Cylinder bore grade No our WwW PD Cylinder bore grade No Ao roo TTA nmMmroeawwWw gt Identification lt Engine front NOTE Piston is available with piston pin as a set for the service part Only 0 grade piston pin is available WHEN NEW CYLINDER BLOCK IS REUSED 1 Measure the cylinder bore inner diameter Refer to EM 147 Cylinder Block Revision 2009 March EM 136 2009 FX35 FX50 HOW TO SELECT PISTON AND BEARING lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR 2 Determine the bore grade by comparing the measurement with the values under the cylinder bore inner diameter of the PIS TON SELECTION TABLE A __ Piston grade number B Front mark C Piston pin grade number 3 Select piston of the same grade PISTON SELECTION TABLE Unit mm in Grade 1 2 3 Cylinder bore inner diameter 95 500 95 510 95 510 95 520 95 520 95 530 3 7598 3 7602 3 7602 3 7606 3 7606 3 7610 Piston skirt diameter 95 480 95 490 95 490 95 500 95 500 95 510 3 7590 3 7594 3 7594 3 7598 3 7598 3 7602 NOTE e Piston is available together with piston pin as assembly e Piston pin piston pin hole grade
8. 0 18 1 1 8 13 EJO 88 0 9 0 65 JPBIA1827GB 1 Sub harness 2 Knock sensor 3 Crankshaft position sensor Cylinder block heater for Canada 5 Cylinder block 6 Thrust bearing Main bearing upper 8 Crankshaft 9 Crankshaft key 10 Main bearing lower 11 O ring 12 Lower cylinder block bolt 13 Baffle plate 14 Lower cylinder block 15 Pilot converter 16 Reinforcement plate 17 Drive plate 18 Rear oil seal 19 Oil jet 20 Top ring 21 Second ring 22 Oil ring 23 Piston 24 Piston pin 25 Snap ring 26 Connecting rod 27 Connecting rod bearing 28 Connecting rod bearing cap 29 Connecting rod bolt A Refer to EM 118 B Chamfered C Front mark Revision 2009 March EM 117 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR lt 3 Crankshaft side Refer to Gl 4 Components for symbols in the figure Disassembly and Assembly INFO1D 0000000003887390 DISASSEMBLY 1 Remove the following parts e Oil pans lower and upper Refer to EM 100 2WD Exploded View 2WD models or EM 103 AWD Exploded View AWD models e Front and rear timing chain case Refer to EM 53 Exploded View and EM 95 Exploded View e Cylinder head Refer to EM 107 Exploded View Remove knock sensor CAUTION Carefully handle sensor avoiding shocks Remove baffle plate from lower cylinder block Remove piston and connecting rod assembly with the following procedure e Before removing pist
9. e VVEL ladder assembly cannot be replaced as a single part because it is machined together with cylinder head assembly VVEL Ladder Assembly amp Cylinder Head Assembly Features TDA DENS f pis LI VG RAY oh sei A TEE wp JPBIA2123ZZ Hexagonal part of drive shaft Hexagonal part of camshaft EXH A for holding B for holding C Stopper of control shaft D Two flat areas of control shaft for holding lt Engine front NOTE The figure shows an example of bank 1 Disassembly and Assembly INFOID 0000000003733451 DISASSEMBLY JPBIA2126ZZ CAUTION Never loosen adjusting bolts A and mounting bolts black color B of VVEL ladder assembly If loos ened the stroke of cam lift becomes out of adjustment In such case replacement of VVEL ladder assembly and cylinder head assembly is required NOTE VVEL ladder assembly cannot be replaced as a single part because it is machined together with cylinder head assembly 1 Remove rocker covers bank 1 and bank 2 Refer to EM 191 Exploded View Revision 2009 March EM 228 2009 FX35 FX50 CAMSHAFT lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE 2 Remove VVEL actuator sub assembly as per the following CAUTION VVEL actuator sub assembly and VVEL control shaft position sensor are not reusable Never remove them unless they are required a Remove VVEL control shaft posi
10. f Tighten all cylinder head bolts again clockwise Angle tightening 95 degrees 13 After installing cylinder head measure distance between front end faces of cylinder block and cylinder head bank 1 and bank 2 Standard 14 1 14 9 mm 0 555 0 587 in e If measured value is out of the standard reinstall cylinder head EMQ0662D 14 Install valve lifter e Install it in the original position Revision 2009 March EM 113 2009 FX35 FX50 CYLINDER HEAD lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR 15 Install spark plug with spark plug wrench commercial service tool 16 Install in the reverse order of removal after this step n S pect i O n INFOID 0000000003887388 INSPECTION AFTER REMOVAL Cylinder Head Bolts Outer Diameter e Cylinder head bolts are tightened by plastic zone tightening method Whenever the size difference between C and B exceeds the limit replace them with new one Limit C B 0 18 mm 0 0071 in A Measuring point e 48 mm 1 89 in d 11 mm 0 43 in e If reduction of outer diameter appears in a position other than B use it as B point JPBIA0173ZZ Cylinder Head Distortion NOTE When performing this inspection cylinder block distortion should be also checking Refer to EM 114 Inspec tion 1 Using a scraper wipe out oil scale gasket sealant and carbon deposits from surface of cylinder head CAUTION Never allow gasket fragments to enter engi
11. 15 0 N m 1 5 kg m 11 ft lb e After all bolts are tightened retighten them to the specified torque in numerical order shown in the figure If liquid gasket protrudes wipe it off immediately f After installing rear timing chain case check the surface height difference between the following parts on the oil pan upper mounting surface 1 Rear timing chain case 2 Lower cylinder block Standard Rear timing chain case to lower cylinder block 0 24 to 0 14 mm 0 0094 to 0 0055 in e If not within the standard repeat the installation procedure 3 Install water pump with new O rings Refer to CO 19 Exploded View 4 Check that dowel pin A and crankshaft key 1 are located as shown in the figure No 1 cylinder at compression TDC NOTE Though camshaft does not stop at the position as shown in the figure for the placement of cam nose it is generally accepted camshaft is placed for the same direction of the figure Camshaft dowel pin At cylinder head upper face side in each bank Crankshaft key At cylinder head side of bank 1 JPBIA0094ZZ 5 Install timing chains secondary and camshaft sprockets as per the following CAUTION Matching marks between timing chain and sprockets slip easily Confirm all matching mark posi tions repeatedly during the installation process a Push plunger of timing chain tensioner secondary and keep it pressed in with a stopper pin A JPBIAO095ZZ
12. 3 Subtract c from d Limit d c 0 09 mm 0 0035 in s PBIAN2EAE 4 If it exceeds the limit large difference in dimensions replace the bolt with new one DRIVE PLATE e Check drive plate and signal plate for deformation or damage CAUTION Never disassemble drive plate Never place drive plate with signal plate facing down e When handling signal plate take care not to damage or scratch it e Handle signal plate in a manner that prevents it from becom ing magnetized e If damage is found replace drive plate JPBIA0192ZZ OIL JET e Check nozzle for deformation and damage Blow compressed air from nozzle and check for clogs e If itis not satisfied clean or replace oil jet OIL JET RELIEF VALVE e Using a clean plastic stick press check valve in oil jet relief valve Check that valve moves smoothly with proper reaction force e If it is not satisfied replace oil jet relief valve EMU0468D Revision 2009 March EM 135 2009 FX35 FX50 HOW TO SELECT PISTON AND BEARING lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR HOW TO SELECT PISTON AND BEARING D esc ri pti O n INFOID 0000000003887392 Selection points Selection parts Selection items Selection methods Determined by match of cylin der block bearing housing Between cylinder block and Main beatin Main bearing grade grade inner diameter of hous crankshaft 9 bearing thickness ing and crankshaft journal grade outer diamet
13. O te ite ie alan fo Q O N Hole diameter 69 993 69 994 2 7556 2 7557 e gt 1O ite N O uw ito N oO oO oO oO N jo jo oO 69 996 69 997 2 7557 2 7558 69 997 69 998 2 7558 2 7558 69 998 69 999 2 7558 2 7559 70 001 70 002 2 7559 2 7560 70 003 70 004 2 7560 2 7561 70 004 70 005 2 7561 2 7561 70 014 70 015 2 7565 2 7565 70 016 70 017 2 7565 2 7566 69 995 69 996 2 7557 2 7557 Q e2 O O Ke 64 975 64 974 2 5581 2 5580 0 Cie 64 974 64 973 2 5580 2 5580 0 0 01 01 1 1 2 12 2 64 972 64 971 2 5579 2 5579 01 01 01 1 1 1 12 12 12 2 2 2 23 23 2 3 64 970 64 969 2 5579 2 5578 01 1 4 2 2 2 23 3 3 3 34 34 34 4 64 969 64 968 2 5578 2 5578 1 1 1 12 2 2 2 23 23 3 3 34 34 34 4 4 3 34 34 a4 4 4 4 34 34 34 4 4 4 45 64 968 64 967 2 5578 2 5578 1 1 12 12 2 2 2al2al23 64 967 64 966 2 5578 2 5577 1 12 12 12 2 23 23 23 3 64 966 64 965 2 5577 2 5577 12 12 12 2 2 2 23 23 23 3 3 34 34 4 4 4 45 45 64 965 64 964 2 5577 2 5576 12 12 2 2 2 23 23 23 3 3 3 34 34 34 4 4 4 45 45 45 5 5 5 64 964 64 963 2 5576 2 5576 12 2 2 2 23 23 23 3 3 3 34 34 34 4 4 4 45 45 45 5 5 5 56 56 64 963 64 962 2 5576 2 5576 2 2 2 23 23 23 3 3 3 3434134 4 4 4 45 45 45 5 5 5 56 50 56 64 9
14. OPERATION PROCEDURE 1 Connect both battery cables NOTE Supply power using jumper cables if battery is discharged 2 Turn the push button ignition switch to ACC position At this time the steering lock will be released 3 Disconnect both battery cables The steering lock will remain released with both battery cables discon nected and the steering wheel can be turned 4 Perform the necessary repair operation 5 When the repair work is completed re connect both battery cables With the brake pedal released turn the push button ignition switch from ACC position to ON position then to LOCK position The steering wheel will lock when the push button ignition switch is turned to LOCK position 6 Perform self diagnosis check of all control units using CONSULT III Draining Engine Coolant INFOID 0000000003887314 Drain engine coolant and engine oil when the engine is cooled Disconnecting Fuel Piping INFO1D 0000000003887315 e Before starting work check that no fire or spark producing items are in the work area e Release fuel pressure before disconnecting and disassembly e After disconnecting pipes plug openings to stop fuel leakage Removal and Disassembly INFOID 0000000003887316 e When instructed to use SST use specified tools Always be careful to work safely avoid forceful or unin structed operations Exercise maximum care to avoid damage to mating or sliding surfaces Dowel pins are used for several parts al
15. e Camshaft EXH and VVEL ladder assembly Refer to EM 227 Exploded View 2 Remove cylinder head e Loosen mounting bolts in reverse order as shown in the figure A Bank2 B Bank 1 lt Engine front e Use TORX socket and power tool JPBIA2145ZZ 3 Remove cylinder head gaskets Remove oil filter for VVEL ladder assembly from cylinder block if necessary 5 Remove valve lifter e Identify installation positions and store them without mixing them up 6 Remove valve collet e Compress valve spring with the valve spring compressor SST KV10116200 J 26336 A A the attachment SST A Y o CAUTION When working take care not to damage valve lifter holes KV10115900 J 26336 20 C and the adapter SST i T KV10109220 B Remove valve collet with a magnet i hand J O JPBIA1365ZZ 7 Remove valve spring retainer and valve spring with valve spring seat Revision 2009 March EM 246 2009 FX35 FX50 CYLINDER HEAD lt UNIT DISASSEMBLY AND ASSEMBLY gt VK50VE 8 Push valve stem to combustion chamber side and remove valve e Identify installation positions and store them without mixing them up 9 Remove valve oil seal using the valve oil seal puller SST KV10107902 J38959 A JPBIA1366ZZ 10 Remove valve seat EXH if valve seat EXH must be replaced e Bore out old seat until it collapses Boring should not continue beyond the bottom face of the s
16. 0 33 mm 0 013 in Revision 2009 March EM 23 2009 FX35 FX50 CAMSHAFT VALVE CLEARANCE lt PERIODIC MAINTENANCE gt VQ35HR e Thickness of new valve lifter can be identified by stamp marks on the reverse side inside the cylinder Stamp mark 788 indicates 7 88 mm 0 3102 in in thickness A Stamp B _ Thickness of valve lifter JPBIA0170ZZ Available thickness of valve lifter 27 sizes with range 7 88 to 8 40 mm 0 3102 to 0 3307 in in steps of 0 02 mm 0 0008 in when manufactured at factory Refer to EM 143 Camshaft Install selected valve lifter Install camshaft Refer to EM 70 Removal and Installation Manually turn crankshaft pulley a few turns Check that the valve clearances for cold engine are within the specifications by referring to the specified values Refer to EM 20 Inspection and Adjustment 10 Install all removal parts in the reverse order of removal 11 Warm up the engine and check for unusual noise and vibration oOo ON Revision 2009 March EM 24 2009 FX35 FX50 COMPRESSION PRESSURE lt PERIODIC MAINTENANCE gt VQ35HR COMPRESSION PRESSURE n S pect i O n INFOID 0000000003887334 1 Warm up engine thoroughly Then stop it 2 Release fuel pressure Refer to EC 567 Inspection 3 Disconnect fuel pump fuse 1 from IPDM E R 2 to avoid fuel injection during measurement 4 Remove engine cover with power tool Refer to EM 27 Exploded View 5 Remove i
17. CAUTION Install avoiding misalignment of both O rings e Tighten mounting bolts in numerical order as shown in the fig ure JPBIA0388ZZ lt Engine front e There are two types of mounting bolts Refer to the following for locating bolts M8 x 90 mm 3 54 in 7 10 13 M8 x 25 mm 0 98 in Except the above JPBIA0022ZZ 2 Install oil strainer to oil pump Install oil pan lower Refer to EM 47 Removal and Installation 4 Install oil pan drain plug e Refer to the figure of components of former page for installation direction of drain plug washer Refer to EM 46 Exploded View 5 Install in the reverse order of removal after this step NOTE At least 30 minutes after oil pan is installed pour engine oil 2W D F n S pect i O n INFOID 0000000003887382 w INSPECTION AFTER REMOVAL Clean oil strainer if any object attached INSPECTION AFTER INSTALLATION 1 Check the engine oil level and adjust engine oil Refer to LU 6 Inspection 2 Start engine and check there is no leakage of engine oil 3 Stop engine and wait for 10 minutes 4 Check the engine oil level again Refer to LU 6 Inspection AWD Revision 2009 March EM 102 2009 FX35 FX50 OIL PAN UPPER lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR AWD Exploded View INFOID 0000000003887383 SEC 110 150 2139253 JPBIA1847GB 1 Oil level gauge 2 Oil level gauge guide 3 O ring 4 Gasket 5 Oil filter bracket 6 W
18. Crankshaft A Rounded lt Engine front e Holding ring gear with the ring gear stopper SST KV10118600 J 48641 JPBIA021222 e Tighten the mounting bolts crosswise over several times n S pect i O n INFOID 0000000003887391 CRANKSHAFT END PLAY e Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with a dial indicator Standard and limit Refer to EM 147 Cylinder Block e If the measured value exceeds the limit replace thrust bearings and measure again If it still exceeds the limit replace crankshaft also CONNECTING ROD SIDE CLEARANCE Revision 2009 March EM 126 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR e Measure the side clearance between connecting rod and crank shaft arm with a feeler gauge Standard and limit Refer to EM 147 Cylinder Block e If the measured value exceeds the limit replace connecting rod and measure again If it still exceeds the limit replace crankshaft also PISTON TO PISTON PIN OIL CLEARANCE Piston Pin Hole Diameter Measure the inner diameter of piston pin hole with an inside micrometer A Standard Refer to EM 147 Cylinder Block JPBIA0217ZZ Piston Pin Outer Diameter Measure the outer diameter of piston pin with a micrometer A Standard _ Refer to EM 147 Cylinder Block JPBIA0218ZZ Piston to Piston Pin Oil Clearance Piston
19. E on crank shaft sprocket is aligned with the yellow link D one on timing chain as shown in the figure JPBIA2119ZZ 4 Install slack guides and tension guides onto correct side by checking with identification mark A on surface Slack guide bank 2 Tension guide bank 2 Slack guide bank 1 Tension guide bank 1 Ron CAUTION Never overtighten slack guide mounting bolt 2 It is nor mal for a gap A to exist under the bolt seats when mount ing bolt are tightened to the specification 1 Slack guide 3 Cylinder block JPBIAO117ZZ 5 Install timing chain tensioner as per the following Revision 2009 March EM 220 2009 FX35 FX50 TIMING CHAIN lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE a Fix the plunger at the most compressed position using a stopper pin A e Remove any dirt and foreign materials completely from the back and the mounting surfaces of timing chain tensioner Pull out stopper pin after installing and then release plunger Check again that the matching marks on sprockets and timing chain have not slipped out of alignment Install oil pump drive chain as per the following Install oil pump drive chain tensioner e Fix the tensioner at the most compressed position using a stopper pin and then install it Install the oil pump sprocket crankshaft side oil pump sprocket oil pump side and oil pump drive chain at the same time e Install each oil
20. Exploded View Intake side NOTE Since the valve INT and valve guide INT cannot be replaced by the piece VVEL ladder assembly amp cylin der head assembly replacement are required Valve Seat Contact e After confirming that the dimensions of valve guides and valves are within the specifications perform this procedure e Apply prussian blue or white lead onto contacting surface of valve seat to check the condition of the valve contact on the surface e Check if the contact area band is continuous all around the circum ference A OK B NG If not grind to adjust valve fitting and check again If the contacting surface still has NG conditions even after the re check replace valve seat EXH Refer to EM 245 Exploded View Exhaust side If not replace VVEL ladder assembly amp cylinder head assembly Refer to EM 227 Exploded View Intake side JPBIA0187ZZ Revision 2009 March EM 252 2009 FX35 FX50 CYLINDER HEAD lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE NOTE Since the valve seat INT cannot be replaced by the piece VVEL ladder assembly amp cylinder head assem bly replacement are required Valve Spring with valve spring seat Squareness e Set a try square A along the side of valve spring with valve spring seat and rotate spring Measure the maximum clearance between the top of spring and try square B Contact Limit Refer to EM 285 Cylinder Head e If it e
21. Identification code JPBIA2278ZZ 3 Select piston of the same grade PISTON SELECTION TABLE Unit mm in Grade 1 2 3 Siner bore innet diameter 95 500 95 510 95 510 95 520 95 520 95 530 y 3 7598 3 7602 3 7602 3 7606 3 7606 3 7610 Re eee 95 480 95 490 95 490 95 500 95 500 95 510 3 7590 3 7594 3 7594 3 7598 3 7598 3 7602 NOTE Piston is available together with piston pin as assembly Connecting Rod Bearing INFOID 0000000003733461 WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED 1 Apply connecting rod big end diameter grade stamped D on connecting rod side face to the row in the CONNECTING ROD BEARING SELECTION TABLE Management code JPBIA2273ZZ A Sample codes B Bearing stopper groove C Small end diameter grade E Weight grade F Cylinder No G H Front mark Revision 2009 March EM 275 2009 FX35 FX50 3 4 HOW TO SELECT PISTON AND BEARING lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE 2 Apply crankshaft pin journal diameter grade stamped on crank shaft front side to the column in the CONNECTING ROD BEARING SELECTION TABLE OACA Pin diameter grade No 1 Pin diameter grade No 2 Pin diameter grade No 3 Pin diameter grade No 4 Journal diameter grade No Journal diameter grade No JPBIA2283ZZ Journal diameter grade No raTtnanmoodadwa ry ot ie Journal diameter grade No 3 4 5
22. Install valve collet with a magnet i hand dp LN CAUTION a gt When working take care not to damage valve lifter holes z Tap valve stem edge lightly with plastic hammer after installa X 7 Ss E tion to check its installed condition ee Ww be N of D es a a JPBIA1365ZZ O 11 Install valve lifter e Install it in the original position 12 Install in the reverse order of removal n S p e ct i O n INFOID 0000000003733455 INSPECTION AFTER DISASSEMBLY Cylinder Head Bolts Outer Diameter e Cylinder head bolts are tightened by plastic zone tightening method Whenever the size difference between B and A exceeds the limit replace them with new one Limit B A 0 18 mm 0 0071 in c 55 mm 2 17 in d 12 mm 0 47 in e If reduction of outer diameter appears in a position other than A use it as A point JPBIA2144ZZ Cylinder Head Distortion NOTE When performing this inspection cylinder block distortion should be also checked Refer to EM 265 Inspec tion 1 Using a scraper wipe out oil scale gasket sealant and carbon deposits from surface of cylinder head CAUTION Never allow gasket fragments to enter engine oil or engine coolant passages Revision 2009 March EM 251 2009 FX35 FX50 CYLINDER HEAD lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE 2 At each of several locations on bottom surface of cylinder head measure the distortion in six directions A B
23. Seal cutter S NT046 KV10112100 Tightening bolts for bearing cap cylinder BT8653 A head etc Angle wrench Revision 2009 March S NT014 EM 159 2009 FX35 FX50 PREPARATION lt PREPARATION gt VK50VE Tool number Kent Moore No Description Tool name KV10114400 Loosening or tightening air fuel ratio sensor 1 J 38365 and heated oxygen sensor 2 Heated oxygen sensor wrench a 2 JPBIA0397ZZ a 22 mm 0 87 in KV10119200 J 49277 Ring gear stopper a O JPBIA0409ZZ Removing and installing crankshaft pulley KV10119300 Ce oe oad Adapter and torque wrench assembly Commercial Service Tool Kent Moore No Tool name Tightening rocker cover mounting bolts specified torque INFOID 0000000003733474 Description J 45488 Quick connector release PBICO198E Removing fuel tube quick connectors in en gine room Tube presser S NT052 Pressing the tube of liquid gasket CS Power tool PBICO190E Loosening nuts and bolts Spark plug wrench Revision 2009 March Ne JPBIAO399ZZ EM 160 Removing and installing spark plug a 14 mm 0 55 in 2009 FX35 FX50 lt PREPARATION gt Kent Moore No Tool name PREPARATION VK50VE Description Manual lift table caddy Removing and installing engine CE Pilot bushing puller NT045 Removing pilot converter Valve se
24. b Insert the seal cutter SST KV10111100 J 37228 A between oil pan upper and oil pan lower CAUTION Be careful not to damage the mating surfaces Never insert a screwdriver this will damage the mating surfaces c Slide the seal cutter by tapping on the side of tool with a ham mer Remove oil pan lower JPBIA0276ZZ 4 Remove oil strainer INSTALLATION 1 Install oil strainer 2 Install oil pan lower as per the following a Use scraper A to remove old liquid gasket from mating sur faces e Remove old liquid gasket from the bolt holes and thread CAUTION Never scratch or damage the mating surfaces when clean ing off old liquid gasket JPBIA0025ZZ b Apply a continuous bead of liquid gasket with the tube presser commercial service tool to the oil pan lower as shown in the figure lt Engine front a 64 0 5 0 mm 0 157 0 197 in Use Genuine RTV Silicone Sealant or an equivalent Refer to GI 15 Recommended Chemical Products and Sealants CAUTION Attaching must be done within 5 minutes after coating JPBIA1556ZZ c Install oil pan lower Revision 2009 March EM 48 2009 FX35 FX50 OIL PAN LOWER AND OIL STRAINER lt REMOVAL AND INSTALLATION gt VQ35HR e Tighten mounting bolts in numerical order as shown in the fig ure lt Engine front JPBIA0021ZZ 3 Install oil pan drain plug e Refer to the figure of components of former page for installati
25. ol olololg a O NJ a a a MAIN BEARING GRADE TABLE ALL JOURNALS Main bearing grade table All journals Refer to EM 151 Main Bearing UNDERSIZE BEARING USAGE GUIDE e When the specified main bearing oil clearance is not obtained with standard size main bearings use under size US bearing e When using undersize US bearing measure the main bearing inner diameter with bearing installed and grind main journal so that the main bearing oil clearance satisfies the standard Revision 2009 March EM 140 2009 FX35 FX50 HOW TO SELECT PISTON AND BEARING lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR CAUTION In grinding crankshaft main journal to use undersize bearings keep the fillet R A 1 5 1 7 mm 0 059 0 067 in JPBIA0216ZZ Bearing undersize table Refer to EM 151 Main Bearing Revision 2009 March EM 141 2009 FX35 FX50 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ35HR SERVICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS General Specification GENERAL SPECIFICATIONS Cylinder arrangement INFOID 0000000003887396 V 6 Displacement em cu in 3 498 213 45 Bore and stroke mm in 95 5 x 81 4 3 760 x 3 205 Valve arrangement DOHC Firing order 1 2 3 4 5 6 Number of piston rings ones s Oil 1 Number of main
26. 2 5573 2 5572 Grade No Y 64 954 64 953 2 5572 2 5572 Grade No 4 64 953 64 952 2 5572 2 5572 Grade No 7 64 952 64 951 2 5572 2 5571 Grade No A 53 974 53 973 2 1250 2 1249 Grade No B 53 973 53 972 2 1249 2 1249 Grade No C 53 972 53 971 2 1249 2 1248 Grade No D 53 971 53 970 2 1248 2 1248 Grade No E 53 970 53 969 2 1248 2 1248 Grade No F 53 969 53 968 2 1248 2 1247 Grade No G 53 968 53 967 2 1247 2 1247 Grade No H 53 967 53 966 2 1247 2 1246 o Grade No J 53 966 53 965 2 1246 2 1246 Pin journal diameter Dp grade Standard Grade No K 53 965 53 964 2 1246 2 1246 Grade No L 53 964 53 963 2 1246 2 1245 Grade No M 53 963 53 962 2 1245 2 1245 Grade No N 53 962 53 961 2 1245 2 1244 Grade No P 53 961 53 960 2 1244 2 1244 Grade No R 53 960 53 959 2 1244 2 1244 Grade No S 53 959 53 958 2 1244 2 1243 Grade No T 53 958 53 957 2 1243 2 1243 Grade No U 53 957 53 956 2 1243 2 1242 Center distance r 40 66 40 74 1 6008 1 6039 EM 150 Revision 2009 March 2009 FX35 FX50 lt SERVICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS VQ35HR Taper Difference between A and B ie 0 0025 0 0001 imi Out of round Difference between X and Y 0 0025 0 0001 Standard Less than 0 05 0 0020 Crankshaft runout TIR Limit 0 10 0 0
27. 4 4 4 4545 E 4 45 45 45 5 5 5 56 2 23 23 23 3 3 3 34 34 34 4 4 4 as 45 45 5 5 5 56 56 63 952 63 951 2 5178 2 5178 63 951 63 950 2 5178 2 5177 63 950 63 949 2 5177 2 5177 23 23 23 3 3 23 23 3 3 34 34 34 34 4 4 4 45 45 45 5 5 5 56 34 34 4 4 4 45 45 45 5 5 5 56 56 2 23 23 23 3 3 3 34 sa sa 4 4 4 45 45 45 5 5 5 56 56 56 6 6 63 949 63 948 2 5177 2 5176 63 948 63 947 2 5176 2 5176 23 23 23 3 3 3 34 34 34 23 23 3 3 3 34 34 34 56 oO 56 4 4 4 45 45 45 5 56 56 6 4 4 45 45 45 5 56 56 56 67 63 947 63 946 2 5176 2 5176 63 946 63 945 2 5176 2 5175 4 23 3 3 3 3434 34 4 4 3 3 3 l34 34 34 4 4 4 4 45 45 45 45 45 45 5 56 6 6 6 67 67 6 67 67 67 63 945 63 944 2 5175 2 5175 63 944 63 943 2 5175 2 5174 3 34 4 4 4 45 45 45 5 5 51 56 56 56 6 6 6 67 67 67 7 34 34 34 4 4 4 45 45 45 5 5 5 56 56 56 6 6 6 67 67 67 7 7 3 45 NJ nj lt lx lt clalol Do oj z z r xj lrioln mj ojojo gt 63 943 63 942 2 5174 2 5174 63 942 63 941 2 5174 2 5174 63 941 63 940 2 5174 2 5173 45 45 45 5 5 5 56 56 56 6 6 6 67 67 67 NJN 3 4 34 3 34 34 34 4 4 4 45 45 45 5 5 56 56 6 6 6 67 67 67 7 7 7 ele lal eelaele sla aae 4 4 4 4
28. 6 Remove rocker cover gasket from rocker cover 7 Use scraper to remove all traces of liquid gasket from cylinder head amp VVEL ladder assembly CAUTION Never scratch or damage the mating surface when cleaning off old liquid gasket 8 Remove PCV valve from rocker cover if necessary 9 Remove oil filler cap and oil catcher from rocker cover if necessary INSTALLATION 1 Apply liquid gasket with the tube presser commercial service tool to VVEL ladder assembly 1 and actuator bracket rear 2 3 VVEL actuator sub assembly A Liquid gasket application point F End surface of VVEL ladder assembly b 4mm 0 16 in c 2 5 3 5mm 0 098 0 138 in d 5mm 0 20 in e 10mm 0 39 in lt Engine front Use Genuine RTV Silicone Sealant or an equivalent Refer to GI 15 Recommended Chemical Products and Sealants NOTE The figure shows an example of bank 1 side Apply liquid gasket on the front and rear side of engine first 5 mm 0 20 in 5 mm 0 20 in side as shown in the figure Revision 2009 March EM 192 2009 FX35 FX50 IGNITION COIL SPARK PLUG AND ROCKER COVER lt REMOVAL AND INSTALLATION gt VK50VE 2 Install rocker cover gasket to rocker cover 3 Install rocker cover e Check that rocker cover gasket does not drop from the installation groove of rocker cover 4 Tighten bolts in two steps separately in numerical order as shown in the figure A Bank2 B Bank 1 lt E
29. A first JPBIA2147ZZ 4 Install pilot converter to crankshaft if removed e With drift outer diameter approx 35 mm 1 38 in press fit as far as it will go EMP0569D Revision 2009 March EM 259 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt e Press fit pilot converter with its chamfering side facing crank shaft as shown in the figure lt Crankshaft side 5 Install main bearings and thrust bearings as per the following CAUTION VK50VE JPBIA0210ZZ Be careful not to drop main bearing and to scratch the surface Install thrust bearings 2 to both sides of the No 3 journal hous ing on cylinder block 1 3 Main bearing upper cylinder block side 4 Crankshaft 5 Main bearing lower main bearing cap side Engine front lt e Install thrust bearings with the oil groove A facing crankshaft arm outside c Install main bearings paying attention to the direction e 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 cut out of cylinder block and main bearing Ensure the oil holes on cylinder block and those on the corre sponding bearing are aligned 6 Install crankshaft to c
30. ASSEMBLY 1 Fully air blow engine coolant and engine oil passages in cylinder block cylinder bore and crankcase to remove any foreign material CAUTION Use a goggles to protect your eye 2 Install each plug to cylinder block as shown in the figure 3 Plug lt Engine front e Apply sealant to the thread of water drain plugs 1 4 Use Genuine RTV Silicone Sealant or an equivalent Refer to GI 15 Recommended Chemical Products and Seal ants e Apply sealant to the thread of plugs Use Genuine high strength thread locking sealant or an equivalent Refer to Gl 15 Recommended Chemical Products and Sealants e Replace washers 2 with new one JPBIAO191ZZ e Tighten each plug as specified below o Pat o Wahe S Tienie SS 1 No 19 6 N m 2 0 kg m 14 ft lb 3 Yes 78 0 N m 8 0 kg m 58 ft lb 4 Yes 12 3 N m 1 3 kg m 9 ft lb 3 Install oil jet Revision 2009 March EM 120 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR e Insert oil jet dowel pin A into cylinder block dowel pin hole and tighten mounting bolts lt 1 Engine front JPBIA0198ZZ 4 Install main bearings and thrust bearings as per the following CAUTION Be careful not to drop main bearing and to scratch the surface a Remove dust dirt and engine oil on bearing mating surfaces of cylinder block and lower cylinder block b Install thrust bearings 1 to the both side
31. CAUTION Never scratch or damage the mating surface when cleaning off old liquid gasket INSTALLATION Revision 2009 March EM 51 2009 FX35 FX50 IGNITION COIL SPARK PLUG AND ROCKER COVER lt REMOVAL AND INSTALLATION gt VQ35HR 1 Apply liquid gasket to the position shown in the figure with the following procedure Liquid gasket application point View F End surface of camshaft bracket No 1 4 mm 0 16 in 02 5 3 5 mm 0 098 0 138 in 5 mm 0 20 in 10 mm 0 39 in lt Engine front aaoo onh Use Genuine RTV silicone sealant or an equivalent Refer to GI 15 Recommended Chemical Products and Sealants a Refer to figure E to apply liquid gasket to joint part of camshaft bracket No 1 1 and cylinder head b Refer to figure H to apply liquid gasket in 90 degrees to figure JPBIA0274ZZ 2 Install rocker cover gasket to rocker cover 3 Install rocker cover e Check if rocker cover gasket is not dropped from the installation groove of rocker cover 4 Tighten bolts in two steps separately in numerical order as shown in the figure lt Engine front lg 1st step 2 0 N m 0 2 kg m 18 in Ib o 2nd step 8 3 N m 0 85 kg m 73 in Ib JPBIA0040ZZ 5 Install in the reverse order of removal after this step Revision 2009 March EM 52 2009 FX35 FX50 TIMING CHAIN lt REMOVAL AND INSTALLATION gt VQ35HR TIMING CHAIN Exploded View INFOID 00000000
32. During alignment be careful to prevent dislocation of matching mark alignments of timing chains secondary JPBIA1601ZZ 5 Install internal chain guide 1 slack guide 2 JPBIA0086ZZ CAUTION Revision 2009 March EM 63 2009 FX35 FX50 TIMING CHAIN lt REMOVAL AND INSTALLATION gt VQ35HR Never overtighten slack guide mounting bolts 2 It is nor mal for a gap A to exist under the bolt seats when mount ing bolts are tightened to the specification 1 Slack guide 3 Cylinder block JPBIAO117ZZ 6 Install the timing chain tensioner primary with the following procedure Pull plunger stopper tab A up or turn lever downward so as to remove plunger stopper tab from the ratchet of plunger D NOTE Plunger stopper tab and lever C are synchronized T b Push plunger into the inside of tensioner body WwW c Hold plunger in the fully compressed position by engaging eves N L plunger stopper tab with the tip of ratchet al d To secure lever insert stopper pin E through hole of lever into tensioner body hole B e The lever parts and the plunger stopper tab are synchronized Therefore the plunger will be secured under this condition JPBIAOTIBZZ NOTE Figure shows the example of 1 2 mm 0 047 in diameter thin screwdriver being used as the stopper pin e Install timing chain tensioner primary 1 e Remove any dirt and foreign materials completely from the back and the mounting sur
33. Exploded View 3 Remove exhaust manifold Refer to EM 36 Exploded View 4 Remove oil pan lower Refer to EM 46 Exploded View 5 Remove ignition coil spark plug and rocker cover Refer to EM 50 Exploded View 6 Remove fuel injector and fuel tube Refer to EM 40 Exploded View 7 Remove timing chain Refer to EM 53 Exploded View 8 Remove rear timing chain case Refer to EM 95 Exploded View 9 Remove camshaft Refer to EM 70 Exploded View 10 Remove cylinder head Refer to EM 107 Exploded View As S e m b y INFOID 0000000003887376 Assembly in the reverse order of disassembly Revision 2009 March EM 94 2009 FX35 FX50 REAR TIMING CHAIN CASE lt UNIT DISASSEMBLY AND ASSEMBLY gt REAR TIMING CHAIN CASE Exploded View VQ35HR INFOID 0000000003887377 SEC 120 130 135 150 210 QO ae a 0 61 3 t 6 3 45 S lt TE QI we 2 9 61 3 OK oe N 6 3 45 Prof 96 098 95 9 28 0 2 9 21 a 4 9 11 3 1 2 8 ge X 9 6 0 98 85 JPBIA2441GB 1 4 7 Timing chain secondary Timing chain secondary Timing chain primary Revision 2009 March Camshaft sprocket EXH Camshaft sprocket EXH Camshaft sprocket INT EM 95 O ring Internal chain guide Timing chain tensioner primary 2009 FX35 FX50 REAR TIMING CHAIN CASE lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR 10 Slack guide 11 Crankshaft sprocket
34. Force fit valve seat into cylinder head WARNING Cylinder head contains heat When working wear protective equipment to avoid getting burned CAUTION Never directly touching cold valve seats d Using the valve seat cutter set commercial service tool or valve seat grinder finish seat to the specified dimensions Refer to EM 145 Cylinder Head CAUTION When using the valve seat cutter firmly grip cutter handle with both hands Then press on the contacting surface all around the circumference to cut in a single drive Improper pressure on with cutter or cutting many different times may result in stage valve seat SEM934C Using compound grind to adjust valve fitting EM 107 Disassembly and Assembly Install new valve oil seals as per the following Apply new engine oil on valve oil seal joint and seal lip Install with the valve oil seal drift SST KV10115600 J 38958 A to match dimension in the figure TP oO Height b Without valve spring seat installed Intake and exhaust 14 3 14 9 mm 0 563 0 587 in JPBIAO178ZZ 4 Install valve spring seat 5 Install valve NOTE Larger diameter valves are for intake side 6 Install valve spring uneven pitch type Revision 2009 March EM 111 2009 FX35 FX50 CYLINDER HEAD lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR e Install narrow pitch end to cylinder head side valve spring seat side Wide pitch Narrow pitch Pai
35. VKSOVE e VVEL actuator arm B is factory fixed at 10 degrees from the small lift with a holding jig A e The holding jig is supplied in the new VVEL actuator sub assembly CAUTION Never disassemble VVEL actuator sub assembly Never loosen actuator motor mounting bolts A shown in the figure Never impact VVEL actuator sub assembly a Move control shaft to the position of small lift stopper e The position where a part of the stopper of control shaft con tacts VVEL ladder bracket 1 VVEL ladder assembly bank 2 2 _ VVEL ladder assembly bank 1 A Stopper of control shaft Small lift side CAUTION Be careful not to damage the stopper surface JPBIA2134ZZ e If control shaft cannot be moved set crankshaft in position referring to the information below To dis place cam nose Bank 1 Turn 360 degrees from No 1 cylinder at TDC Bank2 No 1 cylinder at TDC Revision 2009 March EM 233 2009 FX35 FX50 CAMSHAFT lt UNIT DISASSEMBLY AND ASSEMBLY gt VK50VE b Hold two flat areas of control shaft with a wrench and rotate the control shaft 10 degrees from the stopper to the large lift side This is for aligning the bolt hole of control shaft and the hole of VVEL actuator arm 1 VVEL actuator sub assembly bank 2 A Control shaft B ViewB C Holding jig d 10 degrees Large lift side NOTE The figure shows an example of bank 2 JPBIA2139ZZ c Apply a continuous be
36. dure e Measure inner diameter A of VVEL ladder assembly EXH side with a bore gauge Standard Refer to EM 283 Camshaft PBIC1645E CAMSHAFT EXH JOURNAL OIL CLEARANCE e Oil clearance VVEL ladder assembly EXH side inner diameter Camshaft EXH journal diameter Standard and limit Refer to EM 283 Camshaft If the calculated value exceeds the limit replace either or both camshaft EXH and VVEL ladder assembly amp cylinder head assembly NOTE VVEL ladder assembly cannot be replaced as a single part because it is machined together with cylinder head assembly Camshaft EXH End Play Revision 2009 March EM 238 2009 FX35 FX50 CAMSHAFT lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE e Install a dial indicator in thrust direction on front end of camshaft Measure the end play of a dial indicator when camshaft EXH is moved forward backward in direction of axis Standard and limit Refer to EM 283 Camshaft e Measure the following parts if out of the limit Dimension A for camshaft EXH No 1 journal Standard 30 500 30 548 mm 1 2008 1 2027 in Dimension B for cylinder head No 1 journal bearing Standard 30 360 30 385 mm 1 1953 1 1963 in e Refer to the standards above and then replace camshaft EXH and or VVEL ladder assembly amp cylinder head assembly N OTE C kas Cylinder head assembly cannot be replaced as a single part because i
37. fill to the specified level Refer to MA 12 Fluids and Lubricants e Use procedure below to check for fuel leakage Revision 2009 March EM 115 2009 FX35 FX50 age at connection points CYLINDER HEAD lt UNIT DISASSEMBLY AND ASSEMBLY gt Turn ignition switch ON with engine stopped With fuel pressure applied to fuel piping check for fuel leak VQ35HR Start engine With engine speed increased check again for fuel leakage at connection points e Run engine to check for unusual noise and vibration e Warm up engine thoroughly to check there is no leakage of fuel exhaust gases or any oil fluids including engine oil and engine coolant e Bleed air from lines and hoses of applicable lines such as in cooling system e 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 Items 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 Transmission transaxle CVT fluid power steering fluid brake fluid etc Revision 2009 March EM 116 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR CYLINDER BLOCK Exploded View INFOID 0000000003887389 SEC 110 120 226
38. mm diameter in Axle diameter Unit mm in 68 949 68 950 2 7145 2 7146 68 950 68 951 2 7146 2 7146 68 951 68 952 2 7146 2 7146 68 952 68 953 2 7146 2 7147 68 953 68 954 2 7147 2 7147 68 954 68 955 2 7147 2 7148 68 955 68 956 2 7148 2 7148 68 956 68 957 2 7148 2 7148 68 957 68 958 2 7148 2 7149 68 958 68 959 2 7149 2 7149 68 959 68 960 2 7149 2 7150 68 960 68 961 2 7150 2 7150 68 961 68 962 2 7150 2 7150 68 962 68 963 2 7150 2 7151 68 965 68 966 2 7152 2 7152 68 963 68 964 2 7151 2 7151 68 964 68 965 2 7151 2 7152 68 966 68 967 2 7152 2 7152 68 967 68 968 2 7152 2 7153 63 962 63 961 2 5182 2 5181 12 12 12 2 2 2 23 23 23 3 3 3 34 34 34 4 63 961 63 960 2 5181 2 5181 12 12 2 2 2 23 23 23 3 3 3 34 34 34 4 4 56 5 63 963 63 962 2 5182 2 5182 1 12 12 12 2 2 2 23 23 23 3 3 3 sae 5 5 L 63 960 63 959 2 5181 2 5181 12 2 63 959 63 958 2 5181 2 5180 2 2 23 3 3 3 34 34 4 4 4 45 45 45 5 6 56 n eass ze aer esien 281o f2 a nef a a Ta aalasala a a aslaefas fa Te esleofeele 63 957 63 956 2 5180 2 5179 2 23 23 23 3 34 34 34 4 4 45 45 45 5 56 56 56 6 a feses eoe eers zero flestas fafa sassa tafe aes ef es 63 955 63 954 2 5179 2 5179 23 23 63 954 63 953 2 5179 2 5178 23 3 6 63 953 63 952 2 51
39. with a hammer Heavy vibration could activate the sensor s and deploy the air bag s possibly causing serious injury When using air or electric power tools or hammers always switch the ignition OFF disconnect the battery and wait at least 3 minutes before performing any service Precaution Necessary for Steering Wheel Rotation after Battery Disconnect INFOID 0000000003901617 NOTE e Before removing and installing any control units first turn the push button ignition switch to the LOCK posi tion then disconnect both battery cables e After finishing work confirm that all control unit connectors are connected properly then re connect both battery cables e Always use CONSULT III to perform self diagnosis as a part of each function inspection after finishing work If a DTC is detected perform trouble diagnosis according to self diagnosis results This vehicle is equipped with a push button ignition switch and a steering lock unit If the battery is disconnected or discharged the steering wheel will lock and cannot be turned Revision 2009 March EM 155 2009 FX35 FX50 PRECAUTIONS lt PRECAUTION gt VKSOVE If turning the steering wheel is required with the battery disconnected or discharged 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 Turn the push button ignition switch to AC
40. 4 4 3 4 34 4 4 4 45 45 45 5 5 5 56 56 56 6 6 6 67 67 67 7 7 7 78 78 4 7 7 7 78 78 78 MAIN BEARING GRADE TABLE ALL JOURNALS Main bearing grade table All journals UNDERSIZE BEARING USAGE GUIDE e When the specified main bearing oil clearance is not obtained with standard size main bearings use under side US bearing e When using undersize US bearing measure the main bearing inner diameter with bearing installed and grind main journal so that the main bearing oil clearance satisfies the standard CAUTION Revision 2009 March EM 280 JPBIA2286GB Refer to EM 291 Main Bearing 2009 FX35 FX50 HOW TO SELECT PISTON AND BEARING lt UNIT DISASSEMBLY AND ASSEMBLY gt VK50VE In grinding crankshaft main journal to use undersize bearings keep the fillet R A 1 5 1 7 mm 0 059 0 067 in JPBIA0216ZZ Bearing undersize table Refer to EM 291 Main Bearing Revision 2009 March EM 281 2009 FX35 FX50 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS General Specification GENERAL SPECIFICATIONS Cylinder arrangement VK50VE INFOID 0000000003733463 V 8 Displacement em cu in 5 026 306 69 Bore and stroke mm in 95 5 x 87 7 3 76 x 3 453 Valve arran
41. 6 For the following operations perform steps in the reverse order of removal Revision 2009 March EM 99 2009 FX35 FX50 OIL PAN UPPER lt UNIT DISASSEMBLY AND ASSEMBLY gt OIL PAN UPPER 2WD 2WD Exploded View SEC 110 150 213 253 9 21 6 2 2 16 1 Oil level gauge 2 Oil level gauge guide 4 O ring 5 O ring 7 Connector bolt 8 Oil filter 10 Oil strainer 11 Oil pressure switch 13 Washer 14 Oil pan upper 16 Drain plug washer 17 Oil pan lower A Refer to LU 9 B To oil pump Refer to Gl 4 Components for symbols in the figure 2WD Disassembly and Assembly REMOVAL CAUTION VQ35HR INFOID 0000000003887380 9 17 2 1 8 13 JPBIA1940GB O ring Oil cooler Relief valve Oil temperature sensor Drain plug Rear plate cover Oil pan side INFOID 0000000003887381 Never drain engine oil when the engine is hot to avoid the danger of being scalded 1 Remove oil level gauge oil pressure switch and oil temperature sensor Revision 2009 March EM 100 2009 FX35 FX50 OIL PAN UPPER lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR 2 Remove oil pan lower Refer to EM 47 Removal and Installation 3 Remove oil strainer 4 Loosen mounting bolts in the reverse order as shown in the fig ure with power tool to remove lt 1 Engine front Insert the seal cutter SST KV10111100 J 37228 between oil pan upper and lower cylinder block Slide seal cutter by
42. A __ Triangle press lt Above JPBIA2078ZZ Exhaust Manifold Revision 2009 March EM 206 2009 FX35 FX50 EXHAUST MANIFOLD AND THREE WAY CATALYST lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE e Tighten mounting nuts in numerical order as shown in the figure A Bank 1 B Bank2 lt Engine front NOTE Tighten mounting nuts No 1 to 4 in two steps The numerical order No 9 to 12 shown second steps pale Air Fuel Ratio Sensor 1 Heated Oxygen Sensor 2 CAUTION Before installing a new sensors clean exhaust system threads using oxygen sensor thread cleaner commercial service tool J 43897 18 or J 43897 12 and apply anti seize lubricant commercial ser vice tool Sensors are not reusable Replace them with a new one after removal When replacing them handle with care not to impact on them When installing the new sensors set the heated oxygen sen sor wrench SST KV10114400 J 38365 A in the hexagonal part to tighten the them 1 Heated oxygen sensor 2 bank 1 JPBIA2329ZZ Never over torque sensors Doing so may cause damage to the sensors resulting in MIL coming on n S pect i O n INFOID 0000000003733425 INSPECTION AFTER DISASSEMBLY Surface Distortion e Check the surface distortion of the exhaust manifold mating sur face with a straightedge A and a feeler gauge B Limit Refer to EM 283 Exhaust Manifold e If it exceeds the limit replace exhaust manifold
43. Angle tightening 90 degrees CAUTION Use the angle wrench SST KV10112100 BT8653 A A to check tightening angle Never make judgment by visual inspection f Tighten main bearing cap sub bolts M9 in order of No 11 20 clockwise Angle tightening 90 degrees g Tighten side bolts M10 in order of No 21 30 OJ 49 0 N m 5 0 kg m 36 ft Ib e After installing bolts check that crankshaft can be rotated smoothly by hand e Check the crankshaft end play Refer to EM 287 Cylinder Block 9 Install rear oil seal retainer e Apply a continuous bead of liquid gasket with tube presser commercial service tool to rear oil seal retainer as shown in the figure A Protrusion b 4 0 5 6 mm 0 157 0 220 in c 363 4 4 4 mm 0 134 0 173 in Use Genuine RTV Silicone Sealant or an equivalent Refer to GI 15 Recommended Chemical Products and Sealants JPBIA2102ZZ 10 Install rear oil seal on rear oil seal retainer CYLINDER BLOCK lt Engine inside Engine outside e Apply new engine oil to both oil seal lip A and dust seal lip B e Install it so that each seal lip is oriented as shown in the figure CAUTION Be careful not to scratch or make burrs on circumference of oil seal JPBIA0054ZZ Revision 2009 March EM 261 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE e Press in rear oil seal 1 to the position as shown in the figure B Rear oil seal retainer rear
44. C D E F Limit Refer to EM 285 Cylinder Head If it exceeds the limit replace VVEL ladder assembly amp cylinder head assembly NOTE Cylinder head assembly cannot be replaced as a single part because it is machined together with VVEL ladder assembly JPBIAO176ZZ Valve Dimensions e Check the dimensions of each valve For the dimensions refer to EM 285 Cylinder Head e If dimensions are out of the standard Replace valve EXH and check valve seat contact Refer to VALVE SEAT CONTACT Exhaust side Replace VVEL ladder assembly amp cylinder head assembly Refer to EM 227 Exploded View Intake side NOTE Since the valve INT cannot be replaced by the piece VVEL ladder assembly amp cylinder head assembly replacement are required Valve Guide Clearance Valve Stem Diameter e Measure the diameter of valve stem with micrometer A Standard Refer to EM 285 Cylinder Head Valve Guide Inner Diameter f f e Measure the inner diameter of valve guide with bore gauge Standard Refer to EM 285 Cylinder Head Valve Guide Clearance p e Valve guide clearance Valve guide inner diameter Valve stem diameter JPBIAO183ZZ Standard Refer to EM 285 Cylinder Head e If the calculated value exceeds the limit Replace valve EXH and or valve guide EXH Refer to EM 245 Exploded View Exhaust side Replace VVEL ladder assembly amp cylinder head assembly Refer to EM 227
45. Camshaft PBIC1645E CAMSHAFT JOURNAL OIL CLEARANCE e Oil clearance Camshaft bracket inner diameter Camshaft journal diameter Revision 2009 March EM 75 2009 FX35 FX50 CAMSHAFT lt REMOVAL AND INSTALLATION gt VQ35HR Standard and limit Refer to EM 143 Camshaft e If the calculated value exceeds the limit replace either or both camshaft and cylinder head NOTE Camshaft brackets cannot be replaced as single parts because there are machined together with cylinder head Replace whole cylinder head assembly Camshaft End Play e Install a dial indicator in thrust direction on front end of camshaft Measure the end play of a dial indicator when camshaft is moved forward backward in direction to axis Standard and limit Refer to EM 143 Camshaft e Measure the following parts if out of the limit Dimension A for camshaft No 1 journal Standard 27 500 27 548 mm 1 0827 1 0846 in Dimension B for cylinder head No 1 journal bearing Standard 27 360 27 385 mm 1 0772 1 0781 in e Refer to the standards above and then replace camshaft and or cylinder head KBIA2404J Camshaft Sprocket Runout 1 Put V block on precise flat table and support No 2 and 4 journals of camshaft CAUTION Never support No 1 journal on the side of camshaft sprocket because it has a different diameter from the other three locations 2 Measure the camshaft sprocket runout with
46. Check the engine oil level and adjust engine oil Refer to LU 6 Inspection Start engine and check there is no leakage of engine oil Stop engine and wait for 10 minutes Check the engine oil level again Refer to LU 6 Inspection Revision 2009 March EM 106 2009 FX35 FX50 CYLINDER HEAD lt UNIT DISASSEMBLY AND ASSEMBLY gt CYLINDER HEAD Exploded View VQ35HR INFOID 0000000003887386 SEC 111 130 220 Rix 0 19 6 a6 2 0 14 3 0 28 0 2 9 21 JPBIA1826GB Disassembly and Assembly 1 Valve lifter 2 Valve collet 3 Valve spring retainer 4 Valve spring 5 Valve oil seal 6 Valve spring seat 7 Valve guide 8 Cylinder head bolt 9 Spark plug 10 Spark plug tube 11 Cylinder head bank 1 12 Valve seat EXH 13 Valve EXH 14 Valve INT 15 Valve seat INT 16 Cylinder head gasket bank 1 17 Cylinder head gasket bank 2 18 Cylinder head bank 2 19 Engine rear lower slinger A Refer to EM 107 FAL Apply high strength thread locking sealant or equivalent Refer to Gl 4 Components for symbols not described on the above DISASSEMBLY 1 Remove the following parts Intake manifold collector Refer to EM 31 Exploded View Rocker cover and spark plug Refer to EM 50 Exploded View INFOID 0000000003887387 Fuel tube and fuel injector assembly Refer to EM 40 Exploded View Intake manifold Refer to EM 34 Exploded View Exhaust manifold Refer to EM 36 Explo
47. Clearance Connecting rod bushing oil clearance Connecting rod bushing inner diameter Piston pin outer diame ter Standard and limit Refer to EM 147 Cylinder Block e If the calculated value exceeds the limit replace connecting rod assembly and or piston and piston pin assembly e If replacing piston and piston pin assembly refer to EM 136 Description e If replacing connecting rod assembly refer to EM 137 Connecting Rod Bearing to select the connecting rod bearing A Sample codes B Bearing stopper groove C Small end diameter grade D Big end diameter grade E Weight grade F Cylinder No G Management code JPBIA0208ZZ Revision 2009 March EM 129 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR H Front mark l Management code Factory installed parts grading e Service parts apply only to grade 0 A Piston grade number B Front mark C Piston pin grade number Unit mm in Grade 0 1 Connecting rod bushing 22 000 22 006 22 006 22 012 inner diameter 0 8661 0 8664 0 8664 0 8666 Piston bin hole diameter 21 993 21 999 21 999 22 005 JPRIAOE7A P 0 8659 0 8661 0 8661 0 8663 Piston pin outer diameter 21 989 21 995 21 995 22 001 0 8657 0 8659 0 8659 0 8662 After installing in connecting rod CYLINDER BLOCK DISTORTION e Using a scraper remove gasket on the cylinder
48. Components for symbols in the figure AWD Revision 2009 March EM 46 VQ35HR INFOID 0000000003887353 Pe 9 17 2 1 8 13 9 6 9 0 70 61 JPBIA1940GB O ring Oil cooler Relief valve Oil temperature sensor Drain plug Rear plate cover Oil pan side 2009 FX35 FX50 OIL PAN LOWER AND OIL STRAINER lt REMOVAL AND INSTALLATION gt VQ35HR SEC 110 150 2139253 3 5 25 JPBIA1847GB 1 Oil level gauge 2 Oil level gauge guide 3 O ring 4 Gasket 5 Oil filter bracket 6 Washer 7 Oil temperature sensor 8 Oil pressure sensor 9 Relief valve 10 O ring 11 Oil cooler 12 Connector bolt 13 Oil filter 14 Oil strainer 15 Drain plug 16 Oil pan drain plug 17 Oil pan lower 18 O ring small 19 O ring large 20 Axle pipe 21 Rear plate cover 22 Oil pan upper 23 O ring A Refer to LU 9 B To oil pump C Oil pan side Refer to Gl 4 Components for symbols in the figure Removal and Installation INFOID 0000000003887355 REMOVAL WARNING To avoid the danger of being scalded never drain engine oil when engine is hot 1 Remove engine undercover with power tool 2 Drain engine oil Refer to LU 8 Draining 3 Remove oil pan lower as per the following Revision 2009 March EM 47 2009 FX35 FX50 OIL PAN LOWER AND OIL STRAINER lt REMOVAL AND INSTALLATION gt VQ35HR a Loosen mounting bolts in reverse order as shown in the figure to remove lt Engine front
49. EXH C x B pression TDC INT D x E Measuring position bank 2 H No 2 CYL No 4 CYL No 6 CYL No 1 cylinder atcom INT D x F pression TDC EXH C x G JPBIAO165ZZ c Rotate crankshaft 240 degrees clockwise when viewed from engine front to align No 3 cylinder at TDC its compression stroke NOTE Mark a position 240 degrees b from a corner of the hexagonal part of crankshaft pulley mounting bolt as shown in the figure Use the hexagonal part as a guide 1 Crankshaft pulley A Paint mark Revision 2009 March EM 21 2009 FX35 FX50 CAMSHAFT VALVE CLEARANCE lt PERIODIC MAINTENANCE gt VQ35HR e By referring to the figure measure the valve clearances at locations marked x as shown in the table below locations indicated in the figure lt x Engine front e No 3 cylinder at compression TDC Measuring position bank 1 A No 1 CYL No 3 CYL No 5 CYL No 3 cylinder at com EXH C x B pression TDC INT D x E Measuring position bank 2 H No 2 CYL No 4 CYL No 6 CYL No 3 cylinder at com INT D x F pression TDC EXH C x G JPBIAO167ZZ d Rotate crankshaft 240 degrees clockwise when viewed from engine front to align No 5 cylinder at TDC of compression stroke NOTE Mark a position 240 degrees b from a corner of the hexagonal part of crankshaft pulley mounting bolt as shown in the figure Use the hexagonal part
50. Exploded View INFOID 0000000003887344 SEC 140 fw 7 3 0 74 65 r PBIC5453E 1 Harness bracket 2 Intake manifold 3 Gasket A Refer to EM 34 Refer to Gl 4 Components for symbols in the figure Removal and nstal latio n INFOID 0000000003887345 REMOVAL 1 Release fuel pressure Refer to EC 567 Inspection 2 Remove intake manifold collector Refer to EM 31 Exploded View 3 Remove fuel tube and fuel injector assembly Refer to EM 40 Exploded View 4 Remove harness bracket 5 Loosen mounting bolts and nuts in reverse order as shown in the figure to remove intake manifold with power tool lt Engine front CAUTION e Cover engine openings to avoid entry of foreign materi als e Put a mark on the intake manifold and the cylinder head with paint before removal because they need installed in the specified direction 6 Remove gaskets INSTALLATION Note the following item and install in the reverse order of removal JPBIA0013ZZ INTAKE MANIFOLD e If stud bolts were removed install them and tighten to the specified torque below 10 8 N m 1 1 kg m 8 ft lb Revision 2009 March EM 34 2009 FX35 FX50 INTAKE MANIFOLD lt REMOVAL AND INSTALLATION gt VQ35HR e Tighten all mounting bolts and nuts to the specified torque in two or more steps in numerical order as shown in the figure lt Engine front CAUTION Install intake manifold with the marks put on the intake man
51. Journal diameter grade No Read the symbol at the cross point of selected row and column in the CONNECTING ROD BEARING SELECTION TABLE Apply the symbol obtained to the CONNECTING ROD BEARING GRADE TABLE to select connecting rod bearing WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED 1 2 3 4 Measure connecting rod big end diameter and crankshaft pin journal diameter Refer to EM 265 Inspec tion Correspond the measured dimension in connecting rod big end diameter row of CONNECTING ROD BEARING SELECTION TABLE Correspond the measured dimension in crankshaft pin journal diameter column of CONNECTING ROD BEARING SELECTION TABLE Follow from step 3 in WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED CONNECTING ROD BEARING SELECTION TABLE 53 974 53 973 2 1250 2 1249 _B__ 53 973 53 972 2 1249 2 1249 Cc 53 972 53 971 2 1249 2 1248 0 E _ 53 970 58 009 2 1248 0 1048 F 53 969 53 968 2 1248 2 1247 0 7 J 53 966 53 965 2 1246 2 1246 1 L 53 964 53 963 2 1246 2 1245 1 53 963 53 962 2 1245 2 1245 1 i eae ee P 50 061 58 960 1244 21244 2 2 R 53 960 53 959 2 1244 2 1244 2 2 2 2 53 959 53 958 2 1244 2 1243 2 2 T 53 958 53 957 2 1243 2 1243 2 2 3 U 53 957 53 956 2 1243 2 1242 2 3 3 ws Ej lt 0jojoajuwju Ir gt x z Connecting i Slalalalal a T Flol
52. Never spill engine coolant on drive belts NOTE When removing only intake manifold move electric throttle control actuator without disconnecting the water hoses Remove electric throttle control actuator e Loosen mounting bolts in reverse order as shown in the figure NOTE e The figure shows the electric throttle control actuator bank 1 viewed from the air duct side e Viewed from the air duct side the order of loosening mounting bolts of electric throttle control actuator bank 1 is the same as that of the electric throttle control actuator bank 2 CAUTION Handle carefully to avoid any impact to electric throttle control actuator Never disassemble JPBIA2362ZZ Remove intake manifold with power tool Revision 2009 March EM 180 2009 FX35 FX50 INTAKE MANIFOLD lt REMOVAL AND INSTALLATION gt VKSOVE e Loosen mounting bolts in reverse order as shown in the figure lt o Engine front JPBIA2077ZZ 13 Remove intake manifold gaskets CAUTION Cover engine openings to avoid entry of foreign materials 14 Remove manifold absolute pressure MAP sensor if necessary CAUTION Handle carefully to avoid any impact to manifold absolute pressure MAP sensor 15 Remove acoustic absorbent INSTALLATION Note the following item and install in the reverse order of removal Intake Manifold Tighten in numerical order as shown in the figure lt Engine front Electric Throttle Control Actua
53. Refer to LU 28 C Oil pump side lt Oil pan side Refer to Gl 4 Components for symbols in the figure Revision 2009 March EM 188 2009 FX35 FX50 OIL PAN LOWER AND OIL STRAINER lt REMOVAL AND INSTALLATION gt VKSOVE Removal and Installation INFOID 0000000003733430 REMOVAL WARNING To avoid the danger of being scalded never drain engine oil when engine is hot EM 1 Drain engine oil Refer toLU 26 Draining 2 Remove oil pan lower as per the following a Loosen mounting bolts in reverse order as shown in the figure to remove lt Engine front b Insert the seal cutter SST KV10111100 J 37228 A between oil pan upper and oil pan lower CAUTION e Be careful not to damage the mating surfaces Never insert a screwdriver This damages the mating sur faces c Slide the seal cutter by tapping on the side of tool with a ham mer Remove oil pan lower JPBIA0276ZZ 3 Remove oil strainer INSTALLATION 1 Install oil strainer Install oil pan lower as per the following a Use scraper A to remove old liquid gasket from mating sur faces e Remove old liquid gasket from the bolt holes and thread CAUTION Never scratch or damage the mating surfaces when clean ing off old liquid gasket JPBIA0025ZZ Revision 2009 March EM 189 2009 FX35 FX50 OIL PAN LOWER AND OIL STRAINER lt REMOVAL AND INSTALLATION gt VKSOVE b Apply a continuous bead of liquid gasket with the
54. Standard 69 993 70 017 2 7556 2 7566 EM 147 Revision 2009 March 2009 FX35 FX50 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ35HR Grade No 1 95 500 95 510 3 7598 3 7602 Standard Grade No 2 95 510 95 520 3 7602 3 7606 Cylinder bore Inner diameter Grade No 3 95 520 95 530 3 7606 3 7610 Wear limit 0 2 0 008 Out of round 0 015 0 0006 Taper 0 010 0 0004 Grade No A 69 993 69 994 2 7556 2 7557 Grade No B 69 994 69 995 2 7557 2 7557 Grade No C 69 995 69 996 2 7557 2 7557 Grade No D 69 996 69 997 2 7557 2 7558 Grade No E 69 997 69 998 2 7558 2 7558 Grade No F 69 998 69 999 2 7558 2 7559 Grade No G 69 999 70 000 2 7559 2 7559 Grade No H 70 000 70 001 2 7559 2 7559 Grade No J 70 001 70 002 2 7559 2 7560 Grade No K 70 002 70 003 2 7560 2 7560 Grade No L 70 003 70 004 2 7560 2 7561 F ee Grade No M 70 004 70 005 2 7561 2 7561 Main bearing housing inner diameter grade Without bearing Grade No N 70 005 70 006 2 7561 2 7561 Grade No P 70 006 70 007 2 7561 2 7562 Grade No R 70 007 70 008 2 7562 2 7562 Grade No S 70 008 70 009 2 7562 2 7563 Grade No T 70 009 70 010 2 7563 2 7563 Grade No U 70 010 70 011 2 7563 2 7563 Grade No V 70 011 70 012 2 7563 2 7564 Grade No W 70 012 70 013 2 7564 2 7564 Grade
55. Standard and limit Refer to EM 152 Connecting Rod Bearing ret e If the calculated value exceeds the limit select proper connecting rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance Refer to EM 137 Connecting Rod Bearing Method of Using Plastigage Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely Cut a plastigage slightly shorter than the bearing width and place it in crankshaft axial direction avoiding oil holes Install connecting rod bearings to connecting rod and connecting rod bearing cap and tighten connecting rod bolts to the specified torque Refer to EM 118 Disassembly and Assembly for the tightening proce dure CAUTION Never rotate crankshaft Remove connecting rod 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 MAIN BEARING OIL CLEARANCE Method by Calculation e Install main bearings 3 to cylinder block 1 and lower cylinder block 2 and tighten lower cylinder block bolts to the specified torque Refer to EM 118 Disassembly and Assembly for the tightening procedure e Measure the inner diameter of main bearing with a bore gauge Oil clearance Main bearing inner diameter Crank
56. Valve seat interference fit Exhaust 0 064 0 096 0 0025 0 0038 Intake 34 6 1 362 Di ter d1 Aee Exhaust 27 7 1 091 7 Intake 35 9 36 4 1 413 1 433 Diameter d2 Exhaust 29 3 29 8 1 154 1 173 Angle a1 59 61 Revision 2009 March EM 286 2009 FX35 FX50 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VK50VE Angle a2 88 45 90 15 Angle a3 119 121 Intake 1 0 1 4 0 039 0 055 Contacting width w Exhaust 1 2 1 6 0 047 0 063 EM Intake 5 9 6 0 0 232 0 236 Height h Exhaust 5 9 6 0 0 232 0 236 4 9 5 0 0 1949 0 1988 4 Depth H 6 0 0 236 1 Diameter made by intersection point of conic angles a1 and a2 2 Diameter made by intersection point of conic angles a2 and a3 3 Machining data 4 Parts settings are for exhaust side only VALVE SPRING Standard Item Intake Exhaust Free height 48 69 mm 1 9169 in 47 35 mm 1 8642 in installation 162 192 N 16 5 19 6 kg 36 43 Ib 163 191 N 16 6 19 5 kg 37 43 Ib at 42 40 mm 1 6693 in at 35 45 mm 1 3957 in Pressure Valve open 609 695 N 62 1 70 9 kg 137 156 Ib 370 426 N 37 7 43 5 kg 83 96 Ib p at 28 83 mm 1 1350 in at 25 65 mm 1 0098 in Identification color Yellow Pink Limit Item Intak
57. a dial indicator Total indicator reading Limit Refer to EM 143 Camshaft e If it exceeds the limit replace camshaft sprocket PBICO930E Valve Lifter Revision 2009 March EM 76 2009 FX35 FX50 CAMSHAFT lt REMOVAL AND INSTALLATION gt VQ35HR Check if surface of valve lifter has any wear or cracks e If anything above is found replace valve lifter Refer to EM 143 Camshaft 4 KBIA0182E Valve Lifter Clearance VALVE LIFTER OUTER DIAMETER e Measure the outer diameter at 1 2 height of valve lifter with a micrometer A since valve lifter is in barrel shape Standard Refer to EM 143 Camshaft Intake and exhaust JPBIA0125ZZ VALVE LIFTER HOLE DIAMETER e Measure the inner diameter of valve lifter hole of cylinder head with an inside micrometer Standard Refer to EM 143 Camshaft Intake and exhaust VALVE LIFTER CLEARANCE e Valve lifter clearance Valve lifter hole diameter Valve lifter outer diameter Standard Refer to EM 143 Camshaft Intake and exhaust e If the calculated value is out of the standard referring to each standard of valve lifter outer diameter and valve lifter hole diameter replace either or both valve lifter and cylinder head INSPECTION AFTER INSTALLATION Inspection of Camshaft Sprocket INT Oil Groove CAUTION e Perform this inspection only when DTC P0011 and P0021 are detected in self diagnostic results of CONSULT III an
58. as a guide 1 Crankshaft pulley A Paint mark Revision 2009 March EM 22 2009 FX35 FX50 CAMSHAFT VALVE CLEARANCE lt PERIODIC MAINTENANCE gt VQ35HR e By referring to the figure measure the valve clearances at locations marked x as shown in the table below locations indicated in the figure lt Engine front e No 5 cylinder at compression TDC Measuring position bank 1 A No 1 CYL No 3 CYL No 5 CYL No 5 cylinder at EXH C x B compression TDC INT D x E Measuring position bank 2 H No 2 CYL No 4 CYL No 6 CYL No 5 cylinder at INT D x F compression TDC EXH C x G 3 Perform adjustment if the measured value is out of the standard Refer to ADJUSTMENT ADJUSTMENT e Perform adjustment depending on selected head thickness of valve lifter 1 Measure the valve clearance Refer to INSPECTION Remove camshaft Refer to EM 70 Removal and Installation Remove valve lifters at the locations that are out of the standard Measure the center thickness of the removed valve lifters with a micrometer A AN JPBIA0169ZZ 5 Use the equation below to calculate valve lifter thickness for replacement Valve lifter thickness calculation t t1 C1 C2 t Valve lifter thickness to be replaced t1 Removed valve lifter thickness C1 Measured valve clearance C2 Standard valve clearance Intake 0 30 mm 0 012 in Exhaust
59. b Tighten all cylinder head bolts 40 N m 4 1 kg m 30 ft lb c Tighten all cylinder head bolts clockwise Angle tightening 75 degrees d Completely loosen all cylinder head bolts OJ 0 N m 0 kg m 0 ft Ib CAUTION JPBIA2145ZZ In step d loosen bolts in the reverse order of that indi cated in the figure e Tighten all cylinder head bolts 40 0 N m 4 1 kg m 30 ft Ib f Tighten all cylinder head bolts clockwise Angle tightening 65 degrees CAUTION Check the tightening angle using the angle wrench SST KV10112100 BT8653 A A Never make judgment by visual inspection e Check tightening angle indicated on the angle wrench indica tor plate g Tighten all cylinder head bolts again clockwise a eae ae te ae ad JPBIA0175ZZ Revision 2009 March EM 250 2009 FX35 FX50 CYLINDER HEAD lt UNIT DISASSEMBLY AND ASSEMBLY gt VK50VE Angle tightening 65 degrees 8 Install valve spring with valve spring seat e Install narrow pitch B end paint mark C to cylinder head side valve spring seat side A Wide pitch lt 2 Cylinder head side Paint mark color Intake Yellow Exhaust Pink JPBIAO179ZZ 9 Install valve spring retainer 10 Install valve collet e Compress valve spring with the valve spring compressor SST KV10116200 J26336 A A the attachment SST KV10115900 J26336 20 C and the adapter SST SEIS Lo KV10109220 B
60. 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 e Measure the distortion on the cylinder block upper face at some different points in six directions C D E F G and H with a straightedge A and a feeler gauge B Limit Refer to EM 147 Cylinder Block e If it exceeds the limit replace cylinder block MAIN BEARING HOUSING INNER DIAMETER Install lower cylinder block 2 without installing main bearings and tighten lower cylinder block bolts to the specified torque Refer to EM 118 Disassembly and Assembly for the tightening proce dure Measure the inner diameter of main bearing housing with a bore gauge Standard Refer to EM 147 Cylinder Block If out of the standard replace cylinder block 1 and lower cylinder block as assembly NOTE JPBIA0225ZZ Cylinder block cannot be replaced as a single part because it is machined together with lower cylinder block PISTON TO CYLINDER BORE CLEARANCE Cylinder Bore inner Diameter Revision 2009 March EM 130 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR e Using a bore gauge measure cylinder bore for wear out of round and taper at six different points on each cylinder A and B direc tions at C D and E is in longitudinal direction of engine f 10 mm 0 39 in g 60 mm 2 36 in h
61. chain secondary together with camshaft sprockets CAUTION e Never loosen the mounting bolts with securing anything other than the camshaft hexagonal portion or with ten sioning the timing chain KBIA4379J e Never disassemble Never loosen bolts A and B as shown in the figure JPBIAO096ZZ 35 Remove timing chain tensioners secondary from cylinder head as per the following if necessary a Remove camshaft brackets No 1 Refer to EM 70 Exploded View b Remove timing chain tensioners secondary with a stopper pin attached 36 Use a scraper to remove all traces of old liquid gasket from front and rear timing chain cases and oil pan upper and liquid gas ket mating surfaces CAUTION Be careful not to allow gasket fragments to enter oil pan JPBIA0050ZZ 37 Remove old liquid gasket from bolt hole and thread A Remove sticking old liquid gasket B Bolt hole JPBIA0051ZZ INSTALLATION NOTE The below figure shows the relationship between the matching mark on each timing chain and that on the cor responding sprocket with the components installed Revision 2009 March EM 59 2009 FX35 FX50 lt REMOVAL AND INSTALLATION gt 1 Internal chain guide Camshaft sprocket EXH Timing chain primary 10 Timing chain tensioner secondary A Matching mark punched back side D Matching mark orange link 1 Install timing chain tensioners secondary to cylinder head as Exploded
62. complete drive belt auto tensioner must be replaced as a unit including the pulley 3 Remove idler pulley Installation Installation is the reverse order of removal CAUTION Never swap the pulley between new and old drive belt auto tensioner Revision 2009 March EM 176 2009 FX35 FX50 AIR CLEANER AND AIR DUCT lt REMOVAL AND INSTALLATION gt VK50VE AIR CLEANER AND AIR DUCT Exploded View INFOID 0000000003733415 EM SEC 118 148 165 B 1 5 0 15 13 ew u S ora Z V TZS sS Ls SWF BF G ae JPBIA2063GB 1 Air cleaner filter 2 Holder 3 Air cleaner case bank 2 Air duct inlet 5 Grommet 6 Air cleaner case bank 1 Mass air flow sensor bank 1 8 Clamp 9 PCV hose 10 Air duct bank 1 11 Clamp 12 Air duct bank 2 13 PCV hose 14 Mass air flow sensor bank 2 A To rocker cover bank 2 B ea throttle control actuator c Hae throttle control actuator D To rocker cover bank 1 Refer to Gl 4 Components for symbols in the figure Removal and Installation INFOID 0000000003738416 REMOVAL 1 Remove engine cover and engine room cover RH and LH Refer to EM 174 Exploded View 2 Remove air duct inlet 3 Disconnect mass air flow sensor harness connector 4 Disconnect PCV hose 5 Remove air cleaner case amp mass air flow sensor assembly and air duct by disconnecting their joints e Add matching marks if necessary for easier installation 6 Remove mass air flow sensor
63. cooler hoses and power steering oil pump oil cooler hoses e Install plug to avoid leakage of A T fluid and power steering fluid 2 Disconnect heated oxygen sensor 2 harness Refer to EM 36 Exploded View 3 Remove three way catalyst and exhaust front tube Refer to EX 5 Exploded View Revision 2009 March EM 88 2009 FX35 FX50 ENGINE ASSEMBLY lt UNIT REMOVAL AND INSTALLATION gt VQ35HR 4 Disconnect steering lower joint at power steering gear assembly side and release steering lower shaft Refer to ST 17 WITHOUT ELECTRIC MOTOR Exploded View or ST 20 WITH ELECTRIC MOTOR Exploded View 5 Remove rear propeller shaft Refer to DLN 116 Exploded View en EM D Remove front drive shaft both side Refer to FAX 26 Exploded View 7 Disengage A T control rod at A T shift selector side Then temporarily secure it on the transmission assembly so that it does not sag Refer to TM 187 Exploded View 8 Preparation for the separation work of transaxle is as per the following e Remove rear plate cover from oil pan upper Then remove bolts fixing drive plate to torque converter Refer to EM 46 Exploded View e Remove transmission joint bolts that pierce at oil pan upper lower rear side Refer to EM 46 Exploded View 9 Remove front stabilizer connecting rod from transverse link Refer to FSU 36 Exploded View 10 Remove lower ends of left and right steering knuckle from transverse link Refer to FSU
64. cylinder to re check it for compression If the added engine oil improves the compression piston rings may be worn out or damaged Check pis ton rings and replace if necessary If the compression pressure remains at low level despite the addition of engine oil valves may be mal functioning Check valves for damage Replace valve or valve seat accordingly e If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil cylinder head gaskets are leaking In such a case replace cyl inder head gaskets 9 After inspection is completed install removed parts 10 Start the engine and check that the engine runs smoothly 11 Perform trouble diagnosis If DTC appears erase it Refer to EC 136 Description Revision 2009 March EM 26 2009 FX35 FX50 ENGINE COVER lt REMOVAL AND INSTALLATION gt VQ35HR REMOVAL AND INSTALLATION ENGINE COVER Exp loded View INFOID 0000000003887335 fy 5 5 0 56 49 fy 5 5 0 56 49 1 Engine cover Refer to Gl 4 Components for symbols in the figure JPBIA0256GB Removal and Installation n T REMOVAL Loosen mounting bolts and nuts in the reverse order as shown in the figure and then remove engine cover CAUTION Never damage or scratch engine cover when installing or removing JPBIA1823ZZ INSTALLATION Install engine cover and then tighten mounting bolts and nuts in F numeri
65. e Using a clean plastic stick press check valve in oil jet relief valve Check that valve moves smoothly with proper reaction force e If itis not satisfied clean or replace oil jet Revision 2009 March EM 273 2009 FX35 FX50 HOW TO SELECT PISTON AND BEARING lt UNIT DISASSEMBLY AND ASSEMBLY gt HOW TO SELECT PISTON AND BEARING Description Selection points Selection parts Selection items VK50VE INFOID 0000000003733459 Selection methods Between cylinder block and crankshaft Main bearing Main 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 rod Connecting rod bearing Connecting rod bearing grade bearing thickness Determined by match of con necting rod big end diameter grade inner diameter of hous ing and crankshaft pin outer di ameter Between cylinder block and pis ton Piston and piston pin assembly Piston is available together with piston pin as assembly Piston grade piston skirt diameter Piston grade cylinder bore grade inner diameter of bore e The identification grade stamped on each part is the grade for the dimension measured in new condition This grade cannot apply to reused parts e For reused or repaired parts measure the dimension accurately Determine the grad
66. gt VKSOVE H Journal diameter grade No 4 Journal diameter grade No 5 3 Select main bearing grade at the point where selected row and column meet in MAIN BEARING SELEC TION TABLE CAUTION e Initial clearance for No 1 5 journal and No 2 3 4 journal is different Use two different selection table for each part No 1 5 journal and No 2 3 4 journal have the same signs but different measures Never con fuse 4 Apply sign at crossing in above step 3 to MAIN BEARING GRADE TABLE NOTE e MAIN BEARING GRADE TABLE applies to all journals e Service parts are available as a set of both upper and lower WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED 1 Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter Refer to EM 265 Inspection 2 Correspond the measured dimension in Cylinder block main bearing housing inner diameter row of MAIN BEARING SELECTION TABLE 3 Correspond the measured dimension in Crankshaft main journal diameter column of MAIN BEARING SELECTION TABLE 4 Follow from step 3 in When New Cylinder Block and Crankshaft are Used Revision 2009 March EM 278 2009 FX35 FX50 HOW TO SELECT PISTON AND BEARING lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE MAIN BEARING SELECTION TABLE No 1 and 5 Journal Cylinder block ae 7 main bearing housing inner diameter Hole Crankshaft diameter main journal Unit
67. installing in connecting rod CRANKSHAFT Revision 2009 March 0 20 0 35 0 0079 0 0138 EM 149 0 40 0 0157 2009 FX35 FX50 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS SEM645 VQ35HR Unit mm in Taper Difference between A and B Out of round Difference between X and Y SBIAOS535E Grade No A 64 975 64 974 2 5581 2 5580 Grade No B 64 974 64 973 2 5580 2 5580 Grade No C 64 973 64 972 2 5580 2 5579 Grade No D 64 972 64 971 2 5579 2 5579 Grade No E 64 971 64 970 2 5579 2 5579 Grade No F 64 970 64 969 2 5579 2 5578 Grade No G 64 969 64 968 2 5578 2 5578 Grade No H 64 968 64 967 2 5578 2 5578 Grade No J 64 967 64 966 2 5578 2 5577 Grade No K 64 966 64 965 2 5577 2 5577 Grade No L 64 965 64 964 2 5577 2 5576 naar ate Grade No M 64 964 64 963 2 5576 2 5576 Main journal diameter Dm grade Standard Grade No N 64 963 64 962 2 5576 2 5576 Grade No P 64 962 64 961 2 5576 2 5575 Grade No R 64 961 64 960 2 5575 2 5575 Grade No S 64 960 64 959 2 5575 2 5574 Grade No T 64 959 64 958 2 5574 2 5574 Grade No U 64 958 64 957 2 5574 2 5574 Grade No V 64 957 64 956 2 5574 2 5573 Grade No W 64 956 64 955 2 5573 2 5573 Grade No X 64 955 64 954
68. is provided only for the parts installed at the plant For service parts no pis ton pin grades can be selected Only 0 grade is available e No second grade mark is available on piston Co n n ect i n g Rod B ea ri n g INFOID 0000000003887394 WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED 1 Apply connecting rod big end diameter grade stamped D on connecting rod side face to the row in the CONNECTING ROD BEARING SELECTION TABLE Management code JPBIA0208ZZ Front mark A Sample codes B Bearing stopper groove C Small end diameter grade E Weight grade F Cylinder No G H l Management code 2 Apply crankshaft pin journal diameter grade stamped on crank shaft front side to the column in the CONNECTING ROD BEARING SELECTION TABLE Journal diameter grade No 1 A DOO Journal diameter grade No 2 1 LNSIN i ENENG Yuin N Journal diameter grade No 3 OPOMINA Journal diameter grade No 4 Pin diameter grade No Pin diameter grade No 2 Pin diameter grade No 3 4 5 JPBIA0269ZZ Pin diameter grade No Troaoa Tn MO OW gt Pin diameter grade No Revision 2009 March EM 137 2009 FX35 FX50 lt UNIT DISASSEMBLY AND ASSEMBLY gt Pin diameter grade No 6 HOW TO SELECT PISTON AND BEARING WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED 1 2 3 4 5 CONNECTING ROD BEARING SELECTION TABLE Connecting rod big end diameter
69. it turns smoothly 15 Install drive belt auto tensioner bracket 1 and power steering oil pump bracket 2 as per the following 3 Crankshaft pulley A Engine front side B Engine right side lt Engine front a Install drive belt auto tensioner bracket and tighten mounting bolts No 2 3 temporarily Tighten mounting bolts No 2 3 specified torque c Install power steering oil pump bracket and tighten mounting bolts No 1 4 5 temporarily d Tighten mounting bolts No 1 specified torque e Tighten mounting bolts No 4 5 specified torque JPBIA1786ZZ 16 For the following operations perform steps in the reverse order of removal n S p e ct i O n INFOID 0000000003887361 INSPECTION AFTER REMOVAL Timing Chain Revision 2009 March EM 68 2009 FX35 FX50 TIMING CHAIN lt REMOVAL AND INSTALLATION gt VQ35HR Check for cracks and any excessive wear at link plates and roller links of timing chain Replace timing chain if necessary A Crack B Wear JPBIA0091ZZ INSPECTION AFTER INSTALLATION Inspection for Leakage The following are procedures for checking fluids leakage lubricates leakage 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 Fluids and Lubricants Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With f
70. lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE CYLINDER BLOCK Exploded View INFOID 0000000003733456 SEC 110 118 120 0 88 2 9 0 65 JPBIA2289GB 1 Knock sensor 2 Cylinder block 3 Side bolt 4 Thrust bearing 5 Main bearing upper 6 Crankshaft key 7 Crankshaft 8 Main bearing lower 9 Main bearing cap Revision 2009 March EM 255 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt Disassembly and Assembly 10 13 16 19 22 25 28 A Main bearing cap sub bolt Connecting rod cap Snap ring Oil ring Pilot converter Reinforcement plate Cylinder block heater for Canada Refer to EM 256 lt Crankshaft side 11 14 17 20 23 26 Main bearing cap bolt 12 Connecting rod bearing 15 Piston pin 18 Second ring 21 Piston oil jet 24 Rear oil seal 27 Chamfered Refer to Gl 4 Components for symbol marks in the figure DISASSEMBLY Remove the following parts e Oil pans lower and upper Refer to EM 208 Exploded View e Front cover and timing chain Refer to EM 212 Exploded View e Cylinder head Refer to EM 245 Exploded View Remove knock sensor CAUTION Carefully handle knock sensor avoiding shocks Remove oil filter for VVEL ladder assembly from cylinder block if necessary Refer to EM 245 Exploded View Remove piston and connecting rod assembly as per the following e Before removing piston and connecting rod assembly
71. make judgment by visual inspection e After tightening connecting rod bolts check that crankshaft rotates smoothly e Check the connecting rod side clearance Refer to EM 265 Inspection Install knock sensors e Install knock sensors in the direction shown in the figure lt Engine front e After installing knock sensor connect harness connector and lay it out to front of the engine CAUTION e Never tighten mounting bolts while holding connector e If any impact by dropping is applied to knock sensor replace it with new one NOTE e Check that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor e Check that knock sensor does not interfere with other parts Install oil filter for VVEL ladder assembly Install drive plate e Install drive plate 4 and reinforcement plate 3 as shown in the figure 2 Pilot converter A Rounded lt Engine front e When installing drive plate to crankshaft 1 be sure to cor rectly 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 e Holding ring gear with the ring gear stopper SST KV10119200 J 49277 e Tighten the mounting bolts crosswise over several times Assemble in the reverse order of disassembly JPBIA22752ZZ Revision 2009 March EM 264 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DI
72. measure valve clearance of No 1 cylinder INT valve front side insert feeler gauge commercial service tool from the front side A of the control shaft bracket or camshaft EXH side B 1 Valve lifter JPBIA2326ZZ b Rotate crankshaft 270 degrees clockwise when viewed from engine front to align No 3 cylinder at TDC its compression stroke NOTE Crankshaft pulley mounting bolt flange has an angle mark B every 90 degrees c They can be used as a guide to rotation angle A Paint mark JPBIA2066ZZ e By referring to the figure measure the valve clearances at locations marked x as shown in the table below locations indicated in the figure lt Engine front e No 3 cylinder at compression TDC Measuring position bank 2 A oi ari i a No 3 cylinder at com EXH x C pression TDC INT x D Measuring position bank 1 B ae ce ie oe No 3 cylinder at com INT x E x F pression TDC EXH x G x H JPBIA2068ZZ c Rotate crankshaft 90 degrees clockwise when viewed from engine front to align No 6 cylinder at TDC of compression stroke NOTE Revision 2009 March EM 171 2009 FX35 FX50 CAMSHAFT VALVE CLEARANCE lt PERIODIC MAINTENANCE gt VKSOVE Crankshaft pulley mounting bolt flange has an angle mark B every 90 degrees c They can be used as a guide to rotation angle A Paint mark e By referring to the figure measure the valve clearances a
73. must be replaced Revision 2009 March EM 108 VQ35HR JPBIAO172ZZ 7 JPBIA0177ZZ 2009 FX35 FX50 10 Remove valve guide if valve guide must be replaced a 11 CYLINDER HEAD lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR e Bore out old seat until it collapses Boring should not continue beyond the bottom face of the seat recess in cylinder head Set the machine depth stop to ensure this Refer to EM 145 Cylinder Head CAUTION Prevent to scratch cylinder head by excessive boring To remove valve guide heat cylinder head to 110 to 130 C 230 to 266 F by soaking in heated oil A JPBIAO184ZZ Drive out valve guide with a press under a 20 KN 2 ton 2 2 US ton 2 0 Imp ton pressure or a hammer and the valve guide drift commercial service tool WARNING Cylinder head contains heat When working wear protec tive equipment to avoid getting burned Remove spark plug tube if necessary e Using a pliers pull spark plug tube out of cylinder head CAUTION Take care not to damage cylinder head e Once removed spark plug tube will be deformed and cannot be reused Never remove it unless absolutely necessary ASSEMBLY 1 If valve guide is removed in step 10 DISASSEMBLY install it Replace with oversized 0 2 mm 0 008 in valve guide Using the valve guide reamer commercial service tool A ream cylinder head valve guide hole Valve guide hole diameter for servi
74. of mal function poor starting idle malfunction unusual noise due to aged deterioration in valve clearance CAUTION Valve clearance check on the intake side is not required after replacing the VVEL ladder assembly amp cylinder head assembly with a new one Install new VVEL ladder assembly amp cylinder head assembly in factory shipped condition because it is factory adjusted and inspected NOTE VVEL ladder assembly cannot be replaced as a single part because it is machined together with cylinder head assembly Exhaust side e At the removal installation and replacement of camshaft EXH or valve related parts or at the occurrence of malfunction poor starting idle malfunction unusual noise due to aged deterioration in valve clearance 1 Remove rocker covers bank 1 and bank 2 Refer to EM 191 Removal and Installation 2 Measure the valve clearance as per the following e Use the feeler gauge commercial service tool of curved tip This allows the feeler gauge to access the clearance between camshaft drive shaft nose and valve lifter with ease Valve clearance Refer to EM 283 Camshaft NOTE Be sure to note the following points when measuring valve clearance on the intake side Before measuring check that the position of drive shaft nose is within the angle shown in the figure Bank 2 Feeler gauge commercial service tool 45 degrees drive shaft nose angle View D 0 U gt g
75. oil fluid levels including engine coolant and engine oil If any are less than the required quantity fill them to the specified level Refer to MA 12 Fluids and Lubricants Follow the procedure below to check for fuel leakage Turn ignition switch to the ON position 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 NOTE If hydraulic pressure inside chain tensioner drops after removal installation slack in guide may generate a pounding noise during and just after the engine start However this does not indicate a malfunction The noise will stop after hydraulic pressure rises Warm up engine thoroughly to check that there is no leakage of fuel or any oil fluids including engine oil and engine coolant Bleed air from lines and hoses of applicable lines such as in cooling system Revision 2009 March EM 200 2009 FX35 FX50 ENGINE ASSEMBLY lt UNIT REMOVAL AND INSTALLATION gt VK50VE After cooling down engine again check oil fluid levels including engine oil and engine coolant Refill them to the specified level if necessary Summary of the inspection items items 7 7 Beforestarting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Leve
76. reverse order of removal after this step n S pect i O n INFOID 0000000003887364 INSPECTION AFTER REMOVAL Camshaft Runout Revision 2009 March EM 74 2009 FX35 FX50 CAMSHAFT lt REMOVAL AND INSTALLATION gt VQ35HR 1 Put V block on precise flat table and support No 2 and 4 jour nals of camshaft CAUTION Never support No 1 journal on the side of camshaft sprocket because it has a different diameter from the other three locations 2 Seta dial indicator vertically to No 3 journal 3 Turn camshaft to one direction with hands and measure the camshaft runout on a dial indicator Total indicator reading Standard and limit Refer to EM 143 Camshaft 4 If it exceeds the limit replace camshaft Camshaft Cam Height 1 Measure the camshaft cam height with a micrometer Standard cam height Intake and exhaust Cam wear limit Refer to EM 143 Camshaft Refer to EM 143 Camshaft 2 If wear exceeds the limit replace camshaft EMQ0072D Camshaft Journal Oil Clearance CAMSHAFT JOURNAL DIAMETER e Measure the outer diameter of camshaft journal with a micrometer A Standard Refer to EM 143 Camshaft JPBIAO122ZZ CAMSHAFT BRACKET INNER DIAMETER e Tighten camshaft bracket bolt with the specified torque Refer to INSTALLATION for the tightening proce dure e Measure inner diameter A of camshaft bracket with a bore gauge Standard Refer to EM 143
77. 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 Revision 2009 March EM 267 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE e Measure the distortion on the cylinder block upper face at some different points in six directions C D E F G and H with a straightedge A and a feeler gauge B Limit Refer to EM 287 Cylinder Block e If it exceeds the limit replace cylinder block MAIN BEARING HOUSING INNER DIAMETER e Install main bearing cap 2 without installing main bearings and tighten main bearing cap bolts to the specified torque Refer to EM 256 Disassembly and Assembly for the tightening procedure e Measure the inner diameter of main bearing housing with a bore gauge Standard Refer to EM 287 Cylinder Block e If out of the standard replace cylinder block 1 and main bearing cap as assembly NOTE Cylinder block cannot be replaced as a single part because it is JPBIA0225ZZ machined together with main bearing cap PISTON TO CYLINDER BORE CLEARANCE Cylinder Bore inner Diameter e Using a bore gauge measure cylinder bore for wear out of round and taper at six different points on each cylinder A and B direc tions at C D and E is in longitudinal direction of engine f 10 mm 0 39
78. seal 1 to the position as shown in the figure B Rear oil seal retainer rear end face a 0 0 5 mm 0 0 020 in e Using a suitable drift outer diameter 101 mm 3 98 in press fit until the height of rear oil seal is level with the mounting surface e Check the garter spring is in position and seal lips are not inverted CAUTION Oil seal e Be careful not to damage crankshaft and cylinder block retainer Press fit straight and avoid causing burrs or tilting oil seal 2 Install in the reverse order of removal after this step Revision 2009 March EM 195 2009 FX35 FX50 ENGINE ASSEMBLY lt UNIT REMOVAL AND INSTALLATION gt VKSOVE UNIT REMOVAL AND INSTALLATION ENGINE ASSEMBLY E X p od ed V i ew INFOID 0000000003733439 SEC 112 0 49 0 5 0 36 D 0 92 5 9 4 68 5 0 36 lt 0 49 0 5 0 36 0 49 0 5 0 36 JPBIA2101GB 1 Engine mounting bracket RH 2 Engine mounting insulator RH 3 Engine mounting insulator LH 4 Engine mounting bracket LH 5 Dynamic damper 6 Heat insulator LH 7 Heat insulator RH 8 Rear engine mounting member 9 Engine mounting insulator rear 10 Engine mounting bracket rear A Front mark Refer to Gl 4 Components for symbols in the figure Removal and Installation INFOID 0000000003733440 WARNING e Situate the vehicle on a flat and solid surface Place chocks at the front and back of rear wheels e For engines not equipped w
79. seat j P LOD Using compound grind to adjust valve fitting Check again for normal contact Refer to EM 251 Inspection Install new valve oil seals as per the following Apply new engine oil on new valve oil seal joint and seal lip Using the valve oil seal drift SST KV10115600 J 38958 A press fit valve seal to height b shown in figure me or oO J oO 7 TP oO Height b Intake 14 3 14 9 mm 0 563 0 587 in Exhaust 13 6 14 2 mm 0 535 0 559 in JPBIA1367ZZ 4 Install valve NOTE Larger diameter valves are for intake side Revision 2009 March EM 249 2009 FX35 FX50 CYLINDER HEAD lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE 5 Install oil filter for VVEL ladder assembly 1 in the direction shown in the figure if removed e Check that the oil filter does not protrude from the upper sur face of cylinder block 2 after installation JPBIA21292Z 6 Install new cylinder head gaskets 7 Install cylinder head as per the following CAUTION If cylinder head bolts are re used check their outer diameters before installation Refer to EM 251 Inspection e Before installing cylinder head inspect cylinder head distortion Refer to EM 251 Inspection e Tighten cylinder head bolts in numerical order as shown in fig ure A Bank2 B Bank 1 lt Engine front Use TORX socket a Apply new engine oil to threads and seat surfaces of cylinder head bolts
80. specifications perform this procedure e Apply prussian blue or white lead onto contacting surface of valve seat to check the condition of the valve contact on the surface e Check if the contact area band is continuous all around the circumference e If not grind to adjust valve fitting and check again If the contacting surface still has NG B conditions even after the recheck replace valve seat Refer to EM 107 Disassembly and Assem bly JPBIAO187ZZ Valve Spring Squareness e Set a try square A along the side of valve spring and rotate spring Measure the maximum clearance between the top of spring and try square B Contact Limit Refer to EM 145 Cylinder Head e If it exceeds the limit replace valve spring JPBIAO189ZZ Valve Spring Dimensions and Valve Spring Pressure Load e Check the valve spring pressure at specified spring height Standard Intake and exhaust Free height Installation height Refer to EM 145 Installation load Cylinder Head Height during valve open Load with valve open e If the installation load or load with valve open is out of the stan SEM113 dard replace valve spring INSPECTION AFTER INSTALLATION Inspection for Leakage The following are procedures for checking fluids leakage lubricates leakage and exhaust gases leakage e Before starting engine check oil fluid levels including engine coolant and engine oil If less than required quantity
81. tapping on the side of tool with a hammer Remove oil pan upper CAUTION Be careful not to damage the mating surfaces Never insert a screwdriver this will damage the mating JPBIA0022ZZ surfaces 5 Remove O rings 2 from bottom of lower cylinder block 1 and oil pump 3 lt Engine front INSTALLATION 1 Install oil pan upper as per the following a Use a scraper A to remove old liquid gasket from mating sur faces CAUTION Never scratch or damage the mating surfaces when clean ing off old liquid gasket Also remove old liquid gasket from mating surface of lower cyl inder block e Remove old liquid gasket from the bolt holes and threads b Install new O rings 2 on the bottom of lower cylinder block 1 and oil pump 3 lt Engine front Revision 2009 March EM 101 2009 FX35 FX50 OIL PAN UPPER lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR c Apply a continuous bead of liquid gasket with the tube presser commercial service tool to the cylinder block mating surface of oil pan upper to a limited portion as shown in the figure a 4 0 5 0 mm 0 157 0 197 in lt _ Engine front Use Genuine RTV Silicone Sealant or an equivalent Refer to GI 15 Recommended Chemical Products and Sealants CAUTION e For bolt holes with 4 marks 7 locations apply liquid gasket outside the holes Attaching must be done within 5 minutes after coating d Install oil pan upper
82. to STR 17 VQ35HR Exploded View Separate the engine from the transmission assembly Refer to TIM 199 2WD Exploded View Remove each engine mounting insulator and each engine mounting bracket from the engine with power tool INSTALLATION Note the following item and install in the reverse order of removal e Do not allow engine mounting insulator to be damage and careful no oil gets on it e For a location with a positioning pin insert it securely into hole of mating part e For a part with a specified installation orientation refer to component figure in EM 82 2WD Exploded View e When installing engine mounting bracket RH and LH on cylinder block tighten two upper bolts shown as A in the figure first Then tighten two lower bolts shown as B in the figure w ONO lt Engine front JPBIA2097ZZ e Check all engine mounting insulators are seated properly then tighten mounting nuts e Tighten rear engine mounting member bolts in numerical order as shown in the figure lt 7 Vehicle front JPBIAO160ZZ Revision 2009 March EM 85 2009 FX35 FX50 ENGINE ASSEMBLY lt UNIT REMOVAL AND INSTALLATION gt 2WD Inspection VQ35HR INFOID 0000000003887370 INSPECTION AFTER INSTALLATION Inspection for Leakage The following are procedures for checking fluids leakage lubricates leakage and exhaust gases leakage e Before starting engine check oil fluid levels including engine c
83. undercover power tool e Front cross bar Refer to FSU 15 Exploded View e Cowl top cover Refer to EXT 22 Exploded View e Air duct and air cleaner case assembly Refer to EM 29 Exploded View 5 Discharge refrigerant from A C circuit Refer to HA 25 Collection and Charge 6 Remove radiator hoses upper and lower Refer to CO 14 Exploded View Engine Room LH 1 Disconnect heater hose from vehicle side and fit a plug onto hose end to prevent engine coolant leakage 2 Disconnect A C piping from A C compressor and temporarily fasten it on vehicle with a rope Refer to HA 40 Exploded View 3 Disconnect brake booster vacuum hose 4 Disconnect ground cable Engine Room RH 1 Disconnect battery positive cable at vehicle side and temporarily fasten it on engine 2 Disconnect all clips and connector of the engine room harness from engine back side 3 Disconnect fuel feed hose with damper and EVAP hose Refer to EM 40 Exploded View CAUTION Fit plugs onto disconnected hoses to prevent fuel leakage 4 Remove reservoir tank of power steering oil pump and piping from vehicle and temporarily secure them on engine Refer to ST 47 VQ35HR Exploded View CAUTION When temporarily securing keep the reservoir tank upright to avoid a fluid leakage Vehicle Inside Follow procedure below to disconnect engine room harness connectors at passenger room side and tempo rarily secure them on engine 1 Remove passe
84. upper sur face of front cover 2 after installation PBIC3260J 11 Install front cover as per the following a Install new O ring 1 2 onto cylinder heads and cylinder block JPBIA21152Z Revision 2009 March EM 222 2009 FX35 FX50 TIMING CHAIN lt UNIT DISASSEMBLY AND ASSEMBLY gt VK50VE b Apply a continuous bead of liquid gasket with tube presser commercial service tool to front cover as shown in the figure Use Genuine RTV Silicone Sealant or equivalent Refer to GI 15 Recommended Chemical Products and Sealants Junction between cylinder block and cylinder head Protrusion 4 3 5 3 mm 0 169 0 209 in 03 4 4 4 mm 0 134 0 173 in 04 0 5 6 mm 0 157 0 220 in 04 8 5 8 mm 0 189 0 228 in gt gt o 20M gt c Check again that the matching marks on timing chain and that on each sprocket are aligned Then install front cover CAUTION Be careful not to damage front oil seal by interference with front end of crankshaft JPBIA2106ZZ d Tighten mounting bolts in numerical order as shown in the fig ure JPBIA2116ZZ e There are three types of mounting bolts A 20mm 0 79 in B 45 mm 1 77 in C 80mm 3 15 in e After all mounting bolts are tightened retighten them in numerical order as shown in the figure CAUTION Be sure to wipe out any excessive liquid gasket leaking onto surface mating with oil pan 12 Install valve timing control cover as per
85. 000008738424 DISASSEMBLY 1 Remove heated oxygen sensor 2 CAUTION Heated oxygen sensor 2 is not reusable Never remove heated oxygen sensor 2 unless this is required Revision 2009 March EM 205 2009 FX35 FX50 EXHAUST MANIFOLD AND THREE WAY CATALYST lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE e Using the heated oxygen sensor wrench SST KV10114400 J 38365 A remove heated oxygen sensor 2 1 NOTE e The heated oxygen sensor 2 is removable under vehicle mounted condition e The figure shows an example of bank 1 JPBIA2329ZZ 2 Remove three way catalyst bank 1 and bank 2 3 Remove air fuel ratio sensor 1as per the following CAUTION Air fuel ratio sensor 1 is not reusable Never remove air fuel ratio sensor 1 unless this is required e Using the heated oxygen sensor wrench SST KV10114400 J 38365 remove air fuel ratio sensor 1 NOTE The air fuel ration sensor 1 is removable under vehicle mounted condition 4 Remove exhaust manifold e Loosen nuts in the reverse order of figure to remove exhaust manifold with power tool A Bank 1 B Bank2 lt Engine front NOTE Disregard No 9 to No 12 when loosening 5 Remove exhaust manifold gaskets CAUTION Cover engine openings to avoid entry of foreign materials ASSEMBLY Note the following item and install in the reverse order of removal Exhaust Manifold Gasket e Install exhaust manifold gasket in directional shown in the figure
86. 0000e3673c0 REMOVAL NO Ol Soo Doa 10 11 12 13 14 15 16 17 18 19 20 21 22 a Release the fuel pressure Refer to EC 567 Inspection Disconnect the battery cable from the negative terminal Remove engine cover with power tool Refer to EM 27 Exploded View Remove radiator reservoir tank Refer to CO 14 Exploded View Remove air duct and air cleaner case assembly Refer to EM 29 Exploded View Remove engine undercover with power tool Drain engine coolant from radiator Refer to CO 8 Draining CAUTION e Perform this step when the engine is cold e Never spill engine coolant on drive belt Remove radiator hose upper and lower Refer to CO 14 Exploded View Drain engine oil Refer to LU 8 Draining CAUTION Perform this step when the engine is cold Never spill engine oil on drive belt Remove drive belt Refer to EM 15 Exploded View Remove radiator cooling fan assembly Refer to CO 14 Exploded View Separate engine harnesses removing their brackets from front timing chain case Remove intake manifold collector Refer to EM 31 Exploded View Remove intake manifold Refer to EM 34 Exploded View Remove oil level gauge and oil level gauge guide Remove A C compressor from bracket with piping connected and temporarily secure it aside Refer to HA 38 Exploded View Remove power steering oil pump from bracket with piping connected and temporarily secure
87. 009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VK50VE e Install connecting rod bearing cap without installing connecting rod bearing and tighten connecting rod bolts to the specified torque Refer to EM 256 Disassembly and Assembly for the tightening procedure 1 Connecting rod e Measure the inner diameter of connecting rod big end with an inside micrometer Standard Refer to EM 287 Cylinder Block e If out of the standard replace connecting rod assembly CONNECTING ROD BUSHING OIL CLEARANCE Connecting Rod Bushing Inner Diameter Measure the inner diameter of connecting rod bushing with an inside micrometer A JPBIA0222ZZ Standard Refer to EM 287 Cylinder Block JPBIA0223ZZ Piston Pin Outer Diameter Measure the outer diameter of piston pin with a micrometer A Standard Refer to EM 287 Cylinder Block JPBIA0218ZZ Connecting Rod Bushing Oil Clearance Connecting rod bushing oil clearance Connecting rod bushing inner diameter Piston pin outer diame ter Standard and limit Refer to EM 287 Cylinder Block e If the calculated value exceeds the limit replace connecting rod assembly and or piston and piston pin assembly e If replacing piston and piston pin assembly refer to EM 274 Description e If replacing connecting rod assembly refer to EM 275 Connecting Rod Bearing to select the connecting rod bearing CYLINDER BLOCK DISTORTION e Using a
88. 0157ZZ Slinger bolts O 28 0 N m 2 9 kg m 21 ft lb Revision 2009 March EM 89 2009 FX35 FX50 ENGINE ASSEMBLY lt UNIT REMOVAL AND INSTALLATION gt VQ35HR e To protect rocker cover against damage caused by tilting of engine slinger insert spacer between cylinder head and engine rear lower slinger 3 in direction shown in the figure 1 Engine rear upper slinger lt I Engine front NOTE Spacer 2 is a component part of engine rear upper slinger assembly JPBIAO158ZZ 2 Remove power steering oil pump from engine side Refer to ST 35 VQ35HR Exploded View Remove engine mounting insulators RH and LH under side nuts with power tool 4 Lift with hoist and separate the engine the transmission assembly the transfer assembly and the front final drive assembly from front suspension member CAUTION Before and during this lifting always check if any harnesses are left connected Never damage to and oil grease smearing or spills onto engine mounting insulator 5 Remove alternator Refer to CHG 25 VQ35HR Exploded View 6 Remove starter motor Refer to STR 17 VQ35HR Exploded View 7 Remove front propeller shaft from the front final drive assembly side Refer to DLN 107 VQ35HR Exploded View 8 Separate the engine from the transmission assembly Refer to TM 202 AWD Exploded View 9 Remove the front final drive assembly from oil pan upper Refer to DLN 148 VQ35HR_ Exploded View
89. 03887359 SEC 120 130 135 150 210 QO ria lee 5 6 3 45 lt esa X oP Re F106 7 Lae Zi QD gt Pa z 0 61 3 0 xA i 6 3 45 9 i e H 9 6 0 98 85 P ne 28 0 2 9 21 w 9 11 3 1 2 8 e 9 6 0 98 85 JPBIA2441GB 1 Timing chain secondary 4 Timing chain secondary 7 Timing chain primary Revision 2009 March Camshaft sprocket EXH Camshaft sprocket EXH Camshaft sprocket INT EM 53 O ring Internal chain guide Timing chain tensioner primary 2009 FX35 FX50 TIMING CHAIN lt REMOVAL AND INSTALLATION gt VQ35HR 10 Slack guide 11 Crankshaft sprocket 12 Camshaft sprocket INT 13 ink mai control cover gasket 14 Seal ring 15 Valve timing control cover bank 1 16 Oil level gauge 17 Oil level gauge guide 18 O ring 19 intake valve timing conirolsolenoid 20 Valve timing control cover bank 2 21 Valve timing control cover gasket bank 2 valve bank 2 22 Front oil seal 23 Crankshaft pulley 24 Crankshaft pulley bolt Intake valve timing control solenoid i 25 valve bank 1 26 Power steering oil pump bracket 27 Idler pulley bracket 28 Alternator bracket 29 Water outlet front 30 Front timing chain case 31 Rear timing chain case 32 O ring 33 O ring 34 O ring A Refer to EM 97 B Refer to EM 54 C Oil filter Refer to Gl 4 Components for symbols in the figure Removal and Installation nieoin 00000
90. 039 Standard 0 10 0 25 0 0039 0 0098 Crankshaft end play Limit 0 30 0 0118 Total indicator reading Main Bearing INFOID 0000000003887404 MAIN BEARING Unit mm in Oil hole LY Oil groove Cy Lower cylinder block side PBIC2969E Grade number Thickness Width Identification color Remarks 0 2 500 2 503 0 0984 0 0985 Black 1 2 503 2 506 0 0985 0 0987 Brown 2 2 506 2 509 0 0987 0 0988 Green 3 2 509 2 512 0 0988 0 0989 Yellow Grade is the same for upper and lower 4 2 512 2 515 0 0989 0 0990 Blue bearings 5 2 515 2 518 0 0990 0 0991 Pink 6 2 518 2 521 0 0991 0 0993 Purple 7 2 521 2 524 0 0993 0 0994 White UPR 2 503 2 506 0 0985 0 0987 Brown a LWR 2 500 2 503 0 0984 0 0985 Black z UPR 2 506 2 509 0 0987 0 0988 19 9 20 1 Green LWR 2 503 2 506 0 0985 0 0987 0 783 0 791 Brown UPR 2 509 2 512 0 0988 0 0989 Yellow LWR 2 506 2 509 0 0987 0 0988 Green UPR 2 512 2 515 0 0989 0 0990 Blue Grade and color are 34 different for upper LWR 2 509 2 512 0 0988 0 0989 Yellow and lower bearings i UPR 2 515 2 518 0 0990 0 0991 Pink LWR 2 512 2 515 0 0989 0 0990 Blue z UPR 2 518 2 521 0 0991 0 0993 Purple LWR 2 515 2 518 0 0990 0 0991 Pink xe UPR 2 521 2 524 0 099
91. 04 0 3165 806 8 06 0 3173 808 8 08 0 3181 810 8 10 0 3189 812 8 12 0 3197 814 8 14 0 3205 816 8 16 0 3213 818 8 18 0 3220 820 8 20 0 3228 822 8 22 0 3236 824 8 24 0 3244 826 8 26 0 3252 828 8 28 0 3260 830 8 30 0 3268 832 8 32 0 3276 834 8 34 0 3283 836 8 36 0 3291 838 8 38 0 3299 EM 144 Revision 2009 March 2009 FX35 FX50 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ35HR Identification stamped mark Thickness 840 8 40 0 3307 Stamped mark Valve lifter thickness cece Cyli nder Head INFOID 0000000003887402 CYLINDER HEAD Unit mm in Items Standard Limit Head surface distortion Less than 0 03 0 0012 0 1 0 004 Normal cylinder head height H 126 3 126 5 4 97 4 98 H PBICO924E VALVE DIMENSIONS Unit mm in T Margin thickness a i a L E SEM188 Intake 36 6 36 9 1 441 1 453 Valve head diameter D Exhaust 30 2 30 5 1 189 1 201 Intake 97 13 3 8240 Valve length L Exhaust 94 67 3 7272 Intake 5 965 5 980 0 2348 0 2354 Valve stem diameter d Exhaust 5 962 5 970 0 2347 0 2350 EM 145 2009 FX35 FX50 Revision 2009 March SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ35HR Intake Valve seat angle a 45 15 45 45 Exhaust Intake 1 1 0 043 Valve
92. 09 March EM 65 2009 FX35 FX50 TIMING CHAIN lt REMOVAL AND INSTALLATION gt VQ35HR b Apply liquid gasket to top surface of oil pan upper as shown in the figure A 64 0 5 0 mm 0 157 0 197 in Use Genuine RTV silicone Sealant or an equivalent Refer to GI 15 Recommended Chemical Products and Sealants JPBIA0056ZZ c Assemble front timing chain case Front timing chain case Oil pan upper Cylinder block lt Engine front CAUTION e Be careful not to damage front oil seal by interference with front end of crankshaft Attaching must be done within 5 minutes after liquid gas ket application d Install front timing chain case as to fit its dowel pin hole together dowel pin on rear timing chain case e Tighten mounting bolts to the specified torque in numerical order as shown in the figure e There are two types of mounting bolts Refer to the following for locating bolts on M10 bolts 1 2 3 4 5 6 7 O 55 0 N m 5 6 kg m 41 ft lb M6 bolts Except the above O 12 7 N m 1 3 kg m 9 ft Ib f After all bolts are tightened retighten them to the specified torque in numerical order shown in the figure CAUTION Be sure to wipe out any excessive liquid gasket leaking on surface mating with oil pan upper g Install two mounting bolts in front of oil pan upper in numerical order shown in the figure lt x Engine front Tightening torque Refer to EM 46 Exploded Vi
93. 1 53 970 2 1248 2 1248 Grade No E 53 970 53 969 2 1248 2 1248 Grade No F 53 969 53 968 2 1248 2 1247 Grade No G 53 968 53 967 2 1247 2 1247 Grade No H 53 967 53 966 2 1247 2 1246 ar TEIP Grade No J 53 966 53 965 2 1246 2 1246 Pin journal diameter Dp grade Standard Grade No K 53 965 53 964 2 1246 2 1246 Grade No L 53 964 53 963 2 1246 2 1245 Grade No M 53 963 53 962 2 1245 2 1245 Grade No N 53 962 53 961 2 1245 2 1244 Grade No P 53 961 53 960 2 1244 2 1244 Grade No R 53 960 53 959 2 1244 2 1244 Grade No S 53 959 53 958 2 1244 2 1243 Grade No T 53 958 53 957 2 1243 2 1243 Grade No U 53 957 53 956 2 1243 2 1242 Center distance r 43 81 43 89 1 7248 1 7279 Taper 0 0025 0 0001 Limit Out of round 0 0025 0 0001 Standard Less than 0 05 0 002 Crankshaft runout TIR Limit 0 10 0 0039 Standard 0 10 0 26 0 0039 0 0102 Crankshaft end play Limit 0 30 0 012 Total indicator reading M al n Beari n g INFOID 0000000003733471 MAIN BEARING EM 291 Revision 2009 March 2009 FX35 FX50 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VK50VE Grade number Thickness mm in Width mm in Identification color Re
94. 10 Remove each engine mounting insulator and each engine mounting bracket from the engine with power tool INSTALLATION Note the following item 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 e 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 87 AWD Exploded View When installing engine mounting bracket RH and LH on cylinder block tighten two upper bolts B first Then tighten two lower bolts C w 3 Engine mounting bracket LH A Right side G Left side Install engine mounting bracket RH lower 2 as per the follow ing Temporarily tighten mounting bolts shown as D E and F in the figure Tighten mounting bolts to the specified torque with following mounting surfaces touched Engine mounting bracket RH 1 to engine mounting bracket RH lower shown as and in figure Front final drive to engine mounting bracket RH lower shown as in figure Check all engine mounting insulators are seated properly then tighten mounting nuts JPBIA2466ZZ Revision 2009 March EM 90 2009 FX35 FX50 ENGINE ASSEMBLY lt UNIT REMOVAL AND INSTALLATION gt VQ35HR e Tighten rear engine mounting member bolts in numerical order as shown in the figure lt Vehicle front J
95. 12 Camshaft sprocket INT 13 Ga mai control c v r gasket 14 Seal ring 15 Valve timing control cover bank 1 16 Oil level gauge 17 Oil level gauge guide 18 O ring 19 intake valve timing conirolsolenoid 20 Valve timing control cover bank 2 21 Valve timing control cover gasket bank 2 valve bank 2 22 Front oil seal 23 Crankshaft pulley 24 Crankshaft pulley bolt Intake valve timing control solenoid i 25 valve bank 1 26 Power steering oil pump bracket 27 Idler pulley bracket 28 Alternator bracket 29 Water outlet front 30 Front timing chain case 31 Rear timing chain case 32 O ring 33 O ring 34 O ring A Refer to EM 97 B Refer to EM 54 C Oil filter Refer to Gl 4 Components for symbols in the figure D i sasse m b ly INFOID 0000000003887378 1 Remove front timing chain case and timing chain Refer to EM 54 Removal and Installation 2 Remove water pump Refer to CO 19 Exploded View 3 Remove oil pan upper Refer to EM 100 2WD Exploded View 2WD models or EM 103 AWD Exploded View AWD models 4 Remove rear timing chain case as per the following a Loosen and remove mounting bolts in reverse order as shown in the figure b Cut liquid gasket using the seal cutter SST KV10111100 J 37228 and remove rear timing chain case JPBIAO089ZZ CAUTION Never remove plate metal cover 1 of oil passage After removal handle rear timing chain case carefully so it does not tilt cant or wa
96. 125 mm 4 92 in Standard and limit Refer to EM 147 Cylinder Block e If the measured value exceeds the limit or if there are scratches and or seizure on the cylinder inner wall hone or rebore the inner wall e Oversize piston is provided When using oversize piston rebore cylinder so that the clearance of the piston to cylinder bore satis fies the standard CAUTION When using oversize piston use oversize pistons for all cylin ders with oversize piston rings Oversize O S 0 2 mm 0 008 in SEM843E Piston Skirt Diameter Measure the outer diameter of piston skirt with a micrometer A Measure point R f EM 147 li BI k Standard efer to Cylinder Bloc JPBIA0227ZZ Piston to Cylinder Bore Clearance Calculate by piston skirt diameter and cylinder bore inner diameter direction B position D Clearance Cylinder bore inner diameter Piston skirt diameter Standard and limit Refer to EM 147 Cylinder Block If the calculated value exceeds the limit replace piston and piston pin assembly Refer to EM 136 Piston Re boring Cylinder Bore 1 Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter Re bored size calculation D A B C where A Piston skirt diameter as measured B Piston to cylinder bore clearance standard value C Honing allowance 0 02 mm 0 0008 in D Bored diameter 2 Install lower cylinder block and tighten to t
97. 13 Exploded View 11 Separate steering outer sockets from steering knuckle Refer to ST 25 Exploded View 12 Remove transverse links mounting bolts at suspension member side Refer to FSU 13 Exploded View Removal Work 1 Use a manual lift table caddy commercial service tool or an equivalently rigid tool such as a transmission jack Securely sup port bottom of suspension member and transmission CAUTION Put a piece of wood or something similar as the supporting surface secure a completely stable condition PBICO804E 2 Remove rear engine mounting member bolts Remove front suspension member mounting bolts and nuts Refer to FSU 37 Exploded View 4 Carefully lower jack or raise lift to remove the engine transmission transfer and front final drive assembly and front suspension member When performing work observe the following caution CAUTION e Confirm there is no interference with the vehicle e Check that all connection points have been disconnected Keep in mind the center of the vehicle gravity changes If necessary use jack s to support the vehicle at rear jacking point s to prevent it from falling it off the lift w Separation Work 1 Install engine slingers into front of cylinder head bank 1 and rear of cylinder head bank 2 Engine front slinger Engine rear upper slinger Spacer Engine rear lower slinger Bank 1 Bank 2 lt 2 Engine front U gt AOUN JPBIA
98. 2 JPBIA2302ZZ CAUTION e Never loosen the mounting bolt by securing anything other than the camshaft drive shaft hexago nal portion or with tensioning the timing chain When holding the hexagonal part of camshaft drive shaft with a wrench be careful not to allow the wrench to cause interference with other parts Revision 2009 March EM 216 2009 FX35 FX50 TIMING CHAIN lt UNIT DISASSEMBLY AND ASSEMBLY gt VK50VE e Never disassemble camshaft sprocket Never loosen bolts C D as shown in the figure A Intake B Exhaust 25 Use scraper to remove all traces of old liquid gasket from front cover and opposite mating surfaces e Remove old liquid gasket from bolt hole and thread A Remove old liquid gasket that is stuck B Bolt hole JPBIA0051ZZ ASSEMBLY Revision 2009 March EM 217 2009 FX35 FX50 TIMING CHAIN lt UNIT DISASSEMBLY AND ASSEMBLY gt 1 Timing chain 2 Slack guide bank 2 5 7 Oil pump sprocket oil pump side 8 10 Tension guide bank 1 11 13 Timing chain tensioner bank 1 14 16 Crankshaft sprocket bank 2 side 17 A Crankshaft key B D Matching mark punched E NOTE Camshaft sprocket INT bank 2 Timing chain tensioner bank 2 Oil pump drive chain tensioner Camshaft sprocket EXH bank 1 Slack guide bank 1 Crankshaft sprocket bank 1 side Matching mark outer groove Matching mark yellow link VK50VE JPBIA2112ZZ Camshaft sp
99. 2 1248 0 0 Tyr prpry1y2 2 2 D 8 971 59 970 1248 21248 000 11 1 1 2 2 2 2 E 53 970 53 969 2 1248 2 1248 O 1T 1717 171 2 2 2 2 2 F 53 969 53 968 2 1248 2 1247 1 1 apt 17r 2 2 2 2 2 2 G 58 968 59 067 2 1247 2 1047 1 1 1 1 1 1 fe felelelel2 a 58 967 59 966 2 1247 2 1246 1 1 1 1 2 2 2 2 2 2 9 9 J 53 966 53 965 2 1246 2 1246 1 1 17 2 2 2 2 2 2 3 3 3 K 53 965 53 964 2 1246 2 1246 1 1 2 2 2 2 2 2 3 3 3 3 L 53 964 53 963 2 1246 2 1245 1 1 2 2 2 2 2 2 3 3 3 3J 3 M 53 963 53 962 2 1245 2 1245 1 2 2 2 2 2 2 3 3 3 31 3 3 N 53 962 53 961 2 1245 2 1244 2 2 2 2 2 2 3 3 3 3 3 3 4 R__ 53 960 53 959 2 1244 2 1244 S__ 53 959 53 958 2 1244 2 1243 T 53 958 53 957 2 1243 2 1243 2 2 3 3 3 3 3 3 4 4 4 4 4 U 53 957 53 956 2 1243 2 1242 2 3 3 3 3 3 3 4 4 4 4 4 4 CONNECTING ROD BEARING GRADE TABLE Connecting rod bearing grade table UNDERSIZE BEARING USAGE GUIDE Revision 2009 March Refer to EM 152 Connecting Rod Bearing EM 138 VQ35HR Read the symbol at the cross point of selected row and column in the CONNECTING ROD BEARING SELECTION TABLE Apply the symbol obtained to the CONNECTING ROD BEARING GRADE TABLE to select connecting PBIC5435E 2009 FX35 FX50 HOW TO SELECT PISTON AND BEARING lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR e When the specified connectin
100. 20 kg 485 Ib or more large enough for supporting the engine weight If the load capacity of the stand is not adequate remove the following parts beforehand to reduce the potential risk of overturning the stand Remove intake manifold collector Refer to EM 31 Exploded View Remove intake manifold Refer to EM 34 Exploded View Remove fuel injector and fuel tube assembly Refer to EM 40 Exploded View Remove ignition coil and rocker cover Refer to EM 50 Exploded View Remove exhaust manifold Refer to EM 36 Exploded View Other removable brackets NOTE The figure shows an example of widely use engine stand A that can hold mating surface of transmission with drive plate removed CAUTION Before removing the hanging chains check the engine stand is stable and there is no risk of overturning JPBIA0190ZZ Revision 2009 March EM 92 2009 FX35 FX50 ENGINE STAND SETTING lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR 6 Drain engine oil Refer to LU 8 Draining 7 Drain engine coolant by removing water drain plugs 1 and 4 from cylinder block both sides as shown in the figure 2 Washer 3 Plug lt Engine front JPBIAO191ZZ Revision 2009 March EM 93 2009 FX35 FX50 ENGINE UNIT lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR ENGINE UNIT D i sasse m b ly INFOID 0000000003887375 1 Remove intake manifold collector Refer to EM 31 Exploded View 2 Remove intake manifold Refer to EM 34
101. 262 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE e Position each ring with the gap as shown in the figure referring to the piston front mark D 90 degrees 45 degrees Top ring gap Oil ring upper or lower rail gap either of them Second ring and oil ring spacer gap m moo gt o JPBIA0205ZZ e Check the piston ring side clearance Refer to EM 265 Inspection 13 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 e 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 e When installing align connecting rod bearing stopper protru sion B with cutout A of connecting rods and connecting rod bearing caps to install e Ensure the oil hole C on connecting rod and that on the cor responding bearing are aligned JPBIA2272ZZ 14 Install piston and connecting rod assembly to crankshaft e Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center e Apply engine oil sufficiently to the cylinder bore piston and crankshaft pin journal e Match the cylinder position with the cylinder number on connecting rod to install e Be sure that front mark on piston crown is facing the front of the engine e Using a pist
102. 3 0 0994 White LWR 2 518 2 521 0 0991 0 0993 Purple UNDERSIZE Revision 2009 March EM 151 2009 FX35 FX50 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ35HR Unit mm in Items Thickness Main journal diameter 0 25 0 0098 2 633 2 641 0 1037 0 1040 Grind so that bearing clearance is the specified value MAIN BEARING OIL CLEARANCE Unit mm in Items Standard Limit Main bearing oil clearance 0 035 0 045 0 0014 0 0018 0 065 0 0026 Actual clearance Connecting Rod Bearing INFOID 0000000003887405 CONNECTING ROD BEARING Unit mm in Grade number Thickness Identification color mark 0 1 497 1 500 0 0589 0 0591 Black 1 1 500 1 503 0 0591 0 0592 Brown 2 1 503 1 506 0 0592 0 0593 Green 3 1 506 1 509 0 0593 0 0594 Yellow 4 1 509 1 512 0 0594 0 0595 Blue UNDERSIZE Unit mm in Items Thickness Crank pin journal diameter 0 25 0 0098 1 626 1 634 0 0640 0 0643 Grind so that bearing clearance is the specified value CONNECTING ROD BEARING OIL CLEARANCE Unit mm in Items Standard Limit Connecting rod bearing oil clearance 0 040 0 053 0 0016 0 0021 0 070 0 0028 Actual clearance Revision 2009 March EM 152 2009 FX35 FX50 NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING lt SYMPTOM DIAGNOSIS gt VKSOVE SYMPTOM DIAGNOSIS NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTI
103. 3 to quick connector connection 1 Centralized under floor piping 2 __ Fuel feed hose B Under view e Install quick connector cap with arrow A on surface facing the direction of quick connector fuel feed hose side CAUTION If quick connector cap cannot be installed smoothly quick connector may have not be installed correctly Check the connection again sPBIADOSEZZ 10 Install in the reverse order of removal after this step n S pect i O n INFOID 0000000003887352 INSPECTION AFTER INSTALLATION Check on Fuel Leakage 1 Turn ignition switch ON with the engine stopped With fuel pressure applied to fuel piping check there are no fuel leakage at connection points NOTE Use mirrors for checking at points out of clear sight 2 Start the engine With engine speed increased check again that there are no fuel leakage at connection points CAUTION Never touch the engine immediately after stopped as the engine becomes extremely hot Revision 2009 March EM 45 2009 FX35 FX50 OIL PAN LOWER AND OIL STRAINER Exploded View 2WD models SEC 110 150 213 253 9 21 6 2 2 16 1 Oil level gauge O ring 7 Connector bolt 10 Oil strainer 13 Washer 16 Drain plug washer A Refer to LU 9 OIL PAN LOWER AND OIL STRAINER lt REMOVAL AND INSTALLATION gt Oil level gauge guide O ring Oil filter Oil pressure switch Oil pan upper Oil pan lower To oil pump Refer to Gl 4
104. 3 500 23 521 0 9252 0 9260 No 1 25 935 25 955 1 0211 1 0218 Camshaft journal diameter No 2 3 4 23 445 23 465 0 9230 0 9238 Camshaft end play 0 115 0 188 0 0045 0 0074 0 24 0 0094 Intake 45 865 46 055 1 8057 1 8132 0 2 0 008 Camshaft cam height A Exhaust 45 875 46 065 1 8061 1 8136 0 2 0 008 Camshaft runout TIR Less than 0 02 0 0008 0 05 0 0020 Camshaft sprocket runout TIR 0 15 0 0059 A IX Revision 2009 March EM 143 2009 FX35 FX50 SEM671 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ35HR 1 Cam wear limit 2 Total indicator reading VALVE LIFTER Unit mm in Items Standard Valve lifter outer diameter 33 980 33 990 1 3378 1 3382 Valve lifter hole diameter 34 000 34 016 1 3386 1 3392 Valve lifter clearance 0 010 0 036 0 0004 0 0014 VALVE CLEARANCE Unit mm in Items Cold Hot reference data Intake 0 26 0 34 0 010 0 013 0 304 0 416 0 012 0 016 Exhaust 0 29 0 37 0 011 0 015 0 308 0 432 0 012 0 017 Approximately 80 C 176 F AVAILABLE VALVE LIFTER Unit mm in Identification stamped mark Thickness 788 7 88 0 3102 790 7 90 0 3110 792 7 92 0 3118 794 7 94 0 3126 796 7 96 0 3134 798 7 98 0 3142 800 8 00 0 3150 802 8 02 0 3157 804 8
105. 3118 794P 7 94 0 3126 796P 7 96 0 3134 798P 7 98 0 3142 800P 8 00 0 3150 802P 8 02 0 3157 804P 8 04 0 3165 806P 8 06 0 3173 808P 8 08 0 3181 810P 8 10 0 3189 812P 8 12 0 3197 814P 8 14 0 3205 816P 8 16 0 3213 818P 8 18 0 3220 820P 8 20 0 3228 822P 8 22 0 3236 824P 8 24 0 3244 826P 8 26 0 3252 828P 8 28 0 3260 830P 8 30 0 3268 832P 8 32 0 3276 834P 8 34 0 3283 836P 8 36 0 3291 838P 8 38 0 3299 840P 8 40 0 3307 Revision 2009 March Stamped mark Valve lifter thickness sem7sse EM 284 2009 FX35 FX50 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VK50VE Cyli nder Head INFOID 0000000003733469 CYLINDER HEAD Unit mm in o emes e Sada S S Head surface distortion Less than 0 03 0 0012 0 1 0 004 Normal cylinder head height H 126 4 4 98 lt H PBIC0924E VALVE DIMENSIONS Unit mm in T Margin thickness a I Law L E SEM188 Intake 36 6 36 9 1 441 1 453 Valve head diameter D Exhaust 30 2 30 5 1 189 1 201 Intake 100 11 3 94 Valve length L Exhaust 94 67 3 7272 Intake 5 965 5 980 0 2348 0 2354 Valve stem diameter d Exhaust 5 955 5 970 0 2344 0 2350 Intake Valve seat angle a 45 15 45 45 Exhaust Intake 1 1 0 043 Valve margin T Exhaust 1 3 0 051 Valve margin T limi
106. 49 2 7145 2 7145 68 952 68 953 2 7146 2 7147 01 68 953 68 954 2 7147 2 7147 68 954 68 955 2 7147 2 7148 68 955 68 956 2 7148 2 7148 68 956 68 957 2 7148 2 7148 68 957 68 958 2 7148 2 7149 68 958 68 959 2 7149 2 7149 68 959 68 960 2 7149 2 7150 N wo 2 2 SJA NTN bate ol lo wo 22 IR NTN dja mjt a 0 o o lla N O o o oO j o VK50VE i fel w a ar ar eo to wo 0 0 ejeje alira a kaa A a a ja rata jajaja to 0 0 0 eje e aaia ap ee A al al NIM to oO amp ojojojo ERN ojojo o n r r de jojojnN o o o o sorta A e Par 00 oo o o o o 34 63 963 63 962 2 5182 2 5182 63 962 63 961 2 5182 2 5181 63 961 63 960 2 5181 2 5181 63 960 63 959 2 5181 2 5181 01 olor hehhee 3 3 3 34 5 2s 2s 3 3 3 s4fs4 34 a 4 23 3 3 3 34 34 34 4 4 4 45 R 34 4 4 4 63 959 63 958 2 5181 2 5180 63 958 63 957 2 5180 2 5180 63 957 63 956 2 5180 2 5179 01 1 141 412 12 12 2 2 1 1 1412 12 12 2 2 2 63 956 63 955 2 5179 2 5179 63 955 63 954 2 5179 2 5179 63 954 63 953 2 5179 2 5178 63 953 63 952 2 5178 2 5178 1 12 2 2 2 23 23 12 2 2 23 23 23 12 2 2 23 23 23 3 N Si oe 23 3 33 3 3 3 34 a 34 34 34
107. 5182 2 5183 Grade No B 63 962 63 963 2 5182 2 5182 Grade No C 63 961 63 962 2 5181 2 5182 Grade No D 63 960 63 961 2 5181 2 5181 Grade No E 63 959 63 960 2 5181 2 5181 Grade No F 63 958 63 959 2 5180 2 5181 Grade No G 63 957 63 958 2 5180 2 5180 Grade No H 63 956 63 957 2 5179 2 5180 Grade No J 63 955 63 956 2 5179 2 5179 Grade No K 63 954 63 955 2 5179 2 5179 Grade No L 63 953 63 954 2 5178 2 5179 Main journal diameter Dm grade Standard Grade No M 63 952 63 953 2 5178 2 5178 No 2 3 and 4 journal Grade No N 63 951 63 952 2 5178 2 5178 Grade No P 63 950 63 951 2 5177 2 5178 Grade No R 63 949 63 950 2 5177 2 5177 Grade No S 63 948 63 949 2 5176 2 5177 Grade No T 63 947 63 948 2 5176 2 5176 Grade No U 63 946 63 947 2 5176 2 5176 Grade No V 63 945 63 946 2 5175 2 5176 Grade No W 63 944 63 945 2 5175 2 5175 Grade No X 63 943 63 944 2 5174 2 5175 Grade No Y 63 942 63 943 2 5174 2 5174 Grade No 1 63 941 63 942 2 5174 2 5174 Grade No 2 63 940 63 941 2 5173 2 5174 EM 290 Revision 2009 March 2009 FX35 FX50 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VK50VE Grade No A 53 974 53 973 2 1250 2 1249 Grade No B 53 973 53 972 2 1249 2 1249 Grade No C 53 972 53 971 2 1249 2 1248 Grade No D 53 97
108. 60 to 70 C 140 to 158 F with an industrial use drier A or an equivalent JPBIAO196ZZ c Push out piston pin with stick of outer diameter approximately 20 mm 0 79 in PBICO262E 8 Remove lower cylinder block bolts e Before loosening lower cylinder block bolts measure the crankshaft end play Refer to EM 147 Cylinder Block e Loosen lower cylinder block bolts in the reverse order shown in the figure in several different steps fo lP lt Engine front AL o o f pf sof ilor She fF od i aA jol sole 4 7 O of p I ats lol OM ne 19 iT LG JPBIA0197ZZ 9 Remove lower cylinder block as per the following Revision 2009 March EM 119 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR Screw M8 bolt pitch 1 25 mm 0 0492 in length approximately 50 mm 1 97 in into bolt holes A Then equally tighten each bolt and remove lower cylinder block lt Engine front CAUTION Be careful not to damage the mounting surfaces e Never tighten bolts too much Never insert screw driver this will damage the mating sur face 10 Remove crankshaft 11 Pull rear oil seal out from rear end of crankshaft 12 Remove main bearings and thrust bearings from cylinder block and lower cylinder block CAUTION Be careful not to drop main bearing and to scratch the surface e Identify installation positions and store them without mixing them up 13 Remove oil jet
109. 62 64 961 2 5576 2 5575 2 2 23231233 3 3 34 34 al 4 4 4 45 45 45 5 5 5 56 56 56 6 64 961 64 960 2 5575 2 5575 2 23 23 23 3 3 3 lalala 4 4 4 45 45 45 5 5 5 56 56 56 6 6 64 959 64 958 2 5574 2 5574 2a 23 3 3 3 34 34 3a 4 4 4 45 45 45 5 5 5 56 56 50 6 6 64 958 64 957 2 5574 2 5574 23 3 3 3 34 34 34 4 4 4 45 45 45 5 5 5 l56l56l56 6 6 6 64 957 64 956 2 5574 2 5573 3 3 3 34 34 34 4 4 4 45 45 45 5 5 5 56 56 56 6 6 6 67 64 956 64 955 2 5573 2 5573 3 3 34 34 34 4 4 4 45 45 45 5 5 5 56 56 56 6 6 6 67 67 67 7 64 955 64 954 2 5573 2 5572 3 34 34 34 4 4 4 45 45 45 5 5 5 565656 6 6 6 67 67 67 7 7 64 954 64 953 2 5572 2 5572 34 34 34 4 4 4 45 45 45 5 5 5 56 56 56 6 6 6 67 67 67 7 7 64 953 64 952 2 5572 2 5572 34 34 4 4 4 45 45 45 5 5 5 56 56 56 6 6 67 67 67 7 7 7 64 952 64 951 2 5572 2 5571 34 4 4 4 45 45 45 5 5 5 56 56 56 6 6 6 67 67 67 7 7 7 X X JPBIA0264ZZ en pra pary sls N rh NIN 70 005 70 006 2 7561 2 7561 70 006 70 007 2 7561 2 7562 70 013 70 014 2 7564 2 7565 alala a a jaa NJN M oo ooo NIYII wji RIII oO BIR AR BRIS oja o A A on ojo ASAlalala
110. 7144 2 7145 2 7145 2 7145 2 7145 2 7146 2 7146 2 7146 2 7146 2 7146 2 7146 2 7147 2 7147 2 7147 2 7147 2 7148 2 7148 2 7148 2 7148 2 7148 2 7148 2 7149 2 7149 2 7149 2 7149 2 7150 2 7150 2 7150 2 7150 2 7150 2 7150 2 7151 2 7151 2 7151 2 7151 2 7152 2 7152 2 7152 2 7152 2 7152 2 7152 2 7153 a ne ea en a a ee A en es ee en ee Difference in inner diameter between cylinders AVAILABLE PISTON Standard SEM882E Less than 0 03 0 0012 Unit mm in Items Standard Oversize Service 0 2 0 008 Grade No 1 95 480 95 490 3 7590 3 7594 er SAE MERETE Grade No 2 95 490 95 500 3 7594 3 7598 Grade No 3 95 500 95 510 3 7598 3 7602 Service 95 680 95 710 3 7669 3 7681 Items Standard Limit a dimension 38 8 1 528 Piston pin hole diameter 21 993 21 999 0 8659 0 8661 Piston to cylinder bore clearance 0 010 0 030 0 0004 0 0012 0 08 0 0031 PISTON RING Unit mm in Items Standard Limit Top 0 040 0 080 0 0016 0 0031 0 11 0 0043 Side clearance 2nd 0 030 0 070 0 0012 0 0028 0 10 0 0039 Oil ring 0 055 0 155 0 0022 0 0061 0 19 0 0075 Revision 2009 March EM 288 2009 FX35 FX50 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS 0 23 0 33 0 0091 0 0130 VK50VE 0 55 0 0217
111. 78 2 5178 3 3 3 34 34 34 4 4 4 45 45 45 5 5 56 56 56 6 6 67 67 67 w s951 69 950 25178 25177 3 oaloaloa a 4 la 45 45 45 5 5 5 56 56 56 6 6 Le or o7 o7 7 63 950 63 949 2 5177 2 5177 34 34 34 4 4 4 45 45 45 5 5 56 56 6 6 6 67 67 67 7 7 7 feet he efecto fe teetepet ees eee ee 4 2 60 047 69 946 25176 25176 a a a 45 45 45 5 5 5 56 56 56 6 6 o7 o7 67 7 72 55 a ase esgan esis fs 5s ess sr 63 945 63 944 2 5175 2 5175 4 45 45 45 5 5 56 56 6 6 67 67 67 7 7 7 78 78 78 8 8 63 944 63 943 2 5175 2 5174 45 45 45 5 56 56 63 943 63 942 2 5174 2 5174 cogagg 56 56 g 5 8 x 63 942 63 941 2 5174 2 5174 5 5 X x H J K L M z D ajo lt c aj a lt x O N N N N a x N AJo o JPBIA2285GB Revision 2009 March EM 279 2009 FX35 FX50 mark HOW TO SELECT PISTON AND BEARING lt UNIT DISASSEMBLY AND ASSEMBLY gt MAIN BEARING SELECTION TABLE No 2 3 and 4 Journal Cylinder block main bearing housing inner diameter Hole Crankshaft diameter main journal Unit mm diameter in LB Axle diameter Unit mm in 63 964 63 963 2 5183 2 5182 H J 68 944 68 945 2 7143 2 7144 68 945 68 946 2 7144 2 7144 68 946 68 947 2 7144 2 7144 68 947 68 948 2 7144 2 7145 68 948 68 9
112. 9 FX35 FX50 DRIVE BELTS lt PERIODIC MAINTENANCE gt VKSOVE Tension Adjustment INFOID 0000000003733402 Refer to EM 282 Drive Belts Removal and Installation INFOID 0000000003733403 REMOVAL Alternator Water Pump and A C Compressor Belt 1 2 3 5 Remove air duct inlet Refer to EM 177 Exploded View Remove reservoir tank Refer to CO 39 Exploded View With box wrench and while securely holding the hexagonal part in pulley center of auto tensioner 1 move wrench handle in the direction of arrow loosening direction of belt CAUTION Never place hand in a location where pinching may occur if the holding tool accidentally comes off e Never loosen the hexagonal part in center of auto ten sioner pulley Never turn it clockwise If turned clock wise the complete auto tensioner must be replaced as a unit including the pulley Under the above condition insert a metallic bar A of approxi mately 6 mm 0 24 in in diameter hexagonal bar wrench shown as example in the figure through the holding boss to lock auto tensioner pulley arm e Leave auto tensioner pulley arm locked until belt is installed again Remove alternator water pump and A C compressor belt Power Steering Oil Pump Belt 1 2 3 5 Remove engine undercover with power tool Remove alternator water pump and A C compressor belt Refer to Alternator Water Pump and A C Compressor Belt With box wrench and wh
113. A A the attachment SST KV10115900 J 26336 20 C the adapter SST KV10109220 _ B Remove valve collet with a magnet hand CAUTION When working take care not to damage valve lifter holes 5 Remove valve spring retainer and valve spring 6 Remove valve oil seal using the valve oil seal puller SST KV10107902 J 38959 A INSTALLATION 1 Apply new engine oil on new valve oil seal joint and seal lip 2 Using the valve oil seal drift SST KV10115600 J 38958 A press fit valve seal to height b shown in the figure NOTE Dimension Height measured before valve spring seat installa tion Intake and exhaust 14 3 14 9 mm 0 563 0 587 in 3 Install in the reverse order of removal after this step FRONT OIL SEAL FRONT OIL SEAL Removal and Installation REMOVAL Revision 2009 March EM 79 AY 1 1 1 1 1 1 7 4 l fe 9 N O JPBIA0180ZZ JPBIA0177ZZ JPBIA0178ZZ INFOID 0000000003887366 2009 FX35 FX50 OIL SEAL lt REMOVAL AND INSTALLATION gt VQ35HR 1 Remove the following parts e Engine undercover with power tool e Drive belt Refer to EM 15 Exploded View e Crankshaft pulley Refer to EM 53 Exploded View 2 Remove front oil seal using a suitable tool CAUTION Be careful not to damage front timing chain case and crank shaft PBIC2931E INSTALLATION 1 Apply new engine oil to both oil seal lip and dust seal lip of new
114. ASSEMBLY gt VQ35HR b Apply liquid gasket with the tube presser commercial service tool to rear timing chain case back side as shown in the figure Use Genuine RTV Silicone Sealant or an equivalent Refer to GI 15 Recommended Chemical Products and Sealants CAUTION For A in the figure completely wipe out liquid gasket extended on a portion touching at engine coolant Apply liquid gasket on installation position of water pump and cylinder head very completely JPBIA0092ZZ C Protrusion D Clearance 1 mm 0 04 in E Do not protrude in this area F Run along bolt hole inner side G Frotrusions at beginning and end ot gasket h 3 9 mm 0 154 in i 2 7 mm 0 106 in Refer to Gl 4 Components for symbols in the figure c Align rear timing chain case with dowel pins bank 1 and bank 2 on cylinder block and install rear timing chain case e Check O rings stay in place during installation to cylinder block and cylinder head d Tighten mounting bolts in numerical order as shown in the fig ure e There are two types of mounting bolts Refer to the following for locating bolts Bolt length Bolt position 20 mm 0 79 in 1 2 3 6 7 8 9 10 16 mm 0 63 in 4 5 11 12 13 12 7 N m 1 3 kg m 9 ft lb JPBIAO089ZZ Revision 2009 March EM 98 2009 FX35 FX50 REAR TIMING CHAIN CASE lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR Bolt length Bolt position 16 mm 0 63 in Except the above
115. Bearing JPBIA0228ZZ CRANKSHAFT OUT OF ROUND AND TAPER e Measure the dimensions at four different points as shown in the figure on each main journal and pin journal with a micrometer e Out of round is indicated by the difference in the dimensions between d and c at a and b e Taper is indicated by the difference in the dimensions between JPBIA0229ZZ Out of round Difference between c and d E Refer to EM 287 Cylinder Block Taper Difference between a and b If the measured value exceeds the limit correct or replace crankshaft e If corrected measure the bearing oil clearance of the corrected main journal and or pin journal Then select the main bearing and or connecting rod bearing Refer to EM 277 Main Bearing and or EM 275 Connecting Rod Bearing CRANKSHAFT RUNOUT e Place V block on precise flat table and support the journals on both ends of crankshaft e Place a dial indicator straight up on the No 3 journal e While rotating crankshaft read the movement of the pointer on a dial indicator Total indicator reading Standard and limit Refer to EM 287 Cylinder Block e If it exceeds the limit replace crankshaft SEM346D CONNECTING ROD BEARING OIL CLEARANCE Method by Calculation e Install connecting rod bearings 1 to connecting rod 2 and con necting rod cap and tighten connecting rod bolts to the specified torque Refer to EM 256 D
116. C position At this time the steering lock will be released 3 Disconnect both battery cables The steering lock will remain released with both battery cables discon nected and the steering wheel can be turned 4 Perform the necessary repair operation 5 When the repair work is completed re connect both battery cables With the brake pedal released turn the push button ignition switch from ACC position to ON position then to LOCK position The steering wheel will lock when the push button ignition switch is turned to LOCK position 6 Perform self diagnosis check of all control units using CONSULT III Precaution for Drain Engine Coolant and Engine Oil INFOID 0000000003738478 Drain engine coolant and engine oil when engine is cooled Precaution for Disconnecting Fuel Piping INFOID 0000000003788479 e Before starting work check no fire or spark producing items are in the work area e Release fuel pressure before disconnecting and disassembly e After disconnecting pipes plug openings to stop fuel leakage Precaution for Removal and Disassembly INFOID 0000000003738480 e When instructed to use SST use specified tools Always be careful to work safely avoid forceful or unin structed operations e Exercise maximum care to avoid damage to mating or sliding surfaces e Cover openings of engine system with tape or the equivalent if necessary to seal out foreign materials e Mark and arrange disassembly parts in an organized wa
117. CE gt VQ35HR 2 While securely holding the square hole A in pulley center of auto tensioner 1 with a spinner handle move spinner handle in the direction of arrow loosening direction of drive belt 4m Loosening direction of drive belt CAUTION Never place hand in a location where pinching may occur if the holding tool accidentally comes off 3 Under the above condition insert a metallic bar of approximately 6 mm 0 24 in in diameter hexagonal wrench C shown as example in the figure through the holding boss B to lock auto tensioner pulley arm 4 Remove drive belt INSTALLATION Note the following item and install in the reverse order of removal CAUTION e Check drive belt is securely installed around all pulleys e Check drive belt is correctly engaged with the pulley groove e Check for engine oil and engine coolant are not adhered drive belt and pulley groove n S pect i O n INFOID 0000000003887328 JPBIA0003ZZ INSPECTION AFTER INSTALLATION e Turn crankshaft pulley clockwise several times to equalize tension between each pulley and then confirm tension of drive belt at indicator notch on fixed side is within the possible use range Refer to EM 15 Exploded View Revision 2009 March EM 16 2009 FX35 FX50 AIR CLEANER FILTER lt PERIODIC MAINTENANCE gt VQ35HR AIR CLEANER FILTER Re moval and Installation INFOID 0000000003887329 REMOVAL 1 Unhook clips A 1 Holder 2 Air
118. Camshaft sprocket EXH bank 1 11 Timing chain bank 1 12 Camshaft sprocket INT bank 1 13 Timing chain tensioner bank 1 14 Slack guide bank 1 15 Oil pump sprocket crankshaft side 16 Oil pump sprocket oil pump side 17 Tension guide bank 1 18 Oil pump drive chain Camshaft position sensor INT Camshaft position sensor EXH 19 bank 2 20 bank 2 21 O ring EM 22 Seal ring 23 Valve timing control cover bank 2 24 ee Unting control solenoid valve 25 Fxhaust valve timing control sole 26 Crankshaft pulle 27 Front oil seal noid valve bank 2 pusoy i 28 Intake valve timing control solenoid 29 Exhaust valve timing control sole 30 Valve timing control cover bank 1 valve bank 1 noid valve bank 1 31 Timing chain tensioner cover 32 Front cover 33 Camshaft position sensor EXH bank 1 34 O ring 35 Camshaft position sensor INT 36 Oil filter for valve timing control solenoid bank 1 valve 37 Oil pump 38 Oil pump drive chain tensioner A Refer to EM 213 Refer to Gl 4 Components for symbol marks in the figure 0 22 0 2 2 16 0 55 0 5 6 41 JPBIA2296GB 1 Alternator bracket 2 Power steering pump bracket 3 Alternator support 4 A G compressor bracket A Right side B Front side lt Engine front Refer to Gl 4 Components for symbol marks in the figure Disassembly and Assembly INFOID 0000000003733435 DISASSEMBLY 1 Remove auto tensioners and idler pul
119. ECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ35HR i Intake 34 6 1 362 Diameter d1 Exhaust 27 7 1 091 Intake 35 9 36 4 1 413 1 433 Diameter d2 Exhaust 29 3 29 8 1 154 1 173 EM Intake 60 Angle a1 Exhaust 60 Intake 88 45 90 15 Angle a2 Exhaust 88 45 90 15 Intake 120 Angle a3 Exhaust 120 A Intake 1 0 1 4 0 039 0 055 Contacting width W oe Exhaust 1 2 1 6 0 047 0 063 Heup Intake 5 9 6 0 0 232 0 236 5 05 5 15 0 1988 0 2028 eight h j Exhaust 5 9 6 0 0 232 0 236 4 95 5 05 0 1949 0 1988 Depth H 6 0 0 236 1 Diameter made by intersection point of conic angles a1 and a2 2 Diameter made by intersection point of conic angles a2 and a3 3 Machining data VALVE SPRING Items Standard Free height 43 85 mm 1 7264 in Installation height 37 00 mm 1 4567 in Installation load 166 188 N 16 9 19 2 kg 37 42 Ib Height during valve open 26 8 mm 1 055 in Load with valve open 502 566 N 51 2 57 7 kg 113 127 b Squareness Cylinder Block CYLINDER BLOCK 1 9 mm 0 075 in INFOID 0000000003887403 Unit mm in Unit mm in JPBIA1050GB Standard Less than 0 03 0 0012 Surface flatness Limit 0 1 0 004 Main bearing housing inner diameter
120. EM 57 2009 FX35 FX50 TIMING CHAIN lt REMOVAL AND INSTALLATION gt VQ35HR a Remove lower mounting bolt A b Loosen upper mounting bolt B slowly and then turn timing chain tensioner primary 1 on the upper mounting bolt so that plunger C is fully expanded NOTE Even if plunger is fully expanded it is not dropped from the body of timing chain tensioner primary c Remove upper mounting bolt and then remove timing chain ten sioner primary JPBIA1537ZZ 32 Remove internal chain guide 1 and slack guide 2 JPBIAO086ZZ 33 Remove timing chain primary and crankshaft sprocket CAUTION After removing timing chain tensioner primary never turn crankshaft and camshaft separately or valves will strike the piston heads 34 Remove timing chain secondary and camshaft sprockets as per the following a Attach suitable stopper pin 2 to the timing chain tensioners secondary 1 A Bank 1 B Bank2 NOTE e Use approximately 0 5 mm 0 02 in dia hard metal pin as a stopper pin e For removal of timing chain tensioners secondary refer to EM 70 Exploded View Removing camshaft bracket No 1 is required JPBIA0087ZZ b Remove camshaft sprocket mounting bolts INT and EXH Revision 2009 March EM 58 2009 FX35 FX50 TIMING CHAIN lt REMOVAL AND INSTALLATION gt VQ35HR e Secure the hexagonal portion of camshaft using a wrench to loosen mounting bolts c Remove timing
121. ENGINE SECTION E M ENGINE MECHANICAL CONTENTS VQ35HR AIR CLEANER FILTER eeeeceeeeeeeseeeeees 17 Removal and Installation 17 SYMPTOM DIAGNOSIS cseceeeeeeeeeeeees 5 SPARK PLUG atasan hananira anna danan iaiaaeaia nananana aa 18 NOISE VIBRATION AND HARSHNESS Exploded VieW ccccccccccssscesseeeessseeeecseecsseeeseeeeees 18 NVH TROUBLESHOOTING ecceeeeeeeeees 5 Removal and Installation c scceeseeeeeeeeeetees 18 NVH Troubleshooting Engine Noise 0 5 inspecionar A teeees 19 Use the Chart Below to Help You Find the C ause of the Symptom sesesesseseesrriesrressrrsssrnses 5 CAMSHAFT VALVE CLEARANCE sses 20 Inspection and Adjustment e ee ceeeeeeesteeeeeeneees 20 PRECAUTION sisissssssssstecnccacccsseccteccsaiinatetets 7 COMPRESSION PRESSURE sssssseeeeeeeees 25 PRECAUTIONS ccccccceccceeeseeeeeeessenseenseensensenens 7 inspectio i a cvcincteh nckeGhie ie esate 25 Precaution for Procedure without Cowl Top Cover 7 REMOVAL AND INSTALLATION be Precaution for Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TEN ENGINE COVER nsssssnnnnnnnnnnunnnnnnnnnnnnnnnnnnn ennnen 27 SIONER a e Sean cote AAE A ten T Exploded VieW cceccceceeeeceeeeeeeceeeseeeseeeeeeteneeeee 27 Precaution Necessary for Steering Wheel Rota Removal and Installation 07 tion after Battery Disconnect eect eenee
122. ER HEAD ooeececcecccccccccccccccccecceccccceccecesse 407 Exploded View esi ee er E a SEEE AE 50 3 Removaland Installation 50 Exploded VIEW esserne 107 A E A RE A aig Disassembly and Assembly seeeeeeseeeeeee 107 TIMING CHAIN ccccoccccccecccecccceccecccceccececceseseseeseens 53 INSPOCHON aiie 114 Ua gn Te R 5 GXLINDER BLOCK oisit 117 lide DESHI E eet a naan ee 68 Exploded VieW ccccccccecceceeeeeeceecceeeaeeeeeeeeeeeeeeeees 117 EPEA EE ETEL E AE E E bes ocaratios Disassembly and Assembly 118 CAMSHAPT occ ccccccccccccccecccccccececececececcecccseceeeseeare 70 INSPECHON seeriana a aaa a E aaas 126 Exploded View soeesneeenecnesenecneeeeenetenteneeeneeanennntanetages 70 HOW TO SELECT PISTON AND BEARING 136 Removal and Installation ccseseceeeeeeeeeeees 70 r INSPECHION ieen elie ae i 74 DE P a ta eushiaitasia ht a hatte 198 AEO TA AEAEE E E TA che ee attest tee 136 OIL SEAL viiia i tithe 2 79 Connecting Rod Bearing cee 137 Main Bearg eeii r AR 139 VALVE OIL SEAL eirinen esSaivcnatcniaiddad 79 VALVE OIL SEAL Removal and Installation 79 SERVICE DATA AND SPECIFICATIONS SDS eeceeucch eta cctvsdastectessrtinssvteiesiteeeiseied 142 FRONT OIL SEAL tei ccctcuccncn enki 79 FRONT OIL SEAL Removal and Installation 79 SERVICE DATA AND SPECIFICATIONS REAR OIL SEAL aiae so SDS reves RAE ean ey ay ena m REAR OIL SEAL Removal and Installation 80 General Sp
123. ESS NVH TROUBLESHOOTING lt SYMPTOM DIAGNOSIS gt VQ35HR SYMPTOM DIAGNOSIS NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING NVH Troubleshooting Engine Noise lt commes E Camshaft bearing noise Tappet noise Timing chain and chain tensioner nois Drive belt noise Stick Slipping Drive belt noise Stick Slipping Main bearing noise JPBIA0001GB Use the Chart Below to Help You Find the Cause of the SyMptoM imromooooooooos87s10 1 Locate the area where noise occurs Revision 2009 March EM 5 2009 FX35 FX50 NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING lt SYMPTOM DIAGNOSIS gt VQ35HR 2 Confirm the type of noise 3 Specify the operating condition of the engine 4 Check specified noise source If necessary repair or replace these parts Operating condition of engine Location Type of Before After When f Source of Refer of noise noise warm warm ll stani When When While noise Cheek item ence page idling racing driving up up ing Top oreng Tg E gor C A A B Tappet Valve clearance EM 20 gine clicking noise Rocker cover Camshaft Camshaft runout EM 143 i attle earing amshaft journal oi Cylinder Rattl C A A B C b Camshaft oil head noise clearance Piston to piston pin oil Slap or Piston pin clearance 2 knock A A B a noise Connecting rod bushing a oil clearan
124. Fuel injector 15 O ring black 16 Clip 17 Fuel tube bank 2 18 Fuel feed damper 19 O ring A To centralized under floor piping B Refer to EM 182 Refer to Gl 4 Components for symbols in the figure CAUTION Never remove or disassemble parts unless instructed as shown in the figure Re m oval a n d n stal lat i O n INFOID 0000000003733427 REMOVAL WARNING e Puta CAUTION FLAMMABLE sign in the workshop Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher Never smoke while servicing fuel system Keep open flames and sparks away from the work area To avoid the danger of being scalded never drain engine coolant when engine is hot 1 Remove engine cover and engine room cover RH and LH Refer to EM 174 Exploded View 2 Release fuel pressure Refer to EC 1228 Inspection Revision 2009 March EM 182 2009 FX35 FX50 FUEL INJECTOR AND FUEL TUBE lt REMOVAL AND INSTALLATION gt VKSOVE 3 on Remove the fuel feed hose 2 on the fuel feed damper side with quick connector release commercial service tool J 45488 as per the followings steps 1 Quick connector cap lt 1 Engine front CAUTION Use the quick connector release for removing the fuel feed hose on the centralized under floor piping side as well as the fuel feed damper side although the shape of the quick connector is different Remove quick connector cap from quick connector connec
125. I Measure compression pressure using compression gauge connected with flexible type adapter commer cial service tool 8 With accelerator pedal fully depressed turn ignition switch to START for cranking When the gauge pointer stabilizes read the compression pressure and the engine rpm Perform these steps to check each cylinder NO OS Compression pressure _ Refer to EM 282 General Specification CAUTION Measure a six cylinder under the same conditions since a measurement depends on measure ment conditions engine water temperature etc Always use a fully charged battery to obtain the specified engine speed If the engine speed is out of the specified range check battery liquid for proper gravity Check the engine speed again with normal battery gravity Refer to PG 3 How to Handle Battery If compression pressure is below the minimum value check valve clearances and parts associated with combustion chamber valve valve seat piston piston ring cylinder bore cylinder head and cylinder head gasket After checking measure compression pressure again If a cylinder has low compression pressure pour a small amount of engine oil into the spark plug hole of the cylinder to recheck it for compression If the added engine oil improves the compression piston rings may be worn out or damaged Check pis ton rings and replace if necessary Refer to EM 256 Disassembly and Assembly If the compression pres
126. IFOLD COLLECTOR lt REMOVAL AND INSTALLATION gt INTAKE MANIFOLD COLLECTOR Exploded View 1 0 92 9 8 43 0 86 75 F ei lt L R AL EVAP canister purge control solenoid 1 2 Clamp 3 valve 4 EVAP hose 5 Clamp 6 7 Waterhose 8 Electric throttle control actuator 9 bank1 10 Intake manifold collector 11 Gasket 12 i3 Waterhose 14 Electric throttle contro actuator 15 bank2 16 Water hose 17 EVAP tube assembly 18 A To vacuum pipe B To brake booster C D To water outlet rear Refer to Gl 4 Components for symbols in the figure Removal and Installation REMOVAL WARNING VQ35HR INFOID 0000000003887342 0 11 0 1 1 8 SEC 140 163 223 FF 19 6 2 0 14 wW sites A 9 0 m 80 EVAP hose Water hose Gasket Water hose EVAP hose EVAP hose To heater pipe JPBIA1900GB INFOID 0000000003887343 Never drain engine coolant when the engine is hot to avoid the danger of being scalded 1 Remove engine cover with power tool Refer to EM 27 Exploded View 2 Remove air cleaner case and air duct Refer to EM 29 Exploded View 3 Remove electric throttle control actuator as per the following a Drain engine coolant or when water hoses are disconnected attach plug to prevent engine coolant leak age Revision 2009 March EM 31 2009 FX35 FX50 INTAKE MANIFOLD COLLECTOR lt REMOVAL AND INSTALLATION gt VQ35HR CAUTION Perfor
127. L CAUTION Never damage or scratch engine cover when installing or removing 1 Remove clip and remove engine room cover RH and LH 2 Remove engine cover as per the following Front side Lift and remove fit Rear side Pull out to forward and remove fit 3 Remove battery cover and brake master cylinder cover if necessary 4 Remove air duct inlet Refer to EM 177 Exploded View INSTALLATION Installation is the reverse order of removal Revision 2009 March EM 175 2009 FX35 FX50 DRIVE BELT AUTO TENSIONER AND IDLER PULLEY lt REMOVAL AND INSTALLATION gt VK50VE DRIVE BELT AUTO TENSIONER AND IDLER PULLEY Exploded View INFOID 0000000003733413 JPBIA2073GB Auto tensioner for alternator water pump and A C compressor belt Auto tensioner for power steering oil pump belt Refer to Gl 4 Components for symbols in the figure 1 2 Idler pulley 3 Cover 4 Re m oval a nd n stal lat i O n INFOID 0000000003733414 Removal CAUTION The complete drive belt auto tensioner must be replaced as a unit including the pulley 1 Remove drive belts Refer to EM 163 Exploded View e Keep auto tensioner pulley arm locked after drive belt is removed 2 Remove drive belt auto tensioners e Keep auto tensioner pulley arm locked to install or remove auto tensioner CAUTION Never loosen the hexagonal part in center of drive belt auto tensioner pulley Never turn it clock wise If turned clockwise the
128. LATION Note the following item 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 e For a location with a positioning pin insert it securely into hole of matching part e For a part with a specified installation orientation refer to component figure in EM 196 Exploded View Revision 2009 March EM 199 2009 FX35 FX50 ENGINE ASSEMBLY lt UNIT REMOVAL AND INSTALLATION gt VKSOVE e When installing engine mounting bracket RH and LH on cylinder block tighten two upper bolts A first Then tighten two lower bolts B lt 1 Engine front NOTE This figure shows an example of bank 2 JPBIA20962Z e When installing engine mounting bracket rear on transfer tighten two upper bolts B first Then tighten two lower bolts C A Rear view e When installing engine mounting insulator rear on engine mount ing bracket rear tighten upper bolts D first Then tighten lower bolts E JPBIA2464ZZ e Tighten rear engine mounting member bolts in numerical order as shown in the figure lt I Vehicle front JPBIA2463ZZ e Check that all engine mounting insulators are seated properly then tighten mounting nuts and bolts n S pect i O n INFOID 0000000003733441 INSPECTION AFTER INSTALLATION Inspection for Leakage The following are procedures for checking fluid leakage lubricant leakage Before starting engine check
129. M 179 2009 FX35 FX50 INTAKE MANIFOLD lt REMOVAL AND INSTALLATION gt VKSOVE To centralized under floor piping B To rocker cover bank 2 C To water inlet Front mark E To cylinder head F To rocker cover bank 1 To brake booster Refer to Gl 4 Components for symbols in the figure Re m oval a nd n stal lat i O n INFOID 0000000003733419 REMOVAL WARNING To avoid the danger of being scalded never drain the engine coolant when the engine is hot 1 2 3 4 10 11 12 Remove engine cover and engine room cover RH and LH Refer to EM 174 Exploded View Release fuel pressure Refer to EC 1228 Inspection Remove air duct inlet and air duct Refer to EM 177 Exploded View Remove quick connector cap 1 and disconnect fuel feed hose 2 on engine side Refer to EM 182 Exploded View lt Engine front Remove engine cover bracket Refer to EM 174 Exploded View Remove fuel injector and fuel tube assembly Refer to EM 182 Exploded View Disconnect manifold absolute pressure MAP sensor and air fuel ratio sensor 1 bank 1 harness connec tor Remove vacuum tank EVAP service port hose and EVAP canister purge control solenoid valve Disconnect PCV hoses and vacuum hose from intake manifold e Add matching marks as necessary for easier installation Drain engine coolant from radiator Refer to CO 33 Draining CAUTION e Perform this step when the engine is cold
130. M 212 Exploded View 5 Install actuator bracket rear as per the following Revision 2009 March EM 231 2009 FX35 FX50 CAMSHAFT lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE a Refer to the figure to replace new dowel pins 2 if removed 1 Actuator bracket 3 VVEL ladder assembly a 4 0 6 0 mm 0 157 0 236 in JPBIA2474ZZ b Apply a continuous bead of liquid gasket with tube presser commercial service tool to the actuator bracket rear as shown in the figure A Bank2 B Banki c 103 4 4 4 mm 0 134 0 173 in lt Engine front Use Genuine RTV Silicone Sealant or an equivalent Refer to GI 15 Recommended Chemical Products and Sealants CAUTION Never apply gasket to the oil passage c Tighten mounting bolts in the following steps in numerical order as shown A Bank2 B Bank1 lt Engine front i Tighten bolts in numerical order as shown 1 96 N m 0 20 kg m 1 ft Ib ii Tighten bolts in numerical order as shown JPBIA21252Z 5 88 N m 0 60 kg m 4 ft lb iii Tighten bolts in numerical order as shown 31 4 N m 3 2 kg m 23 ft lb 6 Install new VVEL actuator sub assembly as per the following CAUTION Regarding replacement because VVEL actuator sub assembly and VVEL control shaft position sensor are controlled on a one on one basis replace them as a set NOTE Revision 2009 March EM 232 2009 FX35 FX50 CAMSHAFT lt UNIT DISASSEMBLY AND ASSEMBLY gt
131. N 1 COO 4 Pin diameter grade No Pin diameter grade No JPBIA0269ZZ 2 3 Pin diameter grade No 4 Pin diameter grade No 5 6 Pin diameter grade No AoT TraoaTmtranmoadoaw gt Identification code 3 Select main bearing grade at the point where selected row and column meet in MAIN BEARING SELEC TION TABLE Revision 2009 March EM 139 2009 FX35 FX50 HOW TO SELECT PISTON AND BEARING lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR 4 Apply sign at crossing in above step 3 to MAIN BEARING GRADE TABLE NOTE e MAIN BEARING GRADE TABLE applies to all journals e Service parts is available as a set of both upper and lower WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED 1 Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter Refer to EM 147 Cylinder Block 2 Correspond the measured dimension in Cylinder block main bearing housing inner diameter row of MAIN BEARING SELECTION TABLE 3 Correspond the measured dimension in Crankshaft main journal diameter column of MAIN BEARING SELECTION TABLE 4 Follow from step 3 in When New Cylinder Block and Crankshaft are Used MAIN BEARING SELECTION TABLE D E F L M N X Y 7 Cylinder block main bearing housing inner diameter Unit mm in e gt to Ww PS NYA Crankshaft main journal diameter Unit mm in
132. NG NVH Troubleshooting Engine Noise ed Camshaft bearing noise Timing chain and chain tensioner noise KA D N ey on Connecting rod bearing noise Main bearing noise Drive belt noise Stick Slipping JPBIA2325GB Use the Chart Below to Help You Find the Cause of the Symptom meom oo00000003733387 1 Locate the area where noise occurs Revision 2009 March EM 153 2009 FX35 FX50 NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING lt SYMPTOM DIAGNOSIS gt VKSOVE 2 Confirm the type of noise 3 Specify the operating condition of the engine 4 Check specified noise source If necessary repair or replace these parts Operating condition of engine Location Type of Before After When f Source of F Refer of noise noise warm warm start When When While noise Check item ence page idling racing driving up up ing Top oreng Tieng or C A A B Tappet Valve clearance EM 169 gine clicking noise Rocker cover Camshaft Camshaft runout f Rattle C A A B C bearing Camshaft journal oil EM 236 Cylinder f head noise clearance Piston to piston pin oil Slap or Piston pin clearance i knock A A B a noise Connecting rod bushing oil clearance Piston to cylinder bore Crank clearance shaft pul Piston ring side clear oo eee A ay B B a Piston ance EM 265 y rap slap noise 5 Cylind
133. Never decenter or twist it 4 Install fuel injector to fuel tube as per the following a Insert clip 3 into clip mounting groove D on fuel injector 5 2 O ring Black 4 O ring Green CAUTION e Never reuse clip Replace it with a new one e Be careful to keep clip from interfering with O ring If interference occurs replace O ring b Insert fuel injector into fuel tube 1 with clip attached e Insert it while matching it to the axial center e Insert fuel injector so that protrusion A of fuel tube matches cutout B of clip e Check that fuel tube flange E is securely fixed in flange fixing groove C on clip c Check that installation is complete by checking that fuel injector does not rotate or come off e Check that protrusions of fuel injectors are aligned with cut outs of clips after installation JPBIA0037ZZ 5 Install fuel tube and fuel injector assembly to intake manifold CAUTION Be careful not to let tip of injector nozzle come in contact with other parts Revision 2009 March EM 43 2009 FX35 FX50 FUEL INJECTOR AND FUEL TUBE lt REMOVAL AND INSTALLATION gt VQ35HR e Tighten mounting bolts in two steps in numerical order as shown in the figure lt Engine front OJiststep 10 1 N m 1 0 kg m 7 ft lb 2nd step 23 6 N m 2 4 kg m 17 ft lb JPBIA0034ZZ 6 Connect injector sub harness Install fuel sub tube mounting bolt 8 Connect fuel feed hose with damper e H
134. No 1 piston is set at TDC JPBIA0181ZZ 1 Crankshaft key lt Bank 1 side e Crankshaft key should line up with the bank 1 cylinder center line as shown in the figure JPBIA0174ZZ Revision 2009 March EM 112 2009 FX35 FX50 CYLINDER HEAD lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR 12 Install cylinder head follow the steps below to tighten cylinder head bolts in numerical order as shown in the figure with cylin der head bolts wrench commercial service tool A Bank 1 B Bank2 lt Engine front CAUTION If cylinder head bolts re used check their outer diameters before installation Refer to EM 114 Inspection Before installing cylinder head inspect cylinder head dis tortion Refer to EM 114 Inspection a Apply new engine oil to threads and seat surfaces of cylinder head bolts b Tighten all cylinder head bolts 105 N m 11 kg m 77 ft lb c Completely loosen all cylinder head bolts 0 N m 0 kg m 0 ft Ib CAUTION In step c loosen bolts in reverse order of that indicated in the figure d Tighten all cylinder head bolts JPBIAO172ZZ 40 0 N m 4 1 kg m 30 ft Ib e Tighten all cylinder head bolts clockwise Angle tightening 95 degrees CAUTION Check the tightening angle by using the angle wrench SST KV10112100 BT8653 A A Never make judgment by visual inspection e Check tightening angle indicated on the angle wrench indica tor plate
135. No X 70 013 70 014 2 7564 2 7565 Grade No Y 70 014 70 015 2 7565 2 7565 Grade No 4 70 015 70 016 2 7565 2 7565 Grade No 7 70 016 70 017 2 7565 2 7566 Difference in inner diameter between cylinders AVAILABLE PISTON Standard SEM882E Less than 0 03 0 0012 Unit mm in Items Standard Oversize Service 0 2 0 008 Grade No 95 480 95 490 3 7590 3 7594 Grade No 95 490 95 500 3 7594 3 7598 Piston skirt diameter A Grade No 95 500 95 510 3 7598 3 7602 Service 95 680 95 710 3 7669 3 7681 Items Standard Limit a dimension 38 8 1 528 Grade No 21 993 21 999 0 8659 0 8661 Piston pin hole diameter Grade No 21 999 22 005 0 8661 0 8663 Piston to cylinder bore clearance Revision 2009 March 0 010 0 030 0 0004 0 0012 EM 148 0 08 0 0031 2009 FX35 FX50 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ35HR PISTON RING Unit mm in Items Standard Limit Top 0 040 0 080 0 0016 0 0031 0 11 0 0043 Side clearance 2nd 0 030 0 070 0 0012 0 0028 0 10 0 0039 Oil ring 0 055 0 155 0 0022 0 0061 Top 0 23 0 33 0 0091 0 0130 0 42 0 0165 End gap 2nd 0 33 0 48 0 0130 0 0189 0 57 0 0224 Oil rail ring 0 17 0 47 0 0067 0 0185 0 63 0 0248 PISTON PIN U
136. OID 0000000003733443 Remove intake manifold Refer to EM 179 Exploded View Remove exhaust manifold Refer to EM 205 Exploded View Remove oil pan lower Refer to EM 188 Exploded View Remove ignition coil spark plug and rocker cover Refer to EM 191 Exploded View Remove timing chain Refer to EM 212 Exploded View Remove camshaft EXH and VVEL ladder assembly Refer to EM 227 Exploded View Remove cylinder head Refer to EM 245 Exploded View A se m b y INFOID 0000000003733444 N O Sle GS Assemble in the reverse order of disassembly Revision 2009 March EM 204 2009 FX35 FX50 EXHAUST MANIFOLD AND THREE WAY CATALYST lt UNIT DISASSEMBLY AND ASSEMBLY gt VK50VE EXHAUST MANIFOLD AND THREE WAY CATALYST Exploded View INFOID 0000000003733423 SEC 140 208 226 0 22 0 2 2 16 9 14 7 1 5 11 0 25 5 2 6 19 EE 44 6 4 5 33 3 R 5 8 0 59 51 JPBIA2079GB 1 Exhaust manifold cover bank 2 2 Exhaust manifold bank 2 3 Gasket 4 Exhaust manifold bank 1 5 Exhaust manifold cover bank 1 6 Gasket 7 Three way catalyst bank 1 8 Heated oxygen sensor 2 bank 1 9 Air fuel ratio sensor 1 bank 1 10 Three way catalyst bank 2 11 Heated oxygen sensor 2 bank 2 12 Air fuel ratio sensor 1 bank 2 13 Harness bracket A To cylinder head bank 2 B To exhaust front tube Refer to Gl 4 Components for symbols in the figure Disassembly and Assembly InFo10 0000
137. PBIA2467ZZ AW D F n S p ecti O n INFOID 0000000003887373 INSPECTION AFTER INSTALLATION Inspection for Leakage The following are procedures for checking fluids leakage lubricates leakage and exhaust gases leakage 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 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 leak age 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 check 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 Items 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 Transmission transaxle CVT fluid power steering fluid b
138. Permatex 133AR or an equivalent meeting MIL specifi cation MIL A 907 Revision 2009 March EM 14 Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads 2009 FX35 FX50 DRIVE BELT lt PERIODIC MAINTENANCE gt VQ35HR PERIODIC MAINTENANCE DRIVE BELT Exp loded View INFOID 0000000003887324 JPBIA0002ZZ 1 Power steering oil pump 2 Alternator 3 Drive belt auto tensioner 4 Crankshaft pulley 5 A C compressor 6 Idler pulley 7 Drive belt 8 Idler pulley A Possible use range B Range when new drive belt is installed C Indicator D ViewD C h ecki n g INFOID 0000000003887325 WARNING Be sure to perform this step when engine is stopped e Check that the indicator C notch on fixed side of drive belt auto tensioner is within the possible use range A NOTE e Check the drive belt auto tensioner indication when the engine is cold e When new drive belt is installed the indicator notch on fixed side should be within the range B in the fig ure e Visually check entire drive belt for wear damage or cracks e If the indicator notch on fixed side is out of the possible use range or belt is damaged replace drive belt Tension Adjustment inFo10 0000000008887326 Refer to EM 142 Drive Belt Removal and Installation A REMOVAL 1 Remove engine undercover with power tool Revision 2009 March EM 15 2009 FX35 FX50 DRIVE BELT lt PERIODIC MAINTENAN
139. R e Check the piston ring side clearance Refer to EM 147 Cylinder Block 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 e 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 e When installing align connecting rod bearing stopper protru sion B with cutout C of connecting rods and connecting rod bearing caps to install e Ensure the oil hole A on connecting rod and that on the cor responding bearing are aligned JPBIA0206ZZ 12 Install piston and connecting rod assembly to crankshaft e 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 front of engine Using a piston ring compressor SST EM03470000 J 8037 A or suitable tool install piston with the front mark on the pis ton 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 e Match the stamped cylind
140. RANKSHAFT Revision 2009 March 0 20 0 wo 5 0 0079 0 0138 EM 289 0 40 0 0157 2009 FX35 FX50 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS SEM645 VK50VE Unit mm in Grade No G 63 964 63 963 2 5183 2 5182 Grade No H 63 963 63 962 2 5182 2 5182 Grade No J 63 962 63 961 2 5182 2 5181 Grade No K 63 961 63 960 2 5181 2 5181 Grade No L 63 960 63 959 2 5181 2 5181 Grade No M 63 959 63 958 2 5181 2 5180 Grade No N 63 958 63 957 2 5180 2 5180 Grade No P 63 957 63 956 2 5180 2 5179 Grade No R 63 956 63 955 2 5179 2 5179 Grade No S 63 955 63 954 2 5179 2 5179 Grade No T 63 954 63 953 2 5179 2 5178 Main journal diameter Dm grade Standard Grade No U 63 953 63 952 2 5178 2 5178 No 1 and 5 journal Grade No V 63 952 63 951 2 5178 2 5178 Grade No W 63 951 63 950 2 5178 2 5177 Grade No X 63 950 63 949 2 5177 2 5177 Grade No Y 63 949 63 948 2 5177 2 5176 Grade No 1 63 948 63 947 2 5176 2 5176 Grade No 2 63 947 63 946 2 5176 2 5176 Grade No 3 63 946 63 945 2 5176 2 5175 Grade No 4 63 945 63 944 2 5175 2 5175 Grade No 5 63 944 63 943 2 5175 2 5174 Grade No 6 63 943 63 942 2 5174 2 5174 Grade No 7 63 942 63 941 2 5174 2 5174 Grade No 9 63 941 63 940 2 5174 2 5173 Grade No A 63 963 63 964 2
141. Refer to EM 194 FRONT OIL SEAL Removal and Installation 11 Remove water pump pulley Refer to CO 44 Exploded View 12 Remove oil pan lower and oil strainer Refer to EM 188 Exploded View 13 Remove oil pan upper Refer to EM 208 Exploded View 14 Remove front cover as per the following Revision 2009 March EM 214 2009 FX35 FX50 TIMING CHAIN lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE a Loosen mounting bolts in reverse order as shown in the figure b Insert a suitable tool into the notch at front cover e Pry off case by moving a suitable tool CAUTION e Exercise care not to damage mating surfaces After removal handle front cover carefully so it does not tilt cant or warp under a load JPBIA2116ZZ 15 Remove front oil seal from front cover using suitable tool e Use screwdriver for removal CAUTION Be careful not to damage front cover 16 Remove O rings 1 2 from cylinder heads and cylinder block JPBIA2115ZZ 17 Remove oil filter for valve timing control solenoid valve if necessary 18 Remove timing chain tensioner cover from front cover if necessary e Use seal cutter SST KV10111100 J 37228 to cut liquid gasket for removal 19 Remove oil pump drive chain as per the following a Push oil pump drive chain tensioner 1 b Insert a stopper pin A into the body hole c Hold the two flat parts of oil pump shaft and then loosen the oil pump sprocket oil
142. SASSEMBLY AND ASSEMBLY gt VKSOVE Inspection INFOID 0000000003733458 CRANKSHAFT END PLAY e 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 EM 287 Cylinder Block e If the measured value exceeds the limit replace thrust bearings and measure again If it still exceeds the limit replace crankshaft also JPBIA2477ZZ CONNECTING ROD SIDE CLEARANCE e Measure the side clearance between connecting rod and crank shaft arm with a feeler gauge A Standard and limit Refer to EM 287 Cylinder Block e If the measured value exceeds the limit replace connecting rod and measure again If it still exceeds the limit replace crankshaft also PISTON TO PISTON PIN OIL CLEARANCE Piston Pin Hole Diameter Measure the inner diameter of piston pin hole with an inside micrometer A Standard Refer to EM 287 Cylinder Block JPBIA0217ZZ Piston Pin Outer Diameter Measure the outer diameter of piston pin with a micrometer A Standard _ Refer to EM 287 Cylinder Block JPBIA0218ZZ Piston to Piston Pin Oil Clearance Piston to piston pin oil clearance Piston pin hole diameter Piston pin outer diameter Standard Refer to EM 287 Cylinder Block Revision 2009 March EM 265 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE e If the ca
143. SEMBLY gt VK50VE e Measure the outer diameters A B at two positions as shown in the figure c 20 mm 0 79 in d 50 mm 1 97 in e 9 mm 0 35 in e If reduction appears in A range regard it B Limit B A 0 13 mm 0 0051 in e If it exceeds the limit large difference in dimensions replace main JPBIA228022 bearing cap sub bolts with new one CONNECTING ROD BOLT OUTER DIAMETER 1 Measure the outer diameters a b and c at the position shown in the figure a Value at the end of the smaller diameter of the bolt b Value at the end of the smaller diameter of the bolt opposite side of a c Value of the smallest diameter of the smaller of the bolt 2 Obtain a mean value d of a and b 3 Subtract c from d Limit d c 0 09 mm 0 0035 in JPBIA026277 4 If it exceeds the limit large difference in dimensions replace the bolt with new one DRIVE PLATE e Check drive plate and signal plate A for deformation or damage B Ring gear lt o Engine front CAUTION Never disassemble drive plate e Never place drive plate with signal plate facing down e When handling signal plate take care not to damage or scratch it e Handle signal plate in a manner that prevents it from becom a S ing magnetized A If damage is found replace drive plate OIL JET e Check nozzle for deformation and damage Blow compressed air from nozzle and check for clogs
144. TV Silicone Sealant or an equivalent Refer toGI 15 Recommended Chemical Products and Sealants JPBIA1354ZZ Inspect the outer diameter of lower cylinder block bolt Refer to EM 126 Inspection Install lower cylinder block bolts in numerical order as shown in the figure as per the following Apply new engine oil to threads and seat surfaces of lower cylinder block bolts Tighten lower cylinder block bolts No 17 to 26 in numerical order as shown in the figure oP ON lt 4 Engine front 0 25 0 N m 2 6 kg m 18 ft Ib c Repeat step b d Tighten lower cylinder block bolt No 1 to 16 in numerical order as shown in the figure lt Engine front O 35 3 N m 3 6 kg m 26 ft lb JPBIA0197ZZ e Tighten lower cylinder block bolt No 1 to 16 clockwise Angle tightening 90 degrees CAUTION Use the angle wrench SST KV10112100 BT8653 A A to check tightening angle Never make judgment by visual inspection JPBIA0202ZZ After installing lower cylinder block bolts check that crankshaft can be rotated smoothly by hand e Check the crankshaft end play Refer to EM 126 Inspection Revision 2009 March EM 122 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR 9 Install piston to connecting rod as per the following a Using a snap ring pliers install new snap ring to the groove of piston rear side e Insert it fully into groove to install b Install pi
145. UG AND ROCKER COVER INFOID 0000000003733432 SEC 111 118 220 LA oat Ox I 7 0 0 71 62 P 4 QDO N gt no AET we 2 5 0 26 22 A QA JPBIA2074GB Clamp 2 PCV hose 3 Oil filler cap Oil catcher 5 Ignition coil No 1 6 6 Spark plug Rocker cover bank 2 8 Rocker cover gasket bank 2 9 Rocker cover gasket bank 1 Rocker cover bank 1 11 Ignition coil No 7 8 12 PCV hose PCV hose 14 Clamp 15 PCV valve O ring 17 PCV hose To air duct bank 2 B Refer to EM 191 C To air duct bank 1 To intake manifold Refer to Gl 4 Components for symbols in the figure INFOID 0000000003733433 REMOVAL 1 Remove the following parts Engine cover and engine room cover RH and LH Refer to EM 174 Exploded View e Air cleaner case and air duct Refer to EM 177 Exploded View e Fuel feed hose Refer to EM 182 Exploded View Disconnect PCV hose from rocker cover Remove ignition coil CAUTION Never impact it NOTE Installation position of Ignition coil depends on cylinder position Revision 2009 March EM 191 2009 FX35 FX50 IGNITION COIL SPARK PLUG AND ROCKER COVER lt REMOVAL AND INSTALLATION gt VKSOVE 4 Remove spark plugs Refer to EM 167 Removal and Installation CAUTION Never impact it 5 Remove rocker cover e Loosen bolts in reverse order shown in the figure A Bank2 B Bank 1 lt Engine front LF Or Ho OO JPBIA2093ZZ
146. View B E TIMING CHAIN Camshaft sprocket INT Timing chain tensioner primary Crankshaft sprocket Matching mark yellow link Matching mark notched 2 Check that dowel pin A and crankshaft key 1 are located as shown in the figure No 1 cylinder at compression TDC NOTE Though camshaft does not stop at the position as shown in the figure for the placement of cam noses it is generally accepted camshaft is placed for the same direction of the figure Camshaft dowel pin At cylinder head upper face side in each bank Crankshaft key At cylinder head side of bank 1 VQ35HR JPBIA0066ZZ 3 Timing chain secondary 6 Slack guide 9 Water pump C Matching mark punched F Crankshaft key follows if removed Refer to EM 70 JPBIA0094ZZ 3 Install timing chains secondary and camshaft sprockets as per the following CAUTION Matching marks between timing chain and sprockets slip easily Confirm all matching mark posi tions repeatedly during the installation process Revision 2009 March EM 60 2009 FX35 FX50 TIMING CHAIN lt REMOVAL AND INSTALLATION gt VQ35HR a Push plunger of timing chain tensioner secondary and keep it pressed in with a stopper pin A JPBIA0095ZZ b Install timing chains secondary and camshaft sprockets Align the matching marks on timing chain secondary orange link with the ones on intake and exhaust camshaft sprockets punche
147. Z 7 Remove piston from connecting rod as per the following a Using snap ring pliers A remove snap rings JPBIAO195ZZ b Heat piston to 60 to 70 C 140 to 158 F with an industrial use dryer A or an equivalent JPBIAO196ZZ c Push out piston pin using a stick that has an outer diameter of approximately 20 mm 0 79 in PBICO262E 8 Remove rear oil seal and rear oil seal retainer assembly from cylinder block e 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 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 e Before loosening cylinder block bolts measure the crankshaft end play Refer to EM 265 Inspection Revision 2009 March EM 257 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VK50VE a Loosen side bolts starting from No 30 to 21 to remove lt Engine front b Loosen main bearing cap sub bolts starting from No 20 to 11 to remove c Loosen main bearing cap bolts starting from No 10 to 1 to remove d Remove the main bearing cap e 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 cranksha
148. a f 5 0 20 ra H side B oh Unit mm in JPBIA0396ZZ EM03470000 Installing piston assembly into cylinder bore J 8037 Piston ring compressor ST16610001 Removing pilot converter J 23907 Pilot bushing puller NT045 KV10111100 Removing oil pan lower and upper front and J 37228 rear timing chain case etc Seal cutter NT046 Revision 2009 March EM 11 2009 FX35 FX50 PREPARATION lt PREPARATION gt VQ35HR Tool number Kent Moore No Description Tool name KV10112100 Tightening bolts for connecting rod bearing BT8653 A cap cylinder head etc in angle Angle wrench KV10114400 J 38365 Heated oxygen sensor wrench Ze JPBIA0397ZZ Loosening or tightening air fuel ratio sensor 1 a 22 mm 0 87 in KV10118600 J 48641 Ring gear stopper Commercial Service Tools Kent Moore No Tool name i JPBIA0409ZZ Removing and installing crankshaft pulley INFOID 0000000003887323 Description CE Tube presser NT052 Pressing the tube of liquid gasket Power tool PBIC0190E Loosening bolts and nuts Manual lift table caddy Revision 2009 March EM 12 Removing and installing engine 2009 FX35 FX50 lt PREPARATION gt Kent Moore No Tool name PREPARATION VQ35HR Description J24239 01 Cylinder head bolt wrench pe JPBIA0398ZZ Loosening and tightening cylinder head bolt
149. a screwdriver is used be careful not to damage the mating surfaces LIQUID GASKET APPLICATION PROCEDURE 1 Using a scraper A remove old liquid gasket adhering to the liq uid gasket application surface and the mating surface e 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 JPBIA0052ZZ 3 Attach liquid gasket tube to the tube presser commercial ser vice tool Use Genuine RTV Silicone Sealant or an equivalent Refer to GI 15 Recommended Chemical Products and Sealants 4 Apply liquid gasket without breaks to the specified location with the specified dimensions e If there is a groove for liquid gasket application apply liquid gasket to the groove EMA0622D Revision 2009 March EM 9 2009 FX35 FX50 PRECAUTIONS lt PRECAUTION gt VQ35HR e As for bolt holes B normally apply liquid gasket inside the holes Occasionally it should be applied outside the holes Check to read the text of this manual A Groove lt Inside e Within 5 minutes of liquid gasket application install the mating component e If liquid gasket protrudes wipe it out immediately e Do not retighten mounting bolts or nuts after the installation e After 30 minutes or mor
150. ad of liquid gasket with tube presser commercial service tool to the VVEL actuator sub assembly as shown in the figure VVEL actuator sub assembly bank 2 VVEL actuator sub assembly bank 1 4 0 5 6 mm 0 157 0 220 in b 63 4 4 4 mm 0 134 0 173 in Use Genuine RTV Silicone Sealant or an equivalent Refer to GI 15 Recommended Chemical Products and Sealants CAUTION Never apply gasket to the oil passage v N JPBIA2140ZZ d Install new VVEL actuator sub assembly e Tighten mounting bolts in the following step in numerical order as shown A Bank 1 B Bank2 CAUTION e When installing be careful with VVEL actuator sub assembly bank 1 mounting bolt No 4 because its length is different JPBIA2127ZZ Revision 2009 March EM 234 2009 FX35 FX50 CAMSHAFT lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE e Be sure to check that the VVEL actuator sub assembly is in contact with the cylinder head before tightening the mounting bolts e Remove holding jig f Check that VVEL actuator arm bolt hole is aligned with control shaft tapped hole If it is not aligned turn control shaft for align ment CAUTION Never give an impact to the magnet part A JPBIA2141ZZ g Fix two flat areas C of control shaft with a wrench to tighten mounting bolts of control shaft A Bank 2 B Bank 1 lt 1 Engine front CAUTION e During the operation never allow a wrench to interfere with other
151. age Leakage Leakage Transmission transaxle CVT fluid power steering fluid brake fluid etc Revision 2009 March EM 226 2009 FX35 FX50 CAMSHAFT lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE CAMSHAFT E X p od ed V i ew INFOID 0000000003733450 SEC 110 130 0 24 1 2 5 18 s E 7 0 0 71 62 SS io 7 0 AN oO 0 71 62 a 0 24 1 N W o 7 a Da n 18 2 X D Is Mo PARC ON LOOKS lt S NA Raa v gt Se JPBIA2124GB A VVEL control shaft position sensor bank 2 2 VVEL actuator sub assembly bank 2 3 VVEL ladder assembly bank 2 4 Dowel pin 5 Actuator bracket rear bank 2 6 Washer 7 Camshaft EXH bank 2 8 Cylinder head bank 2 9 Valve lifter INT 10 Cylinder head bank 1 11 Camshaft EXH bank 1 12 Actuator cover 13 Valve lifter EXH 14 VVEL ladder assembly bank 1 15 VVEL actuator sub assembly bank 1 16 Dank e shart position sensor 17 Actuator bracket rear bank 1 A Refer to EM 228 Refer to Gl 4 Components for symbol marks in the figure CAUTION A high degree of precision is required for a valve on the intake side Never remove the valve related parts unless necessary NOTE e As for replacement of parts on the intake side as shown in the exploded view replace VVEL ladder assem bly amp cylinder head assembly Revision 2009 March EM 227 2009 FX35 FX50 CAMSHAFT lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE
152. amshaft EXH journal diameter No 2 3 4 5 25 950 25 970 1 0217 1 0224 Camshaft EXH end play 0 115 0 188 0 0045 0 0074 0 24 0 0094 Camshaft EXH cam height A 45 475 45 665 1 7904 1 7978 44 275 1 7431 Camshaft EXH runout TIR Less than 0 02 mm 0 0008 0 05 0 002 Camshaft sprocket EXH runout TIR 0 2 0 0079 A SEM671 Total indicator reading CAMSHAFT INT Unit mm in Items Standard Limit Drive shaft end play 0 115 0 188 0 0045 0 0074 0 24 0 0094 Camshaft sprocket INT runout TIR 0 15 0 0059 1 Total indicator reading VALVE LIFTER Unit mm in Items Standard Valve lifter outer diameter 33 980 33 990 1 3378 1 3382 Valve lifter hole diameter 34 000 34 016 1 3386 1 3392 Valve lifter clearance 0 010 0 036 0 0004 0 0014 Revision 2009 March EM 283 2009 FX35 FX50 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VK50VE VALVE CLEARANCE Unit mm in Items Cold Hot reference data Intake 0 26 0 34 0 010 0 013 0 304 0 416 0 012 0 016 Exhaust 0 29 0 37 0 011 0 015 0 308 0 432 0 012 0 017 Approximately 80 C 176 F AVAILABLE VALVE LIFTER Unit mm in Identification stamped mark Thickness 788P 7 88 0 3102 790P 7 90 0 3110 792P 7 92 0
153. and engine oil If any are less than the required quantity fill them to the specified level Refer to MA 12 Fluids and Lubricants e Follow the procedure below to check for fuel leakage Revision 2009 March EM 225 2009 FX35 FX50 TIMING CHAIN lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE Turn ignition switch to the ON position 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 NOTE If hydraulic pressure inside chain tensioner drops after removal installation slack in guide may generate a pounding noise during and just after the engine start However this does not indicate a malfunction The noise will stop after hydraulic pressure rises Warm up engine thoroughly to check that there is no leakage of fuel 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 them to the specified level if necessary Summary of the inspection items Items Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluids Level Leakage Level Fuel Leak
154. and used with the angle wrench SST KV10112100 BT8653 A EM a 13 mm 0 51 in dia b 12 mm 0 47 in c 10 mm 0 39 in ra 1 Compression gauge 2 Adapter b4 ZZA0008D Checking compression pressure OE Spark plug wrench 9 JPBIA0399ZZ Removing and installing spark plug a 14 mm 0 55 in a Valve seat cutter set Finishing valve seat dimensions t Piston ring expander NT030 Removing and installing piston ring G Valve guide drift JPBIA0400ZZ Removing and installing valve guide Intake and Exhaust a 9 5 mm 0 374 in dia b 5 5 mm 0 217 in dia Valve guide reamer Revision 2009 March JPBIA0401ZZ EM 13 A Reaming valve guide inner hole B Reaming hole for oversize valve guide Intake and Exhaust c 6 0 mm 0 236 in dia d 10 2 mm 0 402 in dia 2009 FX35 FX50 lt PREPARATION gt Kent Moore No Tool name PREPARATION VQ35HR Description J 43897 18 J 43897 12 Oxygen sensor thread cleaner Reconditioning the exhaust system threads before installing a new air fuel ratio sensor and heated oxygen sensor Use with anti seize lu bricant shown below A J 43897 18 18 mm 0 71 in dia for zir conia heated oxygen sensor and air fuel ratio sensor B J 43897 12 12 mm 0 47 in dia for tita nia heated oxygen sensor C Mating surface shave cylinder D Flutes Cian Anti seize lubricant
155. andard of valve lifter outer diameter and valve lifter hole diameter replace either or both valve lifter and VVEL ladder assembly amp cylinder head assembly NOTE Cylinder head assembly cannot be replaced as a single part because it is machined together with VVEL lad der assembly INSPECTION AFTER DISASSEMBLY INTAKE SIDE Drive Shaft End Play e Install a dial indicator in thrust direction on front end of drive shaft Measure the end play of a dial indicator when drive shaft is moved forward backward in direction of axis Standard and limit Refer to EM 283 Camshaft JPBIA1337ZZ Revision 2009 March EM 240 2009 FX35 FX50 CAMSHAFT lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE e Measure the following parts if out of the limit Dimension A for drive shaft No 1 journal Standard 30 500 30 548 mm 1 2008 1 2027 in Dimension B for cylinder head No 1 journal bearing Standard 30 360 30 385 mm 1 1953 1 1963 in e If it exceeds the limit replace VVEL ladder assembly amp cylinder head assembly NOTE KBIA2404J Cylinder head assembly cannot be replaced as a single part because it is machined together with VVEL ladder assembly Camshaft Sprocket INT Runout 1 Put V block on precise flat table and support No 2 and 5 journals of drive shaft CAUTION Never support No 1 journal on the side of camshaft sprocket because it has a different diameter from the other four locat
156. andling procedure of O ring is the same as that of fuel damper and fuel sub tube e Insert fuel damper straight into fuel sub tube e Tighten mounting bolts evenly in turn e After tightening mounting bolts check that there is no gap between flange and fuel sub tube 9 Connect quick connector between fuel feed hose with damper and centralized under floor piping con nection as per the following a Check no foreign substances are deposited in and around centralized under floor piping and quick con nector and no damage on them Thinly apply new engine oil around centralized under floor piping from tip end to spool end c Align center to insert quick connector straightly into centralized under floor piping e Visually confirm that the two retainer tabs A are connected to the quick connector B CAUTION e Carefully align center to avoid inclined insertion to pre vent damage to O ring inside quick connector Insert until you hear a click sound and actually feel the engagement e To avoid misidentification of engagement with a similar sound be sure to perform the next step N JPBIA2378ZZ d Pull quick connector by hand holding position A Check it is completely engaged connected so that it does not come out from centralized under floor piping 1 PBIC3795E Revision 2009 March EM 44 2009 FX35 FX50 FUEL INJECTOR AND FUEL TUBE lt REMOVAL AND INSTALLATION gt VQ35HR e Install quick connector cap
157. anges If necessary use jack s to support the vehi cle at rear jacking point s to prevent it from falling it off the lift Separation Work 1 Install engine slingers into front of cylinder head bank 1 and rear of cylinder head bank 2 Engine front slinger Engine rear upper slinger Spacer Engine rear lower slinger Bank 1 Bank 2 lt m Engine front WU D gt AOUN JPBIA0157ZZ Revision 2009 March EM 84 2009 FX35 FX50 ENGINE ASSEMBLY lt UNIT REMOVAL AND INSTALLATION gt VQ35HR Slinger bolts O 28 0 N m 2 9 kg m 21 ft lb e To protect rocker cover against damage caused by tilting of engine slinger insert spacer between cylinder head and engine rear lower slinger 3 in direction shown in the figure 1 Engine rear upper slinger lt 2 Engine front NOTE Spacer 2 is a component part of engine rear upper slinger assembly JPBIAO158ZZ 2 Remove power steering oil pump from engine side Refer to ST 35 VQ35HR Exploded View Remove engine mounting insulators RH and LH under side nuts with power tool 4 Lift with hoist and separate the engine and the transmission assembly from front suspension member CAUTION Before and during this lifting always check that any harnesses are left connected Never damage to and oil grease smearing or spills onto engine mounting insulator Remove alternator Refer to CHG 25 VQ35HR Exploded View Remove starter motor Refer
158. art engine and increase engine speed to check engine coolant fuel engine oil and exhaust gases for leakage Revision 2009 March EM 156 2009 FX35 FX50 PRECAUTIONS lt PRECAUTION gt Parts Requiring Angle Tightening VK50VE INFOID 0000000003733483 e Use angle wrench SST KV10112100 BT8653 A for the final tightening of the following engine parts Cylinder head bolts Main bearing cap bolts Main bearing cap sub bolts Connecting rod cap bolts Crankshaft pulley bolt No angle wrench is required as the bolt flange is provided with notches for angle tightening e Ensure thread and seat surfaces are clean and coated with engine oil Precaution for Liquid Gasket REMOVAL OF LIQUID GASKET SEALING e After removing mounting nuts and bolts separate the mating sur face using the seal cutter SST KV10111100 J 37228 A and remove old liquid gasket sealing CAUTION Be careful not to damage the mating surfaces e Tap the seal cutter to insert it B and then slide it C by tapping on the side as shown in the figure e In areas where the seal cutter is difficult to use lightly tap the parts using a plastic hammer to remove it CAUTION If for some unavoidable reason a tool such as a screwdriver is used be careful not to damage the mating surfaces LIQUID GASKET APPLICATION PROCEDURE 1 Using a scraper A remove old liquid gasket adhering to the liq uid gasket application surface and the m
159. as for removing the fuel feed damper CAUTION Disconnect quick connector by using quick connector release commercial service tool J 45488 not by picking out retainer tabs Remove fuel tube and fuel injector assembly Revision 2009 March EM 183 2009 FX35 FX50 9 10 Remove fuel damper and fuel feed damper if necessary INSTALLATION 1 FUEL INJECTOR AND FUEL TUBE lt REMOVAL AND INSTALLATION gt VKSOVE e Loosen mounting bolts b first Then loosen mounting bolts a shown in the figure 1 Fuel tube bank 2 2 Fuel tube bank 1 lt Engine front CAUTION Never tilt it or remaining fuel in pipes may flow out from pipes Remove fuel injector 1 from fuel tube 3 as per the following A _ Installed condition B Clip mounting groove C Protrusion Open and remove clip 2 Remove fuel injector from fuel tube by pulling straight CAUTION Be careful with remaining fuel that may go out from fuel tube Be careful not to damage injector nozzles during removal Never bump or drop fuel injector Never disassemble fuel injector JPBIA20852Z Disconnect sub harness connector from fuel injectors Install fuel damper 4 as per the following 1 Fuel damper cap Install new O ring 3 to fuel tube bank 1 2 as shown When handling new O ring pay attention to the following caution items CAUTION Handle O ring with bare hands Never wear gloves e Lubricate O ring with
160. asher 7 Oil temperature sensor 8 Oil pressure sensor 9 Relief valve 10 O ring 11 Oil cooler 12 Connector bolt 13 Oil filter 14 Oil strainer 15 Drain plug 16 Oil pan drain plug 17 Oil pan lower 18 O ring small 19 O ring large 20 Axle pipe 21 Rear plate cover 22 Oil pan upper 23 O ring A Refer to LU 9 B To oil pump C Oil pan side Refer to Gl 4 Components for symbols in the figure AWD Disassembly and Assembly INFO1D 0000000003887384 REMOVAL CAUTION Never drain engine oil when the engine is hot to avoid the danger of being scalded 1 Remove oil level gauge oil pressure switch and oil temperature sensor 2 Remove oil filter bracket Refer to LU 11 Exploded View 3 Remove oil pan lower Refer to EM 47 Removal and Installation 4 Remove oil strainer Revision 2009 March EM 103 2009 FX35 FX50 OIL PAN UPPER lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR 5 Loosen mounting bolts in the reverse order as shown in the fig ure with power tool to remove lt Engine front e Insert the seal cutter SST KV10111100 J 37228 between oil pan upper and lower cylinder block Slide seal cutter by tapping on the side of tool with a hammer Remove oil pan upper CAUTION Be careful not to damage the mating surfaces e Never insert a screwdriver this will damage the mating JPBIAQO22ZZ surfaces 6 Remove O rings 2 from bottom of lower cylinder block 1 and oil pump 3 lt E
161. at cutter set S NT048 Finishing valve seat EXH dimensions Car Piston ring expander S NT030 Removing and installing piston ring Valve guide drift JPBIA0400ZZ Removing and installing valve guide EXH a 9 5 mm 0 374 in dia b 5 5 mm 0 217 in dia Seam Valve guide reamer Revision 2009 March JPBIA0401ZZ EM 161 1 Reaming valve guide EXH inner hole 2 Reaming hole for oversize valve guide EXH c 6 0 mm 0 236 in dia d 10 2 mm 0 402 in dia 2009 FX35 FX50 PREPARATION lt PREPARATION gt Kent Moore No Tool name VK50VE Description J 43897 18 J 43897 12 Oxygen sensor thread cleaner JPBIA0238ZZ Reconditioning the exhaust system threads before installing a new air fuel ratio sensor and heated oxygen sensor Use with anti seize lu bricant shown below A J 43897 18 18 mm 0 71 in dia for zir conia heated oxygen sensor and air fuel ratio sensor B J 43897 12 12 mm 0 47 in dia for tita nia heated oxygen sensor C Mating surface shave cylinder D Flutes a Anti seize lubricant Permatex 133AR or equivalent meeting MIL specifica tion MIL A 907 Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads E Feeler gauge JPBIA1362ZZ Inspection valve clearance use a curved tip gauge Revision 2009 March a Compression gauge with flexible type adap
162. ate cover from oil pan upper Then remove bolts fixing drive plate to torque converter Refer to EM 188 Exploded View e Remove transmission joint bolts that pierce at oil pan upper lower rear side Refer to EM 188 Exploded View Remove front stabilizer connecting rod from transverse link Refer to FSU 17 Exploded View Remove lower ends of left and right steering knuckle from transverse link Refer to FSU 13 Exploded View Separate steering outer sockets from steering knuckle Refer to ST 25 Exploded View Remove transverse links mounting bolts at suspension member side Refer to FSU 13 Exploded View Removal Work 1 w Use a manual lift table caddy commercial service tool or an equivalently rigid tool such as a transmission jack Securely sup port bottom of suspension member and the transmission assem bly CAUTION Put a piece of wood or something similar as the supporting surface secure a completely stable condition PBIC0804E Remove rear engine mounting member bolts Remove front suspension member mounting bolts and nuts Refer to FSU 18 Exploded View Carefully lower jack or raise lift to remove the engine the transmission assembly and front suspension member When performing work observe the following caution CAUTION Confirm there is no interference with the vehicle Check that all connection points have been disconnected e Keep in mind the center of vehicle gravity ch
163. ating sur faces e Also remove the old liquid gasket from mating surface of cylin der block e Remove old liquid gasket from the bolt holes and threads CAUTION Never scratch or damage the mating surfaces when clean ing off old liquid gasket JPBIA0027ZZ Install new O rings on the bottom of cylinder block and oil pump c Apply a continuous bead of liquid gasket with tube presser commercial service tool to the cylinder block mating surfaces of oil pan upper to a limited portion as shown in the figure a 5 5 7 5mm 0 217 0 295 in b 4 0 5 0 mm 0 157 0 197 in lt Engine front Use Genuine RTV Silicone Sealant or an equivalent Refer to GI 15 Recommended Chemical Products and Sealants CAUTION Attaching must be done within 5 minutes after coating d Tighten mounting bolts in numerical order as shown in the fig ure JPBIA2092ZZ lt Engine front CAUTION Install avoiding misalignment of O rings NOTE Tighten mounting bolts No 1 and 2 in two steps The numerical order No 12 and 17 shown second steps e There are three types of mounting bolts Refer to the following for locating bolts JPBIA2089ZZ M6 x 30 mm 1 18 in 18 19 M8 x 100 mm 3 94 in 3 4 5 7 10 11 14 15 M8 x 45 mm 1 77 in Except the above e Tighten transmission joint bolts f Install rear plate cover 3 Install oil strainer 4 Install oil pan lower Refer to EM 189 Removal and Instal
164. ating surface e 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 3 Attach liquid gasket tube to the tube presser commercial ser vice tool Use Genuine RTV Silicone Sealant or an equivalent Refer to GI 15 Recommended Chemical Products and Sealants 4 Apply liquid gasket without gaps to the specified location accord ing to the specified dimensions e If there is a groove for liquid gasket application apply liquid gasket to the groove Revision 2009 March EM 157 INFOID 0000000003733484 JPBIA0052ZZ EMA0622D 2009 FX35 FX50 PRECAUTIONS lt PRECAUTION gt VK50VE e As for bolt holes B normally apply liquid gasket inside the holes Occasionally it should be applied outside the holes Check to read the text of this manual A Groove lt Inside e Within 5 minutes of liquid gasket application install the mating component e If liquid gasket protrudes wipe it off immediately Do not retighten mounting bolts or nuts after the installation e After 30 minutes or more have passed from the installation fill rr engine oil and engine coolant CAUTION If there are specific instructions in this manual observe them Defini
165. bearings 4 Compression ratio 10 6 Standard 1 275 13 0 185 Compression pressure Minimum 981 10 0 142 kPa kg cm psi 300 rpm Differential limit between cylinders 98 1 0 14 Cylinder number OK cS FRONT SEM713A Valve timing Valve timing control OFF Sp PBICO187E Unit degree a b c d e f 248 248 2 66 0 68 Drive Belt INFOID 0000000003887397 DRIVE BELT Tension of drive belt Belt tension is not necessary as it is automatically adjusted by drive belt auto tensioner Revision 2009 March EM 142 2009 FX35 FX50 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VQ35HR Spark Plug INFOID 0000000003887398 SPARK PLUG Unit mm in Make DENSO ae Standard type FXE22HR11 Standard 1 1 0 043 Gap Limit 1 4 0 055 Intake Manifold INFOID 0000000003887399 INTAKE MANIFOLD Unit mm in Items Limit Surface distortion Intake manifold 0 1 0 004 Exhaust Man ifold INFOID 0000000003887400 EXHAUST MANIFOLD Unit mm in Items Limit Surface distortion Exhaust manifold 0 7 0 028 Ca m S h aft INFOID 0000000003887401 CAMSHAFT Unit mm in Items Standard Limit l l No 1 0 045 0 086 0 0018 0 0034 Camshaft journal oil clearance 0 15 0 0059 No 2 3 4 0 035 0 076 0 0014 0 0030 No 1 26 000 26 021 1 0236 1 0244 Camshaft bracket inner diameter No 2 3 4 2
166. bly and Assembly CAUTION Never loosen adjusting bolts and mounting bolts black color of VVEL ladder assembly 3 Remove valve lifter EXH at the locations that are out of the standard 4 Measure the center thickness of the removed valve lifters EXH with a micrometer A JPBIA0169ZZ 5 Use the equation below to calculate valve lifter EXH thickness for replacement Revision 2009 March EM 236 2009 FX35 FX50 CAMSHAFT lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE Valve lifter EXH thickness calculation t t1 C1 C2 t Valve lifter EXH thickness to be replaced t Removed valve lifter EXH thickness C1 Measured valve clearance C2 Standard valve clearance Exhaust 0 33 mm 0 013 in e Thickness of new valve lifter EXH can be identified by stamp marks on the reverse side inside the cylinder Stamp mark 788 indicates 7 88 mm 0 3102 in in thickness A Stamp B Thickness of valve lifter EXH JPBIAO170ZZ Available thickness of valve lifter EXH 27 sizes with range 7 88 to 8 40 mm 0 3102 to 0 3307 in in steps of 0 02 mm 0 0008 in when manufactured at factory Refer to EM 283 Camshaft Install selected valve lifter EXH Install VVEL ladder assembly and camshaft EXH Refer to EM 228 Disassembly and Assembly Manually turn crankshaft pulley a few turns Check that the valve clearances for cold engine are within the specifications by referring to the specified values R
167. burned JPBIA0186ZZ d Using the valve guide reamer commercial service tool A apply reamer finish to valve guide EXH Standard Refer to EM 285 Cylinder Head 2 Install valve seat EXH if removed Replace with oversize 0 5 mm 0 020 in valve seat EXH a Ream cylinder head recess diameter a for service valve seat EXH Oversize service 0 5 mm 0 020 in Refer to EM 285 Cylinder Head e Be sure to ream in circles concentric to valve guide center This enables valve to fit correctly JPBIA0188ZZ Revision 2009 March EM 248 2009 FX35 FX50 CYLINDER HEAD lt UNIT DISASSEMBLY AND ASSEMBLY gt VK50VE b Heat cylinder head to 110 to 130 C 230 to 266 F by soaking in heated oil A JPBIAO184ZZ c Provide valve seats EXH cooled well with dry ice Force fit valve seat EXH into cylinder head WARNING Cylinder head contains heat When working wear protective equipment to avoid getting burned CAUTION Avoid directly touching cold valve seats d Using the valve seat cutter set commercial service tool or valve seat grinder finish seat to the specified dimensions Refer to EM 285 Cylinder Head CAUTION When using the valve seat cutter firmly grip cutter handle with both hands Then press on the contacting surface all around the circumference to cut in a single drive Improper pressure on cutter or cutting many different times may WS ia c result in staged valve
168. cal Products and Seal ants JPBIA0255ZZ Revision 2009 March EM 73 2009 FX35 FX50 CAMSHAFT lt REMOVAL AND INSTALLATION gt VQ35HR e Apply liquid gasket to camshaft bracket No 1 contact surface on the rear timing chain case backside as shown on both bank 1 and bank 2 1 Rear timing chain case a 3 9 mm 0 154 in Use Genuine RTV Silicone Sealant or an equivalent Refer to GI 15 Recommended Chemical Products and Seal ants CAUTION For camshaft bracket No 1 near installation position JPBIA0881ZZ and install it without disturbing the liquid gasket applied to the surfaces 5 Tighten camshaft bracket bolts in the following steps in numeri cal order as shown in the figure lt Engine front a Tighten No 7 to 10 in numerical order as shown OJ 1 96 N m 0 20 kg m 1 ft lb b Tighten No 1 to 6 in numerical order as shown OJ 1 96 N m 0 20 kg m 1 ft Ib c Tighten No 1 to 10 in numerical order as shown OJ 5 88 N m 0 60 kg m 4 ft lb d Tighten No 1 to 10 in numerical order as shown OJ 10 4 N m 1 1 kg m 8 ft lb JPBIA0257ZZ 6 Install camshaft sensor bracket e Tighten camshaft sensor bracket bolts in numerical order as shown in the figure lt Engine front NOTE The order of tightening bolts is the same for bank 1 and bank 2 JPBIA1960ZZ 7 Inspect and adjust the valve clearance Refer to EM 20 Inspection and Adjustment 8 Install in the
169. cal order as shown in the figure CAUTION i o yyy Never damage or scratch engine cover when installing or removing 3 TT 5 4 JPBIA1823ZZ Revision 2009 March EM 27 2009 FX35 FX50 DRIVE BELT AUTO TENSIONER AND IDLER PULLEY lt REMOVAL AND INSTALLATION gt VQ35HR DRIVE BELT AUTO TENSIONER AND IDLER PULLEY Exploded View INFOID 0000000003887337 SEC 117 0 56 0 5 7 41 y i 2 0 28 0 Ly 2 9 21 o 28 0 2 9 21 JPBIA0004ZZ 1 Front timing chain case 2 Drive belt auto tensioner 3 Idler pulley 4 Idler pulley Refer to Gl 4 Components for symbols in the figure Removal and Installation INFOID 0000000003887338 Removal 1 Remove drive belt Refer to EM 15 Exploded View e Keep auto tensioner pulley arm locked after drive belt is removed 2 Remove auto tensioner and idler pulley e Keep auto tensioner pulley arm locked to install or remove auto tensioner Installation Installation is the reverse order of removal CAUTION If there is damage greater than peeled paint replace drive belt auto tensioner Revision 2009 March EM 28 2009 FX35 FX50 AIR CLEANER AND AIR DUCT lt REMOVAL AND INSTALLATION gt VQ35HR AIR CLEANER AND AIR DUCT Exploded View INFOID 0000000003887339 SEC 118 148 165 i 1 5 0 15 13 9 5 5 0 56 49 fg 15 0 15 13 JPBIA2324GB 1 Air cleaner filter 2 Holder 3 Air cleaner case bank 1 Air duct inlet 5 Grommet 6 Air clean
170. ce Piston to cylinder bore Crank clearance shaft pul Piston ring side clear oo eee A B B a Piston ance EM 147 ey rap slap noise 5 Cylinder Piston ring end gap block Connecting rod bend Side of and torsion pa oe Connect Connecting rod bushing EM 147 pan ing rod oil clearance Knock A p c 8 B B bearing Connecting rod bearing EM 152 noise oil clearance Mainibear Main bearing oil clear EM 151 Knock A B A B C ing noise ance 9 Crankshaft runout EM 147 Timing Front of chain and Timing chain cracks EM 68 engine Tapping or A A _ B B B timing and wears Timing ticking chain ten Timing chain tensioner EM 54 chain case sioner operation noise Squeak a ing or fizz A B B C or slip Drive belt deflection in is g ping EM 15 Front of R R i Drive belt Idler pulley bearing op engine Creaking A B A B A B Slipping eration Squall Water Creak A B B A B pump Water pump operation CO 19 noise A Closely related B Related C Sometimes related Not related Revision 2009 March EM 6 2009 FX35 FX50 PRECAUTIONS lt PRECAUTION gt VQ35HR PRECAUTION PRECAUTIONS Precaution for Procedure without Cowl Top Cover inFo10 0000000008887311 When performing the procedure after removing cowl top cover cover the lower end of windshield with urethane etc PIIB3706J Precaution for Supplemental Restraint System SRS AIR BAG and SEAT BELT P R E T E N S O N E R INFOID 0000000003887312 Th
171. ce parts Intake and exhaust Refer to EM 145 Cylinder Head eZ JPBIAO185ZZ Revision 2009 March EM 109 2009 FX35 FX50 CYLINDER HEAD lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR b Heat cylinder head to 110 to 130 C 230 to 266 F by soaking in heated oil A JPBIA0184ZZ c Using the valve guide drift commercial service tool press valve guide from camshaft side to the dimensions as shown in the fig ure Projection A Intake and exhaust Refer to EM 145 Cylinder Head WARNING Cylinder head contains heat When working wear protec tive equipment to avoid getting burned JPBIAO186ZZ d Using the valve guide reamer commercial service tool A apply reamer finish to valve guide Standard Refer to EM 145 Intake and exhaust Cylinder Head 2 If valve seat is removed in step 9 DISASSEMBLY install it Replace with oversize 0 5 mm 0 020 in valve seat a Ream cylinder head recess diameter a for service valve seat Oversize Refer to EM 145 Intake and exhaust Cylinder Head e Be sure to ream in circles concentric to valve guide center This enables valve to fit correctly JPBIAO188ZZ Revision 2009 March EM 110 2009 FX35 FX50 CYLINDER HEAD lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR b Heat cylinder head to 110 to 130 C 230 to 266 F by soaking in heated oil A JPBIA0184ZZ c Provide valve seats cooled well with dry ice
172. check the connecting rod side clearance Refer to 1 EM 265 Inspection 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 CAUTION Be careful not to damage the cylinder wall and crankshaft pin resulting from an interference of the connecting rod big end Using a hammer handle A or similar tool push piston and con necting rod assembly out to the cylinder head side VK50VE Connecting rod cap bolt Connecting rod Piston Top ring Drive plate Rear oil seal retainer INFOID 0000000003733457 JPBIA24752ZZ 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 e Identify installation positions and store them without mixing them up Remove piston rings from piston e Before removing piston rings check the piston ring side clearance Refer to EM 265 Inspection Revision 2009 March EM 256 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE e Use a piston ring expander commercial service tool A CAUTION e When removing piston rings be careful not to damage piston Be careful not to damage piston rings by expanding them excessively JPBIA0194Z
173. clean exhaust system threads using heated oxygen sensor thread cleaner tool commercial service tool J 43897 18 or J 43897 12 and apply anti seize lubricant Never over torque sensors Doing so may cause damage to sensors resulting in the MIL coming on n S pect i O n INFOID 0000000003887349 INSPECTION AFTER REMOVAL Surface Distortion Revision 2009 March EM 38 2009 FX35 FX50 EXHAUST MANIFOLD lt REMOVAL AND INSTALLATION gt VQ35HR e Check the surface distortion of the exhaust manifold mating sur face with a straightedge A and a feeler gauge B Limit Refer to EM 143 Exhaust Manifold e If it exceeds the limit replace exhaust manifold JPBIA0018ZZ Revision 2009 March EM 39 2009 FX35 FX50 FUEL INJECTOR AND FUEL TUBE lt REMOVAL AND INSTALLATION gt VQ35HR FUEL INJECTOR AND FUEL TUBE Exploded View INFOID 0000000003887350 SEC 164 ig 8 4 0 86 74 fw 9 0 0 92 80 JPBIA1708GB 1 Quick connector cap 2 Fuel feed hose with damper 3 O ring 4 Fuel sub tube 5 O ring 6 Fuel damper cap 7 Fuel damper 8 O ring 9 Fuel tube 10 Clip 11 O ring black 12 Fuel injector 13 O ring green A Refer to EM 40 Refer to Gl 4 Components for symbols in the figure CAUTION Never remove or disassemble parts unless instructed as shown in the figure Re m oval a nd n stal lat i O n INFOID 0000000003887351 REMOVAL WARNING Puta CAUTION FLAMMABLE sign in th
174. cleaner case 2 Remove holder 3 from air cleaner case 2 and then remove air cleaner filter 1 from holder AS d EN C5 INSTALLATION Note the following item and install in the reverse order of removal e Install the air cleaner filter by aligning the seal with the notch of air cleaner case Revision 2009 March EM 17 2009 FX35 FX50 lt PERIODIC MAINTENANCE gt SPARK PLUG Exploded View SEC 1119118 fg 7 0 erie aM 19 6 2 0 Q 2 5 0 26 2 xla i S lt 1 PCV hose 4 Spark plug 7 Rocker cover gasket bank 1 Camshaft position sensor PHASE bank 1 Exhaust valve timing control position sensor bank 2 16 PCV hose A To intake manifold collector D To air duct 10 13 14 SPARK PLUG s Clamp PCV valve Rocker cover bank 1 Exhaust valve timing control position sensor bank 1 Rocker cover gasket bank 2 Oil filler cap Refer to EM 50 Refer to Gl 4 Components for symbols in the figure Removal and Installation REMOVAL VQ35HR INFOID 0000000003887330 7 0 0 71 62 JPBIA1622GB 3 Ignition coil 6 O ring O ring 12 Camshaft position sensor PHASE bank 2 15 Rocker cover bank 2 18 PCV hose C Camshaft bracket side INFOID 0000000003887331 1 Remove engine cover with power tool Refer to EM 27 Exploded View 2 Remove air duct Refer to EM 29 Exploded View 3 Remove electric throttle control act
175. d and install them Camshaft sprocket INT back face Orange link Matching mark Circle Matching mark Oval Dowel groove Matching mark 2 oval Camshaft sprocket EXH back face Matching mark 2 circle IrIO0O n mMoOo OUV gt Dowel hole Es Timing chain secondary NOTE e Figure shows bank 1 rear view e Matching marks for camshaft sprockets are on the back side of camshaft sprockets secondary e There are two types of matching marks circle and oval types They should be used for the bank 1 and bank 2 respectively JPBIA1791ZZ Bank 1 Use circle type Bank2 Use oval type Align dowel pin camshafts with the groove or dowel hole on sprockets and install them On the intake side align dowel pin on camshaft front end with pin groove on the back side of camshaft sprocket and install them On the exhaust side align dowel pin on camshaft front end with pin hole on camshaft sprocket and install them In case that positions of each matching mark and each dowel pin are not fit on matching parts make fine adjustment to the position holding the hexagonal portion on camshaft with wrench or an equivalent Mounting bolts for camshaft sprockets must be tightened in the next step Tightening them by hand is enough to prevent the dislocation of dowel pins Check the matching marks punched D on each camshaft sprocket are positioned on the matching marks orange link C on timing c
176. d View Air cleaner case and air duct Refer to EM 29 Exploded View Intake manifold collector Refer to EM 31 Exploded View 2 Disconnect PCV hose from rocker cover Revision 2009 March EM 50 VQ35HR INFOID 0000000003887357 7 0 0 71 62 JPBIA1622GB 3 Ignition coil 6 O ring O ring 12 Camshaft position sensor PHASE bank 2 15 Rocker cover bank 2 18 PCV hose C Camshaft bracket side INFOID 0000000003887358 2009 FX35 FX50 IGNITION COIL SPARK PLUG AND ROCKER COVER lt REMOVAL AND INSTALLATION gt VQ35HR 3 Remove camshaft position sensor PHASE and exhaust valve timing control position sensor bank 1 and bank 2 A _ Keep off any magnetic materials CAUTION e Handle carefully to avoid dropping and shocks Never disassemble Never allow metal powder to adhere to magnetic part at sensor tip Never place sensors in a location where they are exposed to magnetism 4 Remove PCV valve and O ring from rocker cover if necessary Remove oil filler cap from rocker cover if necessary 6 Remove ignition coil CAUTION Never impact ignition coil 7 Remove harness clips on the rocker cover 8 Loosen mounting bolts with power tool in reverse order shown in the figure on lt Engine front JPBIA0040ZZ 9 Remove rocker cover gasket from rocker cover 10 Use scraper to remove all traces of liquid gasket from cylinder head and camshaft bracket No 1
177. d it is directed according to inspection procedure of EC section Refer to EC 111 Diagnosis Description e Check when engine is cold so as to prevent burns from the splashing engine oil 1 Check engine oil level Refer to LU 6 Inspection 2 Perform the following procedure so as to prevent the engine from being unintentionally started while checking a Release the fuel pressure Refer to EC 567 Inspection Revision 2009 March EM 77 2009 FX35 FX50 CAMSHAFT lt REMOVAL AND INSTALLATION gt VQ35HR b Disconnect ignition coil and injector harness connectors Refer to EM 50 Exploded View and EM 40 Exploded View 3 Remove intake valve timing control solenoid valve Refer to EM 53 Exploded View 4 Crank engine and then check that engine oil comes out from intake valve timing control solenoid valve hole A End crank after checking 1 Valve timing control cover bank 1 lt Engine front WARNING Be careful not to touch rotating parts drive belt idler pul ley and crankshaft pulley etc CAUTION Prevent splashing by using a shop cloth so as to prevent the worker from injury from engine oil and so as to prevent engine oil contamination e Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to engine and vehicle Especially be careful no to apply engine oil to rubber parts of drive belt engine mounting insulator etc Wipe engine oil off immediate
178. ded View Water inlet and thermostat assembly Refer to CO 22 Exploded View e Water outlets front and rear water pipe and heater pipe Refer to CO 24 Exploded View e Timing chain Refer to EM 53 Exploded View Revision 2009 March EM 107 2009 FX35 FX50 CYLINDER HEAD lt UNIT DISASSEMBLY AND ASSEMBLY gt e Rear timing chain case Refer to EM 95 Exploded View e Camshaft Refer to EM 70 Exploded View 2 Remove cylinder head e Loosen cylinder head bolts in reverse order as shown in the figure with cylinder head bolt wrench commercial service tool and power tool A Bank 1 B Bank2 lt Engine front 3 Remove cylinder head gaskets 4 Remove valve lifter e Identify installation positions and store them without mixing them up 5 Remove valve collet Compress valve spring with the valve spring compressor SST KV10116200 J 26336 A A the attachment SST KV10115900 J 26336 20 C and the adapter SST KV10109220 B Remove valve collet with a magnet hand CAUTION When working take care not to damage valve lifter holes NS Se gee nce ae 6 Remove valve spring retainer valve spring and valve spring seat 7 Push valve stem to combustion chamber side and remove valve e Identify installation positions and store them without mixing them up 8 Remove valve oil seal using the valve oil seal puller SST KV10107902 J 38959 A 9 Remove valve seat if valve seat
179. e 0 035 0 045 0 0014 0 0018 0 065 0 0026 Actual clearance Co n n ecti n g Rod Beari n g INFOID 0000000003733472 CONNECTING ROD BEARING Grade number Thickness mm in Width mm in Identification color mark 0 1 497 1 500 0 0589 0 0591 Red 1 1 500 1 503 0 0591 0 0592 Black 18 1 18 3 2 1 503 1 506 0 0592 0 0593 0 713 0 720 Brown 3 1 506 1 509 0 0593 0 0594 Green 4 1 509 1 512 0 0594 0 0595 Yellow Revision 2009 March EM 292 2009 FX35 FX50 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VK50VE UNDERSIZE Unit mm in Items Thickness Pin journal diameter 0 25 0 0098 1 626 1 634 0 0640 0 0643 Grind so that bearing clearance is the specified value CONNECTING ROD BEARING OIL CLEARANCE Unit mm in Items Standard Limit Connecting rod bearing oil clearance 0 040 0 053 0 0016 0 0021 0 070 0 0028 Actual clearance Revision 2009 March EM 293 2009 FX35 FX50
180. e Exhaust Out of square 2 1 mm 0 083 in 2 0 mm 0 079 in Cylinder Block INFOID 0000000003733470 CYLINDER BLOCK Unit mm in Surface flatness Limit 0 1 0 004 Main bearing housing inner diameter Standard 68 944 68 968 2 7143 2 7153 Grade No 1 95 500 95 510 3 7598 3 7602 Standard Grade No 2 95 510 95 520 3 7602 3 7606 Cylinder bore Inner diameter Grade No 3 95 520 95 530 3 7606 3 7610 Wear limit 0 2 0 008 Out of round E 0 015 0 0006 Limit Taper 0 010 0 0004 Revision 2009 March EM 287 2009 FX35 FX50 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS Main bearing housing inner diameter grade Without bearing Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No Grade No NA KK S lt CHMODVZSTHACLIOMmMVODS 68 944 68 945 68 945 68 946 68 946 68 947 68 947 68 948 68 948 68 949 68 949 68 950 68 950 68 951 68 951 68 952 68 952 68 953 68 953 68 954 68 954 68 955 68 955 68 956 68 956 68 957 68 957 68 958 68 958 68 959 68 959 68 960 68 960 68 961 68 961 68 962 68 962 68 963 68 963 68 964 68 964 68 965 68 965 68 966 68 966 68 967 68 967 68 968 VK50VE 2 7143 2 7144 2 7144 2 7144 2 7144 2 7144 2
181. e If the measured value exceeds the limit replace piston ring and measure again If it still exceeds the limit rebore cylinder and use oversize piston and piston rings CONNECTING ROD BEND AND TORSION e Check with a connecting rod aligner JPBIA0220ZZ A Bend B Torsion C Feeler gauge Bend limit ER Refer to EM 147 Cylinder Block Torsion limit e If it exceeds the limit replace connecting rod assembly JPBIA0221ZZ CONNECTING ROD BIG END DIAMETER Revision 2009 March EM 128 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR e Install connecting rod bearing cap without installing connecting rod bearing and tightening connecting rod bolts to the specified torque Refer to EM 118 Disassembly and Assembly for the tightening procedure 1 Connecting rod e Measure the inner diameter of connecting rod big end with an inside micrometer Standard Refer to EM 147 Cylinder Block e If out of the standard replace connecting rod assembly CONNECTING ROD BUSHING OIL CLEARANCE Connecting Rod Bushing Inner Diameter Measure the inner diameter of connecting rod bushing with an inside micrometer A JPBIA0222ZZ Standard Refer to EM 147 Cylinder Block JPBIA0223ZZ Piston Pin Outer Diameter Measure the outer diameter of piston pin with a micrometer A Standard Refer to EM 147 Cylinder Block JPBIA0218ZZ Connecting Rod Bushing Oil
182. e Supplemental Restraint System such as AIR BAG and SEAT BELT PRE TENSIONER used along with a front seat belt helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision This system includes seat belt switch inputs and dual stage front air bag modules The SRS system uses the seat belt switches to determine the front air bag deployment and may only deploy one front air bag depending on the severity of a collision and whether the front occupants are belted or unbelted Information necessary to service the system safely is included in the SRS AIR BAG and SEAT BELT of this Service Manual WARNING To avoid rendering the SRS inoperative which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation all maintenance must be performed by an authorized NISSAN INFINITI dealer Improper maintenance including incorrect removal and installation of the SRS can lead to personal injury caused by unintentional activation of the system For removal of Spiral Cable and Air Bag Module see the SRS AIR BAG Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual SRS wiring harnesses can be identified by yellow and or orange harnesses or har ness connectors PRECAUTIONS WHEN USING POWER TOOLS AIR OR ELECTRIC AND HAMMERS WARNING When working near t
183. e by comparing the measurement with the values of each selection table e 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 Piston WHEN NEW CYLINDER BLOCK IS USED Check the cylinder bore grade 1 2 or 3 on rear side of cylinder block and select piston of the same grade Treron moO gt lt x Engine front NOTE Cylinder bore grade No Cylinder bore grade No Cylinder bore grade No Cylinder bore grade No Cylinder bore grade No Cylinder bore grade No Cylinder bore grade No Cylinder bore grade No Bearing housing grade No 1 Bearing housing grade No 2 Bearing housing grade No 3 Bearing housing grade No 4 Bearing housing grade No 5 o NOOA OMN INFOID 0000000003733460 JPBIA2284ZZ Piston is available with piston pin as a set for the service part WHEN NEW CYLINDER BLOCK IS REUSED 1 Measure the cylinder bore inner diameter Refer to EM 287 Cylinder Block Revision 2009 March EM 274 2009 FX35 FX50 HOW TO SELECT PISTON AND BEARING lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE 2 Determine the bore grade by comparing the measurement with the values under the cylinder bore inner diameter of the PIS TON SELECTION TABLE Bank 2 Bank 1 Front mark Piston grade number Piston pin grade number nmo 0O gt
184. e is passed after the installation fill oun engine oil and engine coolant CAUTION If there are specific instructions in this manual observe them Definitions of Bank Names INFOID 0000000003887321 e In this manual each bank name is defined as per the following A Bank 1 The conventional right bank B Bank 2 The conventional left bank lt 2 Engine front e For cylinder numbers and bank layout refer to the figure Bank1 The bank side including cylinder No 1 odd numbered cylinder side Bank 2 The other bank side of the above JPBIA1135ZZ even numbered cylinder side Revision 2009 March EM 10 2009 FX35 FX50 PREPARATION lt PREPARATION gt VQ35HR PREPARATION PREPARATION Special Service Tools inFo10 0000000008887322 The actual shapes of Kent Moore tools may differ from those of special service tools illustrated here Tool number Kent Moore No Description Tool name KV10116200 Disassembling valve mechanism J 26336 A Part 1 is a component of KV10116200 J Valve spring compressor 1 KV10115900 J 26336 20 Attachment 2 KV10109220 C Adapter PBIC1650E KV10107902 Replacing valve oil seal J 38959 Valve oil seal puller 26336 A but Part 2 is not so NTO11 KV10115600 Installing valve oil seal J 38958 Use side A G Valve oil seal drift a 20 0 79 dia d 8 0 31 dia ay b 13 0 51 dia e 10 7 0 421 j a c 10 3 0 406 di
185. e procedure when the measured value exceeds the limit is the same as that described in the Method by Calculation JPBIA0231ZZ MAIN BEARING CRUSH HEIGHT e When main bearing cap is removed after being tightened to the specified torque with main bearings 1 installed the tip end of bearing must protrude Refer to EM 256 Disassembly and Assembly for the tightening procedure A Crush height Standard There must be crush height e If the standard is not met replace main bearings JPBIA0233ZZ CONNECTING ROD BEARING CRUSH HEIGHT e When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings 1 installed the tip end of bearing must protrude Refer to EM 256 Disassem bly and Assembly for the tightening procedure A Crush height Standard There must be crush height e If the standard is not met replace connecting rod bearings MAIN BEARING CAP BOLT OUTER DIAMETER e Measure the outer diameters A B at two positions as shown in the figure c 20mm 0 79 in d 40 mm 1 57 in e 12 mm 0 47 in e If reduction appears in A range regard it B Limit B A 0 18 mm 0 0071 in e If it exceeds the limit large difference in dimensions replace main JPBIA228022 bearing cap bolts with new one MAIN BEARING CAP SUB BOLT OUTER DIAMETER Revision 2009 March EM 272 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND AS
186. e workshop Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher Never smoke while servicing fuel system Keep open flames and sparks away from the work area Never drain engine coolant when the engine is hot to avoid the danger of being scalded Release fuel pressure Refer to EC 567 Inspection Disconnect battery cable from the negative terminal Refer to PG 120 Exploded View Remove engine cover with power tool Refer to EM 27 Exploded View Remove air cleaner case and air duct Refer to EM 29 Exploded View Fons Revision 2009 March EM 40 2009 FX35 FX50 FUEL INJECTOR AND FUEL TUBE lt REMOVAL AND INSTALLATION gt VQ35HR 5 Remove intake manifold collector Refer to EM 31 Exploded View 6 Remove fuel feed hose with damper 1 from fuel sub tube 2 and remove harness bracket 3 lt Engine front NOTE There is no fuel return route CAUTION e While hoses are disconnected plug them to prevent fuel from draining Never separate damper and hose 7 When separating fuel feed hose with damper and centralized under floor piping connection disconnect quick connector as per the following a Remove quick connector cap 2 from quick connector connec tion on right member side b Disconnect fuel feed hose with damper 1 from bracket hose clamp JPBIA0254ZZ c Pushin retainer tabs 2 d Draw and pull out quick connector 1 straigh
187. eat recess in cylinder head Set the machine depth stop to ensure this Refer to EM 285 Cylinder Head CAUTION Prevent to scratch cylinder head by excessive boring 11 Remove valve guide EXH if valve guide EXH must be replaced a To remove valve guide EXH heat cylinder head to 110 to 130 C 230 to 266 F by soaking in heated oil A JPBIA0184ZZ b Drive out valve guide EXH with a press under a 20 kN 2 ton 2 2 US ton 2 0 Imp ton pressure or a hammer and the valve guide drift commercial service tool WARNING Cylinder head contains heat When working wear protec tive equipment to avoid getting burned ASSEMBLY 1 Install valve guide EXH if removed Replace with oversized 0 2 mm 0 008 in valve guide EXH a Using the valve guide reamer commercial service tool A ream cylinder head valve guide EXH hole Oversize service 0 2 mm 0 008 in Refer to EM 285 Cylinder Head Revision 2009 March EM 247 2009 FX35 FX50 CYLINDER HEAD lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE b Heat cylinder head to 110 to 130 C 230 to 266 F by soaking in heated oil A JPBIA0184ZZ c Using the valve guide drift commercial service tool press valve guide EXH from camshaft side to the dimensions as shown in the figure Projection A Refer to EM 285 Cylinder Head WARNING Cylinder head contains heat When working wear protec tive equipment to avoid getting
188. ecification resin isesi itakata 142 Drive Belt aacicissssedagece i a a aae 142 UNIT REMOVAL AND INSTALLATION 82 Spark Plug eha ni arat raea aE son aariat 143 Intake Manifold sessseeeseessennnnensseeseennrrnnrrnnssnsseens 143 ENGINE ASSEMBLY ccccccceccceeeeeeeeeeeeeneens 82 Exhaust Manifold crina 143 GaiMShalbinisccccaussoentessscactaashetaccsataves coaetavedechecesaets 143 2WD Spsttgarencatnacttacnes sess A A A 82 Cylinder Head an a e aa A Bats De 145 2WD Exploded View rdan ea ienee erases eee aS 82 Cylinder BIOGK iscsaccloscutasustersaaciadclasuhienids 147 2WD Removal and Installation eeee 82 Main Bearing oiaci cd tends Toaacetd fonscade cde duninceedusnscad e 151 QWD INSPOCHION sisirain 86 Connecting Rod Bearing scsssssessssesssecsseeeseeen 152 AAD e e ROR Be Pe ea 86 VK50VE AWD Exploded View eeeceecceeeeeeteeeeeeeenteeeeeeeee 87 AWD Removal and Installation eee 87 SYMPTOM DIAGNOSIS ssecsecsseeeteeteeess 153 AWD Inspection EIEEE PEERAA NE EATE ATT 91 NOISE VIBRATION AND HARSHNESS UNIT DISASSEMBLY AND ASSEMBLY 92 NVH TROUBLESHOOTING bhtrrsrerarnnnereseenennns 153 NVH Troubleshooting Engine Noise 153 ENGINE STAND SETTING ccccceeeseeeeeeeneees 92 Use the Chart Below to Help You Find the C E Sara e DEA PENS E EEE A TO ATEN 92 ause of the Symptom cccsssceeeesssteeeeeenaes 153 ENGINE UNIT eeseeeseeseeeseeeseesseeseesse
189. eeeees Tp pee ae ge ee gene eee gag Draining Engine Coolant 0 cence 8 DRIVE BELT AUTO TENSIONER AND IDLER Disconnecung Fuel PIPING esti aseni w POLLE VAa A OANE A 28 Removal and Disassembly eeiee 8 Exploded VIEW ix sid ec cssdatcendate dels Stade iuctend ate 28 Inspection Repair and Replacement 8 Removal and Installation s 28 Assembly and Installation c cc eeeeeeeeeeeteeeeees 8 Parts Requiring Angle Tightening ccce 9 AIR CLEANER AND AIR DUCT 00000 29 EIQUIG Gasket eieiei aane att e ea E ria 9 Exploded VI W see seceecceseeeeeeeeeeeeeeseeeseeerseeeenees 29 Definitions of Bank Names sessen 10 Removal and Installation ccceeeeeeceseeeeeeeeeeees 29 INSPOCHON cans dented whee hk tea eee 30 PREPARATION sssssssssssssssssssssssesssesssseessen 11 INTAKE MANIFOLD COLLECTOR 00 31 PREPARATION a n rene ssnnttns 11 Exploded VieW ssssssssssessrresssrrresssnrneesrnnnesernenneennena 31 Special Service TOONS 1 0 11 Removal and Installation 0ccseeeeeneeeee 31 Commercial Service Tools s 12 INTAKE MANIFOLD cc ececceeeeesseeeeeeeeeeeees 34 PERIODIC MAINTENANCE ssserseens 15 Exploded V EW cisi6 vabrcinsies0 comebecitet ehiwselusinisenivecnedts 34 Removal and Installation 34 DRIVE BELT T gE OIE Ge NR WEL ge he INSPECTION steer erin a E tase R 35 Exploded View assssssssisessssrressnrnessrrnn
190. efer to EM 169 Inspection 10 Install all removed parts in the reverse order of removal 11 Warm up the engine and check for unusual noise and vibration INSPECTION AFTER DISASSEMBLY EXHAUST SIDE Camshaft EXH Runout 1 Put V block on precise flat table and support No 2 and 5 jour nals of camshaft CAUTION Never support No 1 journal on the side of camshaft sprocket because it has a different diameter from the other four locations 2 Seta dial indicator vertically to No 3 journal 3 Turn camshaft EXH to one direction with hands and measure the camshaft runout on a dial indicator Total indicator reading Oo ON D Standard and limit Refer to EM 283 Camshaft 4 If it exceeds the limit replace camshaft EXH Camshaft EXH Cam Height Revision 2009 March EM 237 2009 FX35 FX50 CAMSHAFT lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE e Measure the camshaft EXH cam height with a micrometer Standard and limit Refer to EM 283 Camshaft e If wear exceeds the limit replace camshaft EXH EMQ0072D Camshaft EXH Journal Oil Clearance CAMSHAFT EXH JOURNAL DIAMETER e Measure the outer diameter of camshaft EXH journal with a micrometer A Standard Refer to EM 283 Camshaft JPBIA0122ZZ VVEL LADDER ASSEMBLY EXH SIDE INNER DIAMETER e Tighten VVEL ladder assembly bolts to the specified torque Refer to ASSEMBLY for the tightening proce
191. enaees 94 PRECAUTION sississeciscisticcetioncteccwotenesecninet 155 Aer PRECAUTIONS eain eniai 155 Precaution for Procedure without Cowl Top Cover 155 REAR TIMING CHAIN CASE ccccccssseseeeee 95 Precaution for Supplemental Restraint System Exploded View sr frrr ai 95 SRS AIR BAG and SEAT BELT PRE TEN DISASSEMBLY seiri kiasa rrn e AEEA 96 DIONE m AEA EAEE tet caret A A 155 ASSOMDIV eee Deor ENE a E en AERES EONA TERS 97 Revision 2009 March EM 2 2009 FX35 FX50 Precaution Necessary for Steering Wheel Rota FUEL INJECTOR AND FUEL TUBE tion after Battery Disconnect 0 ee 155 Exploded VieW ccccccecsseeceeeeeeeeceeeseeeeseceeeseneees Precaution for Drain Engine Coolant and Engine Removal and Installation ccccceeceeseeeeeeeeeees OM is sosaet E ET 156 Inspection iepr nu a e ia Precaution for Disconnecting Fuel Piping 156 Precaution for Removal and Disassembly 156 OIL PAN LOWER AND OIL STRAINER Precaution for Inspection Repair and Replace Exploded VIGW a2nciades fs asttoest EAT MeNe ea ire Tear evant a ETC rn terrier errr 156 Removal and Installation ccssseseeseeeeteeeens Precaution for Assembly and Installation 156 Inspection riea CaA a aaraa ee Aaa e Eaa eaa EAEan Parts Requiring Angle Tightening o 157 2 Precaution for Liquid Gasket cccceeeeeeeees 157 IGNITION COIL SPARK PLUG AND ROCK Definitions of Bank Names sec
192. end face a 0 0 5 mm 0 0 020 in e Using a suitable drift outer diameter 101 mm 3 98 in e Check the garter spring is in position and seal lips are not inverted 0 JPBIAO1522Z 11 Install piston to connecting rod as per the following e 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 B Oilhole C Front mark lt Engine front a Using snap ring pliers install new snap ring to the groove of pis ton rear side e Insert it fully into groove to install b Install piston to connecting rod e 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 c Install new snap ring to the groove of the piston front side e Insert it fully into groove to install e After installing check that connecting rod moves smoothly 12 Using a piston ring expander commercial service tool A install piston rings CAUTION e When installing piston rings be careful not to damage piston Be careful not to damage piston rings by expending them excessively JPBIA22712Z JPBIA0194ZZ e If there is stamped mark on ring mount it with marked side up Stamped mark Top ring A 1N Second ring B 2N JPBIA1720ZZ Revision 2009 March EM
193. er Piston ring end gap block Connecting rod bend Side of and torsion pa oe Connect Connecting rod bushing pan ing rod oil clearance Knock A E G B E B bearing Connecting rod bearing EM EES noise oil clearance Mainibear Main bearing oil clear Knock A B A B C ing noise ance EM 265 9 Crankshaft runout Timing Front of chain and Timing chain cracks engine Tapping or A A _ B B B timing and wears EM 225 Timing ticking chain ten Timing chain tensioner chain case sioner operation noise Squeak ace ing or fizz A B B C or slip Drive belts deflection in z E g ping EM 164 Front of R i Drive belts Idler pulley bearing op engine Creaking A B A B A B Slipping eration Squall Water Creak A B B A B pump Water pump operation CO 45 noise A Closely related B Related C Sometimes related Not related Revision 2009 March EM 154 2009 FX35 FX50 PRECAUTIONS lt PRECAUTION gt VK50VE PRECAUTION PRECAUTIONS Precaution for Procedure without Cowl Top Cover inFo10 0000000008001618 When performing the procedure after removing cowl top cover cover the lower end of windshield with urethane etc PIIB3706J Precaution for Supplemental Restraint System SRS AIR BAG and SEAT BELT P R E T E N S O N E R INFOID 0000000003901616 The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE TENSIONER used along with a front seat belt helps to reduce the risk or severity of injury t
194. er case bank 2 Mass air flow sensor bank 2 8 Clamp 9 Air duct bank 2 10 Clamp 11 PCV hose 12 Clamp 13 PCV hose 14 Air duct bank 1 15 Mass air flow sensor bank 1 A To electric throttle control actuator B To electric throttle control actuator C To rocker cover bank 2 bank 2 bank 1 Refer to Gl 4 Components for symbols in the figure Re moval and Installation INFOID 0000000003887340 REMOVAL 1 Disconnect mass air flow sensor harness connector 2 Disconnect PCV hose 3 Remove air cleaner case with mass air flow sensor and air duct disconnecting each joints e Add matching marks if necessary for easier installation 4 Remove mass air flow sensor from air cleaner case if necessary CAUTION Handle mass air flow sensor with the following cares Never impact mass air flow sensor Never disassemble mass air flow sensor e Never touch mass air flow sensor INSTALLATION Revision 2009 March EM 29 2009 FX35 FX50 AIR CLEANER AND AIR DUCT lt REMOVAL AND INSTALLATION gt VQ35HR Note the following item and install in the reverse order of removal Align marks Attach each joint Screw clamps firmly Clamp tightening torque W 4 5 N m 0 46 kg m 40 in Ib n S pect i O n INFOID 0000000003887341 INSPECTION AFTER REMOVAL Inspect air duct and resonator if assembly for crack or tear e If damage found replace air duct and resonator assembly Revision 2009 March EM 30 2009 FX35 FX50 INTAKE MAN
195. er number marks on connecting rod with those on connecting rod bearing cap to install Management code A Sample codes B Bearing stopper groove C Small end diameter grade D Big end diameter grade E Weight grade F Cylinder No G JPBIA0208ZZ Management code e Be sure that front mark H on connecting rod bearing cap is facing front of the engine 14 Tighten connecting rod bolt as per the following a Inspect the outer diameter of connecting rod bolt Refer to EM 126 Inspection Apply engine oil to the threads and seats of connecting rod bolts c Tighten connecting rod bolts O 28 4 N m 2 9 kg m 21 ft Ib d Completely loosen connecting rod bolts Revision 2009 March EM 124 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR O 0 N m 0 kg m 0 ft Ib e Tighten connecting rod bolts O 24 5 N m 2 5 kg m 18 ft Ib f Tighten connecting rod bolts clockwise Angle tightening 90 degrees CAUTION Always use the angle wrench SST KV10112100 BT8653 A A Never tightening based on visual check alone e After tightening connecting rod bolts check that crankshaft rotates smoothly e Check the connecting rod side clearance Refer to EM 126 Inspection 15 Install baffle plate 16 Install new rear oil seal Refer to EM 80 REAR OIL SEAL Removal and Installation Apply new engine oil to both oil seal lip and dust seal lip
196. er of jour nal Combining service grades for Between crankshaft and con f Connecting rod bearing grade connecting rod big ng dame Connecting rod bearing s ter and crankshaft pin outer di necting rod bearing thickness ameter determine connecting rod bearing selection Piston and piston pin assembly Piston is available together with piston pin as assembly Between cylinder block and pis ton Piston grade Piston grade cylinder bore piston skirt diameter grade inner diameter of bore Between piston and connecting rod For the service parts the grade for fitting cannot be selected between piston pin and connecting rod Only 0 grade is available The information at the shipment from the plant is described as a reference e The identification grade stamped on each part is the grade for the dimension measured in new condition This grade cannot apply to reused parts e For reused or repaired parts measure the dimension accurately Determine the grade by comparing the measurement with the values of each selection table e 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 P l sto n INFOID 0000000003887393 WHEN NEW CYLINDER BLOCK IS USED Check the cylinder bore grade 1 2 or 3 on rear side of cylinder block and select piston of the same grade Bearing housing grade No 1
197. ertion to pre vent damage to O ring inside quick connector Insert until you hear a click sound and actually feel the engagement e To avoid misidentification of engagement with a similar sound be sure to perform the next step JPBIA2378ZZ Fuel feed damper side e Insert quick connector to fuel feed damper piping until top spool 2 is completely inside quick connector and 2nd level spool 3 exposes just below quick connector B Fitted condition lt m Upright insertion CAUTION Hold A position as shown in the figure when inserting fuel feed hose 1 into quick connector Carefully align center to avoid inclined insertion to pre vent damage to O ring inside quick connector _ _ e s e Insert until you hear a click sound and actually feel the engagement e To avoid misidentification of engagement with a similar sound be sure to perform the next step d Pull quick connector by hand holding position A Check it is completely engaged connected so that it does not come out from fuel piping 1 PBIC3795E Revision 2009 March EM 186 2009 FX35 FX50 FUEL INJECTOR AND FUEL TUBE lt REMOVAL AND INSTALLATION gt VKSOVE e Install quick connector cap 3 to quick connector connection 1 Fuel tube bank 1 2 Fuel hose center e Install quick connector cap with arrow A on surface facing the direction of quick connector CAUTION If cap cannot be installed smoothly quick connecto
198. ese 158 Barat pant PEGEADEC ESSE ARSE peng emeptopeasspesesteayng tee be PREPARATION ccscecceescseseeceseeeeeeneees 159 Removal and Installation ccceeseeeseeeees 191 PREPARATION cecccccccccccececececcccccccceceseseacececerees 159 OIL SEAL siiin tere ieee keene 194 Special Service Tool cccceceeseeeeeeeeeeteneeeeees 159 FRONT OIL SEAL 194 Commercial Service Tool cccceceeeeeseseeeeees 160 FRONT OIL SEAL Removal and Installation 194 PERIODIC MAINTENANCE sssss100 163 REAR OIL SEAL sssssssssssssssssssssssssessssssssssssssssssssssecs 194 DRIVE BELTS susie wansuias Acces ipa REBT OIE SEB ss Ciney al ano Sia llaliordrerhge Exploded MIGW dana a cucehhrtede secuvebaiey 163 UNIT REMOVAL AND INSTALLATION 196 Checking visiini ina nee aana aa aie 163 Tension Adjustment c ccceceeeeeeeeeeteeeeeeeeeeeees 164 ENGINE ASSEMBLY ccccccceccecececcecnsceseees 196 Removal and Installation 0 0 0 0 eee 164 Exploded VIEW vi e tiec tied isvtincciivaubnduevars sila cones 196 Inspectii weeds cnadevessacieeteenctnte rede sahana cnet 164 Removal and Installation ccccccccccccccccccecececececeeeee 196 AIR CLEANER FILTER cosecccccccoccocccccceccocceccoccce 166 IMSPOCTION sirridir iei E S 200 Removal and Installation 0 ee 166 UNIT DISASSEMBLY AND ASSEMBLY 202 SPARK PLUG ai ceoccctatca cei aetnecsineeeeanaennains 1677 ENGINE STAND SETTING ceccccocccocccocccccccccceeee 202 Exploded V
199. ew JPBIA0047ZZ 11 Install valve timing control covers bank 1 and bank 2 as per the following Revision 2009 March EM 66 2009 FX35 FX50 TIMING CHAIN lt REMOVAL AND INSTALLATION gt VQ35HR a Install new seal rings 1 in shaft grooves A Bank2 CAUTION When replacing seal ring replace all rings with new one JPBIA0060ZZ b To check the joint between dowel pins and dowel pin holes check the looseness in the axle direction by pushing the circum ferential looseness between dowel pins and dowel pin holes by twisting in the circumferential direction A Mating surface of magnet retarder B Moves slightly C Not shaken CAUTION Always perform this procedure when removing because the gap between dowel pins and dowel pin holes may not be caused on purpose c Install valve timing control cover with new gasket to front timing chain case 1 Valve timing control cover 2 Magnet retarder CAUTION Never face the magnet retarder side down to prevent mag net retarder from dropping Check the mating surface of magnet retarder and the drum of exhaust side camshaft sprocket for foreign mate rials Align the center of both shaft holes of the shaft and the intake side camshaft sprocket and then insert them Be careful not to drop the seal ring from the shaft groove When setting the valve timing control cover in position by hand if valve timing control cover is not contacting with the front ti
200. ey 25 B f l A 92 5 9 4 68 2 0 49 0 5 0 36 20 5 2 1 15 92 5 9 4 68 Engine mounting bracket RH low JPBIA2100GB 1 Engine mounting bracket RH 2 er 3 Dynamic damper 4 Washer 5 Engine mounting insulator RH 6 Engine mounting bracket LH 7 Engine mounting insulator LH 8 Heat insulator 9 Rear engine mounting member 10 Engine mounting insulator rear 11 Dynamic damper A Front mark Refer to Gl 4 Components for symbols in the figure AWD Removal and Installation iNirononnanoonaaaiem WARNING e Situate the vehicle on a flat and solid surface e Place chocks at front and back of rear wheels For engines not equipped with engine slingers attach proper slingers and bolts described in PARTS CATALOG CAUTION Always be careful to work safely avoid forceful or uninstructed operations Never start working until exhaust system and engine coolant are cool enough If items or work required are not covered by the engine section refer to the applicable sections Always use the support point specified for lifting Use either 2 pole lift type or separate type lift as best you can If board on type is used for unavoid able reasons support at rear axle jacking point with transmission jack or similar tool before starting work in preparation for the backward shift of center of gravity e For supporting points for lifting and jacking point at rear axle refer to Gl 26 Ga
201. faces of timing chain tensioner pri mary f Pull out stopper pin A after installing and then release plunger 7 Check again that the matching marks on sprockets and timing chain have not slipped out of alignment 8 Install new O rings 1 on rear timing chain case A Bank 1 B Bank2 9 Install new front oil seal on front timing chain case Revision 2009 March EM 64 2009 FX35 FX50 TIMING CHAIN lt REMOVAL AND INSTALLATION gt VQ35HR e Apply new engine oil to both oil seal lip A and dust seal lip B lt 2 Engine inside 4a Engine outside e Install it so that each seal lip is oriented as shown in the figure JPBIA0054ZZ e Using a suitable drift outer diameter 60 mm 2 36 in A press fit oil seal until it becomes flush with front timing chain case end face e Check the garter spring is in position and seal lip is not inverted 10 Install front timing chain case as per the following e Check O rings stay in place during installation to rear timing chain case a Apply a continuous bead of liquid gasket with the tube presser commercial service tool to front timing chain case back side as shown in the figure B Protrusion c 303 4 4 4 mm 0 134 0 173 in d 2 6 3 6 mm 0 102 0 142 in e 4 0 5 6 mm 0 157 0 220 in Use Genuine RTV Silicone Sealant or an equivalent Refer to GI 15 Recommended Chemical Products and Sealants Z Z JPBIA1138ZZ Revision 20
202. fer to EC 706 Diag nosis Description e Check when engine is cold to prevent burns from the splashing engine oil Check engine oil level Refer to LU 25 Inspection Perform the following procedure to prevent the engine from being unintentionally started while checking Release the fuel pressure Refer to EC 1228 Inspection Disconnect ignition coil and injector harness connectors Refer to EM 191 Exploded View Remove valve timing control solenoid valve Refer to EM 212 Exploded View Crank engine and then check that engine oil comes out from valve timing control solenoid valve hole A End crank after checking PO op NM gt 1 Valve timing control cover bank 2 WARNING Be careful not to touch rotating parts drive belt idler pul ley and crankshaft pulley etc CAUTION e Prevent splashing by using a shop cloth to prevent the worker from injury from engine oil and to prevent engine oil contamination e Prevent splashing by using a shop cloth to prevent engine oil from being splashed to engine and vehicle Especially be careful not to apply engine oil to rubber parts of drive belt engine mount ing insulator etc Wipe engine oil out immediately if it is splashed 5 Perform the following inspection if engine oil does not come out from valve timing control solenoid valve oil hole of the valve timing control cover e Remove oil filter and then clean it Refer to EM 212 Exploded View e Clean o
203. from air cleaner case if necessary CAUTION Handle mass air flow sensor according to the following instructions Revision 2009 March EM 177 2009 FX35 FX50 AIR CLEANER AND AIR DUCT lt REMOVAL AND INSTALLATION gt VKSOVE Never impact mass air flow sensor Never disassemble mass air flow sensor Never touch mass air flow sensor INSTALLATION Note the following item and install in the reverse order of removal Align marks Attach each joint Screw clamps firmly Clamp tightening torque 4 5 N m 0 46 kg m 40 in Ib n S pect i O n INFOID 0000000003733417 INSPECTION AFTER REMOVAL Inspect air duct assembly for crack or tear e If damage is found replace air duct assembly Revision 2009 March EM 178 2009 FX35 FX50 INTAKE MANIFOLD lt REMOVAL AND INSTALLATION gt VKSOVE INTAKE MANIFOLD Exploded View INFOID 0000000003733418 SEC 118 140 163 211 223 JPBIA2075GB EVAP canister purge control sole 1 2 Clamp 3 EVAP hose noid valve 4 EVAP hose 5 EVAP hose 6 _EVAP tube 7 Electric throttle control actuator 8 Water hose 9 Clamp bank 2 10 Gasket 11 Water hose 12 Water pipe 13 Gasket 14 Acoustic absorbent 15 Water hose 16 Water hose 17 Electric throttle control actuator 18 PCV hose bank 1 19 Vacuum hose 20 Manifoldabsolute pressure MAP 21 Intake manifold sensor 22 PCV hose 23 EVAP hose 24 Vacuum tank 25 EVAP service port hose 26 Clamp Revision 2009 March E
204. front oil seal 2 Install front oil seal e Install front oil seal so that each seal lip is oriented as shown in the figure A Oil seal lip B Dust seal lip lt Engine inside 4m Engine outside JPBIA0054ZZ e Using a suitable drift press fit until the height of front oil seal is level with the mounting surface Suitable drift outer diameter 60 mm 2 36 in inner diameter 50 mm 1 97 in e Check the garter spring is in position and seal lips are not inverted CAUTION e Be careful not to damage front timing chain case and crankshaft Press fit straight and avoid causing burrs or tilting oil seal 3 Install in the reverse order of removal after this step REAR OIL SEAL REAR OIL SEAL Removal and Installation INFOID 0000000003887367 PBIC2931E REMOVAL 1 Remove transmission assembly Refer to TM 199 2WD Exploded View 2WD models or TM 202 AWD Exploded View AWD models 2 Remove drive plate Refer to EM 117 Exploded View 3 Remove rear oil seal with a suitable tool CAUTION Revision 2009 March EM 80 2009 FX35 FX50 OIL SEAL lt REMOVAL AND INSTALLATION gt VQ35HR Be careful not to damage crankshaft and cylinder block INSTALLATION 1 Install rear oil seal e Install rear oil seal so that each seal lip is oriented as shown in the figure A Oil seal lip B Dust seal lip lt Engine inside 4m Engine outside JPBIA0054ZZ e Press in rear oil seal 1 t
205. ft 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 e Identify installation positions and store them without mixing them up 13 Remove pilot converter using the pilot bushing puller commercial service tool if necessary 14 Remove oil jet ASSEMBLY 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 Revision 2009 March EM 258 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE 2 Install each plug to cylinder block as shown in the figure lt Engine front e 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 65 0 N m 6 6 kg m 48 ft lb e Replace washers 1 5 with new ones e Apply sealant to the thread of water drain plug 8 Use Genuine RTV Silicone Sealant or an equivalent Refer to Gl 15 Recommended Chemical Products and Seal ants e Apply sealant to the thread of plug 4 Use Genuine High Strength Thread Locking Sealant or an equivalent Refer to Gl 15 Recommended Chemical Products and Sealants 3 Install oil jet e Insert oil jet into cylinder block hole and tighten the mounting bolt on the corner side
206. fuel leakage Turn ignition switch to the ON position 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 NOTE If hydraulic pressure inside chain tensioner drops after removal installation slack in guide may generate a pounding noise during and just after the engine start However this does not indicate a malfunction The noise will stop after hydraulic pressure rises Warm up engine thoroughly to check that there is no leakage of fuel 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 them to the specified level if necessary Revision 2009 March EM 253 2009 FX35 FX50 Summary of the inspection items CYLINDER HEAD lt UNIT DISASSEMBLY AND ASSEMBLY gt VK50VE Items Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluids Level Leakage Level Fuel Leakage Leakage Leakage Transmission transaxle CVT fluid power steering fluid brake fluid etc Revision 2009 March EM 254 2009 FX35 FX50 CYLINDER BLOCK
207. fuel ratio sensor 1 e Discard any air fuel ratio sensor 1 which has been dropped onto a hard surface such as a concrete floor Replace with a new sensor 13 Remove exhaust manifold cover upper bank 1 and bank 2 14 Loosen mounting nuts in the reverse order as shown in the fig ure to remove exhaust manifold A Bank 1 B Bank2 lt Engine front NOTE Disregard the numerical order No 7 and 8 in removal JPBIA0017ZZ 15 Remove gaskets CAUTION Cover engine openings to avoid entry of foreign materials INSTALLATION Note the following item and install in the reverse order of removal Revision 2009 March EM 37 2009 FX35 FX50 EXHAUST MANIFOLD lt REMOVAL AND INSTALLATION gt VQ35HR EXHAUST MANIFOLD GASKET oa e Install exhaust manifold gasket in direction shown in the figure Follow same procedure for both banks A Bank 1 B Triangle press C Bank2 lt Engine front JPBIA0019ZZ EXHAUST MANIFOLD e If stud bolts were removed install them and tighten to the specified torque below Tightening torque Refer to EM 36 Exploded View e Install exhaust manifold and tighten mounting nuts in numerical order as shown in the figure A Bank 1 B Bank2 lt Engine front NOTE Tighten nuts No 1 and 2 in two steps The numerical order No 7 and 8 shows second step JPBIA0017ZZ AIR FUEL RATIO SENSOR 1 HEATED OXYGEN SENSOR 2 CAUTION Before installing a new sensors
208. g m 8 ft lb e Tighten mounting bolts and nuts in numerical order as shown in the figure lt 2 Engine front Ta Ta an Tan a a n SIS cao 1 320000 4 WATER HOSE e Insert hose by 27 to 32 mm 1 06 to 1 26 in from connector end e Clamp hose at location of 3 to 7 mm 0 12 to 0 28 in from hose end ELECTRIC THROTTLE CONTROL ACTUATOR BANK 1 AND BANK 2 Revision 2009 March EM 32 2009 FX35 FX50 INTAKE MANIFOLD COLLECTOR lt REMOVAL AND INSTALLATION gt VQ35HR e Tighten in numerical order as shown in the figure NOTE e The figure shows the electric throttle control actuator bank 1 viewed from the air duct side e Viewed from the air duct side order of tightening mounting bolts of electric throttle control actuator bank 2 is the same as that of the electric throttle control actuator bank 1 Perform the Throttle Valve Closed Position Learning when har ness connector of electric throttle control actuator is disconnected Refer to EC 25 THROTTLE VALVE CLOSED POSITION LEARNING Description Perform the Idle Air Volume Learning and Throttle Valve Closed Position Learning when electric throttle control actuator is replaced Refer to EC 25 IDLE AIR VOLUME LEARNING Description and EC 25 THROTTLE VALVE CLOSED POSITION LEARNING Description JPBIA0011ZZ Revision 2009 March EM 33 2009 FX35 FX50 INTAKE MANIFOLD lt REMOVAL AND INSTALLATION gt VQ35HR INTAKE MANIFOLD
209. g rod bearing oil clearance is not obtained with standard size connecting rod bearings use undersize US bearings e When using undersize US bearing measure the connecting rod bearing inner diameter with bearing installed and grind crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard CAUTION In grinding crankshaft pin to use undersize bearings keep the fillet R A 1 5 1 7 mm 0 059 0 067 in JPBIA0216ZZ Bearing undersize table Refer to EM 152 Connecting Rod Bearing M ai n Bea ri n g INFOID 0000000003887395 WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE USED 1 MAIN BEARING SELECTION TABLE rows correspond to bearing housing grade on rear left side of cylinder block Bearing housing grade No 1 VAY VAVYR T g Bearing housing grade No 2 S a lt p AGO Bearing housing grade No 3 4 EX XK XAK XD Bearing housing grade No 4 Cylinder bore grade No Cylinder bore grade No 2 Cylinder bore grade No 3 Cylinder bore grade No 4 5 6 JPBIA0268ZZ Cylinder bore grade No Cylinder bore grade No Identification code Ao rata nmvoeawva gt if Engine front 2 MAIN BEARING SELECTION TABLE columns correspond to journal diameter grade on front side of crankshaft Journal diameter grade No 1 Journal diameter grade No 2 Journal diameter grade No 3 Journal diameter grade No 4 Pin diameter grade No VENIEN EXP ENE
210. gement DOHC Firing order 1 8 7 3 6 5 4 2 Compression 2 Number of piston rings Oil 1 Number of main bearings 5 Compression ratio 10 9 Standard 1 667 17 242 ak ice dae Minimum 1 226 12 5 178 kPa kg cm psi 200 rpm Differential limit between cylinders 98 1 0 14 Cylinder number SEM957C Unit degree Intake valve open BTDC 66 61 Intake valve close ABDC 71 84 Valve timing Exhaust valve open BBDC 32 62 Exhaust valve close ATDC 2 28 Drive Belts INFOID 0000000003733464 DRIVE BELT Tension of drive belts Belt tension is not necessary as it is automatically adjusted by drive belt auto tensioner Spark Plug SPARK PLUG INFOID 0000000003733465 Unit mm in Make DENSO Standard type FXE22HR11 Revision 2009 March EM 282 2009 FX35 FX50 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VK50VE Standard 1 1 0 043 Gap Limit 1 4 0 055 Exhaust Manifold INFOID 0000000003733467 EM EXHAUST MANIFOLD Unit mm in Items Limit Surface distortion Exhaust manifold 0 7 0 028 Ca m S h aft INFOID 0000000003733468 CAMSHAFT EXH Unit mm in Items Standard Limit No 1 0 045 0 086 0 0018 0 0034 Camshaft EXH journal oil clearance No 2 3 4 5 0 030 0 071 0 0012 0 0028 0 150 0 0059 VVEL ladder assembly bracket inner diameter EXH side 26 000 26 021 1 0236 1 0244 No 1 25 935 25 955 1 0211 1 0218 C
211. gnition coil and spark plug from each cylinder Refer to EM 50 Exploded View 6 Connect engine tachometer not required in use of CONSULT III 7 Install compression gauge with an adapter commercial service tool onto spark plug hole PBICO900E e Use the adapter hat has a smaller than 20 mm 0 79 in a as shown in the figure Otherwise it may be caught by cylinder head during removal a 20mm 0 79 in 8 With accelerator pedal fully depressed turn ignition switch to START for cranking When the gauge pointer stabilizes read the compression pressure and the engine rpm Perform these steps to check each cylinder Compression pressure _ Refer to EM 142 General Specification CAUTION Always use a fully charged battery to obtain the specified engine speed e If the engine speed is out of the specified range check battery liquid for proper gravity Check the engine speed again with normal battery gravity Refer to PG 3 How to Handle Battery e If compression pressure is below minimum value check valve clearances and parts associated with combustion chamber valve valve seat piston piston ring cylinder bore cylinder head cylinder head gasket After the checking measure compression pressure again Revision 2009 March EM 25 2009 FX35 FX50 COMPRESSION PRESSURE lt PERIODIC MAINTENANCE gt VQ35HR e If some cylinder has low compression pressure pour small amount of engine oil into the spark plug hole of the
212. hain secondary A Intake side B Exhaust side NOTE Matching mark punched in the figure is for checking loose at this step be JPBIAO114ZZ Revision 2009 March EM 61 2009 FX35 FX50 TIMING CHAIN lt REMOVAL AND INSTALLATION gt VQ35HR c After confirming the matching marks are aligned tighten camshaft sprocket mounting bolts e Secure camshaft using a wrench at the hexagonal portion to tighten mounting bolts d Pull stopper pins 2 out from timing chain tensioners second ary 1 A Bank1 B Bank 2 JPBIA0087ZZ 4 Install timing chain primary as per the following a Install crankshaft sprocket 1 A Matching mark Front side lt Engine front e Check the matching marks on crankshaft sprocket face the front of the engine JPBIA1108ZZ b Install timing chain primary Revision 2009 March EM 62 2009 FX35 FX50 TIMING CHAIN lt REMOVAL AND INSTALLATION gt VQ35HR e Install timing chain primary so the matching mark punched B on camshaft sprocket INT 1 is aligned with the yellow link A on timing chain while the matching mark notched C on crankshaft sprocket 2 is aligned with the orange link D one on timing chain as shown in the figure 3 Water pump When it is difficult to align matching marks of timing chain pri mary with each sprocket gradually turn camshaft using wrench on the hexagonal portion to align it with the matching marks
213. he Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the ignition ON or engine running DO NOT use air or electric power tools or strike near the sensor s with a hammer Heavy vibration could activate the sensor s and deploy the air bag s possibly causing serious injury When using air or electric power tools or hammers always switch the ignition OFF disconnect the battery and wait at least 3 minutes before performing any service Precaution Necessary for Steering Wheel Rotation after Battery Disconnect INFOID 0000000003887313 NOTE e Before removing and installing any control units first turn the push button ignition switch to the LOCK posi tion then disconnect both battery cables e After finishing work confirm that all control unit connectors are connected properly then re connect both battery cables e Always use CONSULT III to perform self diagnosis as a part of each function inspection after finishing work If a DTC is detected perform trouble diagnosis according to self diagnosis results This vehicle is equipped with a push button ignition switch and a steering lock unit If the battery is disconnected or discharged the steering wheel will lock and cannot be turned Revision 2009 March EM 7 2009 FX35 FX50 PRECAUTIONS lt PRECAUTION gt VQ35HR If turning the steering wheel is required with the battery disconnected or discharged follow the procedure below before starting the repair operation
214. he mag net retarder side up to prevent the cover from falling from magnet retarder Never remove magnet retarder from valve timing control cover Disassembly prohibited parts 23 Remove rocker covers bank 1 and bank 2 Refer to EM 50 Exploded View 24 Obtain No 1 cylinder at TDC of its compression stroke as per the following a Rotate crankshaft pulley clockwise to align timing mark grooved line without color with timing indicator 4m Timing mark grooved line without color b Check that intake and exhaust cam noses on No 1 cylinder engine front side of bank 1 are located as shown in the figure lt Engine front e If not turn crankshaft one revolution 860 degrees and align as shown in the figure 25 Remove crankshaft pulley as per the following a Remove front cross bar Refer to FSU 15 Exploded View 2WD models or FSU 34 Exploded View AWD models b Remove power steering pipe mounting bolt Refer to ST 47 VQ35HR Exploded View Revision 2009 March EM 55 2009 FX35 FX50 TIMING CHAIN lt REMOVAL AND INSTALLATION gt VQ35HR c Remove rear cover plate and set the ring gear stopper SST KV10118600 J 48641 A as shown in the figure 1 Oil pan upper 2 Drive plate lt 7 Vehicle front d Loosen crankshaft pulley bolt and rotate bolt seating surface at 10 mm 0 39 in from its original position 1 Crankshaft pulley CAUTION Never remove crankshaft pulley b
215. he specified torque Otherwise cylinder bores may be distorted in final assembly 3 Cut cylinder bores NOTE Revision 2009 March EM 131 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR e When any cylinder needs boring all other cylinders must also be bored e Do not cut too much out of cylinder bore at a time Cut only 0 05 mm 0 0020 in or so in diameter at a time 4 Hone cylinders to obtain the specified piston to cylinder bore clearance 5 Measure finished cylinder bore for the out of round and taper NOTE Measurement should be done after cylinder bore cools down CRANKSHAFT MAIN JOURNAL DIAMETER e Measure the outer diameter of crankshaft main journals with a micrometer Standard Refer to EM 147 Cylinder Block e If out of the standard measure the main bearing oil clearance Then use undersize bearing Refer to EM 139 Main Bearing CRANKSHAFT PIN JOURNAL DIAMETER e Measure the outer diameter of crankshaft pin journal with a micrometer A Standard Refer to EM 147 Cylinder Block e If out of the standard measure the connecting rod bearing oil clearance Then use undersize bearing Refer to EM 137 Connecting Rod Bearing JPBIA0228ZZ CRANKSHAFT OUT OF ROUND AND TAPER e Measure the dimensions at four different points as shown in the figure on each main journal and pin journal with a micrometer e Out of round is indicated by the difference in the dimens
216. i fold and the cylinder head before removal aligned 1st step o 7 4 N m 0 75 kg m 5 ft lb 2nd step and after O 25 5 N m 2 6 kg m 19 ft Ib JPBIA0013ZZ n S pect i O n INFOID 0000000003887346 INSPECTION AFTER REMOVAL Surface Distortion e Check the surface distortion of the intake manifold mating surface with a straightedge A and a feeler gauge B Limit Refer to EM 143 Intake Manifold e If it exceeds the limit replace intake manifold JPBIA0015ZZ Revision 2009 March EM 35 2009 FX35 FX50 EXHAUST MANIFOLD lt REMOVAL AND INSTALLATION gt VQ35HR EXHAUST MANIFOLD Exploded View INFOID 0000000003887347 SEC 140 208 0 50 0 5 1 37 5 8 E3 E 45 0 4 6 33 9 j 0 25 5 2 6 19 G Marus 11 51 3 eg 5 8 0 59 eek R j A V 2 25 5 2 6 19 o e r o E73 0 45 0 4 6 33 i 3 fl 5 8 0 59 aed JPBIA1909GB 1 Heated oxygen sensor 2 bank 1 2 Air fuel ratio sensor 1 bank 1 3 Exhaust manifold cover upper 4 Exhaust manifold bank 1 5 Exhaust manifold cover lower 6 Gasket 7 Ring gasket 8 Three way catalyst bank 1 9 Gasket 10 Heated oxygen sensor 2 bank 2 11 Gasket 12 Three way catalyst bank 2 13 Ring gasket 14 Exhaust manifold bank 2 15 Exhaust manifold cover lower 16 Gasket 17 Air fuel ratio sensor 1 bank 2 18 Exhaust manifold cover upper Refer to GI 4 Components for symbo
217. iew ssscssessersersessesseeseesiesneeseetesneenes 167 Sethi AA E E E E 202 Removal and Installation 0 0 0 eceeeeeeeeeeeeeeeeee 167 IS BECHON er rE E E ERA 168 ENGINE UNIT cc eeeeeeessseeeeeeeeeeneseeneeeeeeees 204 DiSaSSGOImbly 2 niet derivate ea a vers 204 CAMSHAFT VALVE CLEARANCE 169 PASSO MMB Y ec ceetiez Sor Siete anne eh ances eam hee 204 INS POCTION maa a ie aiid de 169 EXHAUST MANIFOLD AND THREE WAY COMPRESSION PRESSURE sssssssssssssen 173 CATALYST ciccoe sicrscstentceegitroartesceatneseatanee 205 INSPECTION arenie e EN EEA 173 Exploded V EW o on 205 REMOVAL AND INSTALLATION 174 frees and Assembly n se ae ENGINE ROOM COVER s seeeeeeeeeeeeeeseees 174 OIL PAN UPPER 208 Exploded VIEW e cceecceeeeceeeeeeeeeeeeeeeseeeeneeeeeeees 174 Exploded VW aniani 208 Removal and Installation 0 0 0 eecsceeeeeeneeeeeeeeee 175 Disassembly and Assembly ST a 209 DRIVE BELT AUTO TENSIONER AND IDLER INSPECTION aas eie ieina daiar iaaea raadi AS 210 PULLEY A COUPEE 176 TIMING CHAIN Bart wt Oe Ee att DP i Bale 212 EX DIO RCO VION Beets aii e eek 176 Exploded VieW sssssssssssssrrsssssrresrsrnessrnnneeerrenneenns 212 Removal and Installation 0 0 0 eecseeeeeeeeeeeeee 176 Disassembly and ASS mbly cccccccccssccccccsseceeseseee0 213 AIR CLEANER AND AIR DUCT an 177 INSPECTION sorrisi ii AE E E OANE 225 Exploded AE E E EEEE EE AEE E 177 CAMSHAFT OEE EE EEEE EEREN 297 Removal a
218. ify installation positions and store them without mixing them up ASSEMBLY 1 Install valve lifter e Install it in the original position 2 Install camshaft EXH e Distinction between camshaft EXH is performed with the identification mark lt Engine front Paint marks Bank Identification rib E M1 C M2 D Bank 2 A No Green Yes Bank 1 B No Green No iniz 3 Install VVEL ladder assembly as per the following Revision 2009 March EM 230 2009 FX35 FX50 CAMSHAFT lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE a Apply a continuous bead of liquid gasket with tube presser commercial service tool to the cylinder head as shown in the figure A Bank 1 B Bank2 c 303 4 4 4 mm 0 134 0 173 in ea f ptr I CN CAL Y B lt 1 Engine front E mraba a alm ar i inal Eng RA EACE E Use Genuine RTV Silicone Sealant or an equivalent Refer to GI 15 Recommended Chemical Products and Sealants Imanan f TH a tl FUA JPBIA2131ZZ b Tighten mounting bolts in the following step in numerical order as shown A Bank2 B Bank1 lt Engine front i Tighten bolts in numerical order as shown 1 96 N m 0 20 kg m 1 ft Ib ii Tighten bolts in numerical order as shown 5 88 N m 0 60 kg m 4 ft Ib iii Tighten bolts in numerical order as shown 10 4 N m 1 1 kg m 8 ft lb JPBIA2128ZZ 4 Install camshaft sprockets and timing chains Refer to E
219. ignment When replacing and reassembling parts with dowel pins check that dowel pins are installed in the original position Cover openings of engine system with a tape or equivalent if necessary to seal out foreign materials Mark and arrange disassembly parts in an organized way for easy troubleshooting and re 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 in the step Inspection Repair and Replacement INFOID 0000000003887317 Before repairing or replacing thoroughly inspect parts Inspect new replacement parts in the same way and replace if necessary Asse m bly and l n sta latio n INFOID 0000000003887318 Use torque wrench to tighten bolts or nuts to specification When tightening bolts and nuts 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 specified do exactly as specified Replace with new gasket packing oil seal or O ring Dowel pins are used for several parts alignment When replacing and reassembling parts with dowel pins check that dowel pins are installed in the original position Thoroughly wash clean and air blow each part Carefully check engine oil or engine coolant passages for any restriction and bloc
220. il groove between oil strainer and valve timing control solenoid valve Refer to LU 21 Engine Lubrication System and LU 22 Engine Lubrication System Schematic 6 Remove components between valve timing control solenoid valve and camshaft sprocket and then check each oil groove for clogging e Clean oil groove if necessary Refer to LU 21 Engine Lubrication System and LU 22 Engine Lubri cation System Schematic 7 After inspection install removed parts in the reverse order Inspection for Leakage Revision 2009 March EM 243 2009 FX35 FX50 CAMSHAFT lt UNIT DISASSEMBLY AND ASSEMBLY gt The following are procedures for checking fluid leakage lubricant leakage i e Before starting engine check oil fluid levels including engine coolant and engine oil If any are less than the required quantity fill them to the specified level Refer to e Follow the procedure below to check for fuel leakage Turn ignition switch to the ON position 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 e Run engine to check for unusual noise and vibration NOTE VK50VE MA 12 Fluids and Lubricants If hydraulic pressure inside chain tensioner drops after removal installation slack in guide may generate a pounding noise during and just after the engine start Ho
221. ile securely holding the hexagonal part in pulley center of auto tensioner 1 move wrench handle in the direction of arrow loosening direction of belt CAUTION Never place hand in a location where pinching may occur if the holding tool accidentally comes off e Never loosen the hexagonal part in center of auto ten sioner pulley Never turn it clockwise If turned clock wise the complete auto tensioner must be replaced as a unit including the pulley Under the above condition insert a metallic bar A of approxi pines mately 6 mm 0 24 in in diameter hexagonal bar wrench shown as example in the figure through the holding boss to lock auto tensioner pulley arm e Leave auto tensioner pulley arm locked until belt is installed again Remove power steering oil pump belt INSTALLATION Note the following item and install in the reverse order of removal CAUTION e Check drive belts are securely installed around all pulleys e Check drive belts are correctly engaged with the pulley groove e Check for engine oil and engine coolant are not adhered drive belts and pulley groove n S pect i O n INFOID 0000000003733404 INSPECTION AFTER INSTALLATION Revision 2009 March EM 164 2009 FX35 FX50 DRIVE BELTS lt PERIODIC MAINTENANCE gt VK50VE e Turn crankshaft pulley clockwise several times to equalize tension between each pulley and then confirm tension of drive belts at indicator notch on fixed side is with
222. in g 60 mm 2 36 in h 120 mm 4 72 in JPBIA2279ZZ Wear limit Out of round Difference between A and B Refer to EM 287 Cylinder Block Taper limit Difference between C and E e 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 e Oversize piston is provided When using oversize piston re bore cylinder so that the clearance of the piston to cylinder bore satisfies the standard CAUTION When using oversize piston use oversize pistons for all cylinders with oversize piston rings Oversize O S 0 2 mm 0 008 in Piston Skirt Diameter Revision 2009 March EM 268 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VK50VE Measure the outer diameter of piston skirt with a micrometer A Measure point R f EM 2 TA r li BI k Standard efer to 87 Cylinder Bloc JPBIA0227ZZ Piston to Cylinder Bore Clearance Calculate by piston skirt diameter and cylinder bore inner diameter direction B position D Clearance Cylinder bore inner diameter Piston skirt diameter Standard and limit Refer to EM 287 Cylinder Block e If the calculated value exceeds the limit replace piston and piston pin assembly Refer to EM 287 Cylinder Block Re boring Cylinder Bore 1 Cylinder bore size is determined by adding piston to cylinder bore clearance to piston sk
223. in the possible use range Refer to EM 163 Exploded View Revision 2009 March EM 165 2009 FX35 FX50 AIR CLEANER FILTER lt PERIODIC MAINTENANCE gt VKSOVE AIR CLEANER FILTER Removal and Installation INFOID 0000000003733405 REMOVAL 1 Unhook clips A 1 Holder 2 Air cleaner case 2 Remove air cleaner filter 2 from air cleaner case 3 1 Holder INSTALLATION Note the following item and install in the reverse order of removal e Install the air cleaner filter by aligning the seal with the notch of air cleaner case Revision 2009 March EM 166 2009 FX35 FX50 SPARK PLUG lt PERIODIC MAINTENANCE gt VK50VE SPARK PLUG E X p od ed V i ew INFOID 0000000003733406 SEC 111 118 220 A E a Ox E i g A DOQ Qe T I 2 5 0 26 22 A A Paa CT Ai He ene lt Zz qe D 9 7 0 0 71 62 io 7 0 0 71 6 JPBIA2074GB 1 Clamp 2 PCV hose 3 Oil filler cap 4 Oil catcher 5 Ignition coil No 1 6 6 Spark plug 7 Rocker cover bank 2 8 Rocker cover gasket bank 2 9 Rocker cover gasket bank 1 10 Rocker cover bank 1 11 Ignition coil No 7 8 12 PCV hose 13 PCV hose 14 Clamp 15 PCV valve 16 O ring 17 PCV hose A To air duct bank 2 B Refer to EM 191 C To air duct bank 1 D To intake manifold Refer to Gl 4 Components for symbols in the figure Removal and Installation INFOID 0000000003733491 REMOVAL 1 Remove engine co
224. ing valve clearance In cases of removing installing or replacing camshaft and valve related parts or of unusual engine conditions due to changes in valve clearance found malfunctions during stating idling or causing noise perform inspection as follows RS lt Engine front JPBIA0164ZZ 1 Remove rocker covers bank 1 and bank 2 Refer to EM 50 Removal and Installation 2 Measure the valve clearance as per the following Set No 1 cylinder at TDC of its compression stroke e Rotate crankshaft pulley clockwise to align timing mark grooved line without color with timing indicator 4a Timing mark grooved line without color e Check that intake and exhaust cam nose on No 1 cylinder engine front side of bank 1 are located as shown in the fig ure lt Engine front e If not turn crankshaft one revolution 360 degrees and align as shown in the figure b Use a feeler gauge measure the clearance between valve lifter and camshaft Valve clearance Refer to EM 143 Camshaft Revision 2009 March EM 20 2009 FX35 FX50 CAMSHAFT VALVE CLEARANCE lt PERIODIC MAINTENANCE gt VQ35HR e By referring to the figure measure the valve clearances at locations marked x as shown in the table below locations indicated in the figure lt Engine front e No 1 cylinder at compression TDC Measuring position bank 1 A No 1 CYL No 3 CYL No 5 CYL No 1 cylinder atcom
225. ions 2 Measure the camshaft sprocket INT runout with a dial indicator Total indicator reading Limit Refer to EM 283 Camshaft 3 If it exceeds the limit replace camshaft sprocket INT Valve Lifter INT e Check if surface of valve lifter has any wear or crack e If wear or crack is found replace VVEL ladder assembly amp cylinder head assembly Refer to EM 283 Camshaft 4 NOTE Since the valve lifter INT cannot be replaced by the piece VVEL ladder assembly amp cylinder head assembly replacement are 4 required KBIA0182E Valve Lifter Clearance INT VALVE LIFTER OUTER DIAMETER e Measure the outer diameter at 1 2 height of valve lifter INT with a micrometer A since valve lifter is in barrel shape Standard Refer to EM 283 Camshaft JPBIAO125ZZ VALVE LIFTER HOLE DIAMETER Revision 2009 March EM 241 2009 FX35 FX50 CAMSHAFT lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE e Measure the inner diameter of valve lifter hole of cylinder head with an inside micrometer Standard Refer to EM 283 Camshaft VALVE LIFTER CLEARANCE e Valve lifter clearance Valve lifter hole diameter Valve lifter outer diameter Standard Refer to EM 283 Camshaft e If the calculated value is out of the standard replace VVEL ladder assembly amp cylinder head assembly NOTE Since the valve lifter INT cannot be replaced by the piece VVEL ladder assembly amp cylinde
226. ions between d and c at a and b e Taper is indicated by the difference in the dimensions between Limit Refer to EM 147 Cylinder Block e If the measured value exceeds the limit correct or replace crank shaft If corrected measure the bearing oil clearance of the corrected main journal and or pin journal Then select the main bearing and JPBIA0229ZZ or connecting rod bearing Refer to EM 139 Main Bearing and or EM 137 Connecting Rod Bearing CRANKSHAFT RUNOUT e Place V block on precise flat table and support the journals on the both end of crankshaft e Place a dial indicator straight up on the No 3 journal e While rotating crankshaft read the movement of the pointer on a dial indicator Total indicator reading Standard and limit Refer to EM 147 Cylinder Block e If it exceeds the limit replace crankshaft SEM346D CONNECTING ROD BEARING OIL CLEARANCE Method by Calculation Revision 2009 March EM 132 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR e Install connecting rod bearings 1 to connecting rod 2 and con necting rod cap and tighten connecting rod bolts to the specified torque Refer to EM 118 Disassembly and Assembly for the tightening procedure e Measure the inner diameter of connecting rod bearing with an inside micrometer Oil clearance Connecting rod bearing inner diameter Crank shaft pin journal diameter
227. irt diameter Re bored size calculation D A B C where A Piston skirt diameter as measured B Piston to cylinder bore clearance standard value C Honing allowance 0 02 mm 0 0008 in D Bored diameter 2 Install main bearing cap and tighten to the specified torque Otherwise cylinder bores may be distorted in final assembly 3 Cut cylinder bores NOTE e When any cylinder needs boring all other cylinders must also be bored Do not cut too much out of cylinder bore at a time Cut only 0 05 mm 0 0020 in or so in diameter at a time 4 Hone cylinders to obtain the specified piston to cylinder bore clearance 5 Measure finished cylinder bore for the out of round and taper NOTE Perform measurement after cylinder bore cools down CRANKSHAFT MAIN JOURNAL DIAMETER e Measure the outer diameter of crankshaft main journals with a micrometer Standard Refer to EM 287 Cylinder Block e If out of the standard measure the main bearing oil clearance Then use undersize bearing Refer to EM 277 Main Bearing CRANKSHAFT PIN JOURNAL DIAMETER Revision 2009 March EM 269 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE e Measure the outer diameter of crankshaft pin journal with a micrometer A Standard Refer to EM 287 Cylinder Block e If out of the standard measure the connecting rod bearing oil clearance Then use undersize bearing Refer to EM 275 Connecting Rod
228. isassembly and Assembly for the tightening procedure JPBIA0230ZZ Revision 2009 March EM 270 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VK50VE e Measure the inner diameter of connecting rod bearing with an inside micrometer Oil clearance Connecting rod bearing inner diameter Crankshaft pin journal diameter Standard and limit Refer to EM 292 Connecting Rod Bearing e If the calculated value exceeds the limit select proper connecting rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance Refer to EM 274 Description Method of Using Plastigage Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely Cut a plastigage slightly shorter than the bearing width and place it in crankshaft axial direction avoiding oil holes Install connecting rod bearings to connecting rod and connecting rod bearing cap and tighten connecting rod bolts to the specified torque Refer to EM 256 Disassembly and Assembly for the tightening proce dure CAUTION Never rotate crankshaft Remove connecting rod 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 the same as that described in the Method by Calculation ALJ J ri PBIA0231ZZ
229. it aside Refer to ST 47 VQ35HR Exploded View Remove power steering oil pump bracket Remove idler pulley auto tensioner and bracket Remove alternator and alternator bracket Refer to CHG 25 VQ35HR Exploded View Remove water outlet front and water piping Refer to CO 24 Exploded View Remove valve timing control covers bank 1 and bank 2 and gasket as per the following Disconnect valve timing control harness connector Revision 2009 March EM 54 2009 FX35 FX50 TIMING CHAIN lt REMOVAL AND INSTALLATION gt VQ35HR b Loosen mounting bolts in reverse order as shown in the figure A Bank 1 B Bank2 C Dowel pin hole CAUTION Shaft is internally jointed with camshaft sprocket INT cen ter hole When removing keep it horizontal until it is com pletely disconnected c Shaft is engaged with intake side camshaft sprocket center hole on inside pull straight out so as not to tilt until the joint is disengaged e The mating surface of magnet retarder 2 may be fitted with the exhaust side camshaft sprocket via the engine oil Open valve timing control cover 1 carefully e If the mating surface of magnet retarder is fitted with the cam shaft sprocket open the cover within the range that the load is not applied to the harness And then remove it so as to pre vent magnet retarder from dropping CAUTION Be careful not to damage magnet retarder e When carrying valve timing control cover face t
230. ith engine slingers attach proper slingers and bolts described in PARTS CATALOG CAUTION Always be careful to work safely and avoid forceful or uninstructed operations Never start working until exhaust system and engine coolant are cool enough If items or work required are not covered by the engine section refer to the applicable sections Always use the support point specified for lifting Use either 2 pole lift type or separate type lift as much as possible If board on type is used for unavoidable reasons support at rear axle jacking point with transmission jack or similar tool before starting work in preparation for the backward shift of the center of gravity Revision 2009 March EM 196 2009 FX35 FX50 ENGINE ASSEMBLY lt UNIT REMOVAL AND INSTALLATION gt VK50VE e For supporting points for lifting and jacking point at rear axle refer to Gl 26 Garage Jack and Safety Stand and 2 Pole Lift NOTE When removing installing only the engine mounting the hold engine assembly as instructed bellow 1 Remove food assembly Refer to DLK 225 HOOD ASSEMBLY Exploded View 2 Install engine slinger on both front right and front left sides of the engine 3 Hoist the slinger to obtain room for engine assembly CAUTION Use an engine lifter to prevent the engine slinger from fall ing and damaging the rocker cover JPBIA2507ZZ REMOVAL Outline At first remove the engine transmission transfer and fro
231. itioned as shown in the figure No 1 cylinder TDC on its compression stroke 1 Crankshaft key NOTE Though camshaft does not stop at the portion as shown in the figure for the placement of cam nose it is generally accepted camshaft is placed for the same direction of the figure JPBIA0094ZZ Revision 2009 March EM 72 2009 FX35 FX50 CAMSHAFT lt REMOVAL AND INSTALLATION gt VQ35HR 4 Install camshaft brackets No 1 No 2 No 3 No 4 Camshaft brackets bank 1 Exhaust side Intake side Camshaft brackets bank 2 Intake side c gt ro nmo 0u gt Exhaust side o Engine front e Remove foreign material completely from camshaft bracket backside and from cylinder head installation face e Install camshaft bracket in original position and direction as shown in figure JPBIA0258ZZ Install camshaft brackets No 2 to 4 aligning the stamp marks A as shown in the figure B Bank 1 C Bank2 lt Engine front NOTE There are no identification marks indicating bank 1 and bank 2 for camshaft bracket No 1 JPBIA0272ZZ Apply liquid gasket to mating surface of camshaft bracket No 1 as shown on both bank 1 and bank 2 8 5 mm 0 335 in 2 mm 0 08 in Clearance 5 mm 0 20 in 62 5 mm 0 098 in Apply liquid gasket to rear timing chain side ta O g Use Genuine RTV Silicone Sealant or an equivalent Refer to GI 15 Recommended Chemi
232. kage 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 the engine and increase engine speed to check engine coolant fuel engine oil and exhaust gases for leakage Revision 2009 March EM 8 2009 FX35 FX50 PRECAUTIONS lt PRECAUTION gt VQ35HR Parts Requiring Angle Tightening INFOID 0000000003887319 e Use the angle wrench SST KV10112100 BT8653 A for the final tightening of the following engine parts Cylinder head bolts Lower cylinder block bolts Connecting rod cap bolts e Do not use a torque value for final tightening e The torque value for these parts are for a preliminary step e Ensure thread and seat surfaces are clean and coated with engine oil L iq u i d G as ket INFOID 0000000003887320 REMOVAL OF LIQUID GASKET SEALING e After removing mounting bolts and nuts separate the mating sur face using the seal cutter SST KV10111100 J 37228 A and remove old liquid gasket sealing CAUTION Be careful not to damage the mating surfaces Tap the seal cutter to insert it B and then slide it C by tapping on the side as shown in the figure In areas where the seal cutter is difficult to use use a plastic ham mer to lightly tap the parts to remove it CAUTION If for some unavoidable reason tool such as
233. l Other oils and fluids Level Leakage Level Fuel Leakage Leakage Leakage Transmission transaxle CVT fluid power steering fluid brake fluid etc Revision 2009 March EM 201 2009 FX35 FX50 ENGINE STAND SETTING lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE UNIT DISASSEMBLY AND ASSEMBLY ENGINE STAND SETTING S ett i n g INFOID 0000000003733442 NOTE Explained here is how to disassemble with engine stand supporting transmission surface When using a differ ent type of engine stand note the difference in the steps etc 1 Remove the engine assembly from the vehicle Refer to EM 196 Exploded View 2 Remove crankshaft pulley Refer to EM 194 FRONT OIL SEAL Removal and Installation NOTE The drive plate is fixed with a ring gear stopper SST KV10119200 J 49277 Loosen the crankshaft pul ley mounting bolts before installing the engine stand 3 Remove the parts that may restrict installation of engine to a widely used engine stand e Fix crankshaft with a ring gear stopper SST KV10119200 J 49277 Loosen drive plate mounting bolt with power tool e Check for deformation or damage of drive plate Refer to EM 265 Inspection NOTE The procedure is described assuming that you use a widely used engine stand holding the surface to which transmission is installed 4 Remove pilot converter using the pilot bushing puller commercial service tool if necessary 5 Lift the engine with hoist to install i
234. lation 5 Install in the reverse order of removal NOTE At least 30 minutes after oil pan is installed pour engine oil n S pect i O n INFOID 0000000003733447 INSPECTION AFTER DISASSEMBLY Clean oil strainer if any object is attached INSPECTION AFTER ASSEMBLY 1 Check the engine oil level and adjust engine oil Refer to LU 25 Inspection Revision 2009 March EM 210 2009 FX35 FX50 OIL PAN UPPER lt UNIT DISASSEMBLY AND ASSEMBLY gt VK50VE 2 Start engine and check there is no leakage of engine oil 3 Stop engine and wait for 15 minutes 4 Check the engine oil level again Refer to LU 25 Inspection Revision 2009 March EM 211 2009 FX35 FX50 TIMING CHAIN lt UNIT DISASSEMBLY AND ASSEMBLY gt VK50VE TIMING CHAIN Exploded View INFOID 0000000003733434 SEC 120 130 1359221 9 16 7 1 7 12 6 9 0 70 61 W A 0 103 11 76 k 8 1 0 8 fe 6 9 omen 0 16 7 1 7 12 e 0 12 8 1 3 9 0 28 0 2 9 21 Nase o a Kg 7 0 0 71 62 35 0 go 3 6 26 9 12 8 1 3 9 9 9 6 0 98 la ne 9 9 6 0 98 85 JPBIA2120GB 1 O ring 2 O ring 4 Timing chain bank 2 5 7 Slack guide bank 2 3 Tension guide bank 2 Camshaft sprocket INT bank 2 6 Camshaft sprocket EXH bank 2 Timing chain tensioner bank 2 9 Crankshaft sprocket Revision 2009 March EM 212 8 2009 FX35 FX50 TIMING CHAIN lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE 10
235. lculated value is out of the standard replace piston and piston pin assembly e When replacing piston and piston pin assembly refer to EM 274 Description NOTE Piston is available together with piston pin as assembly PISTON RING SIDE CLEARANCE e Measure the side clearance of piston ring 1 and piston ring groove with a feeler gauge C A OK B NG Standard and limit Refer to EM 287 Cylinder Block e If the measured value exceeds the limit replace piston ring and measure again If it still exceeds the limit replace piston also JPBIA2276ZZ PISTON RING END GAP e Check that the cylinder bore inner diameter is within the specifica tion e Lubricate with new engine oil to piston 1 and piston ring 2 and then insert piston ring until middle of cylinder with piston and mea sure the piston ring end gap with a feeler gauge B A Press fit Standard and limit Refer to EM 287 Cylinder Block e If the measured value exceeds the limit replace piston ring and measure again If it still exceeds the limit re bore cylinder and use anere oversize piston and piston rings CONNECTING ROD BEND AND TORSION e Check with a connecting rod aligner A Bend B Torsion C Feeler gauge Bend limit Refer to EM 287 Torsion limit Cylinder Block e If it exceeds the limit replace connecting rod assembly JPBIA0221ZZ CONNECTING ROD BIG END DIAMETER Revision 2009 March EM 266 2
236. ley Refer to EM 176 Exploded View 2 Remove oil level gauge and oil level gauge guide Refer to EM 212 Exploded View 3 Remove alternator bracket and alternator stay Revision 2009 March EM 213 2009 FX35 FX50 TIMING CHAIN lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE 4 Remove camshaft position sensors A Keep free from magnetic materials CAUTION Handle carefully to avoid dropping and shocks e Never disassemble Never allow metal powder to adhere to magnetic part at sensor tip Never place sensors in a location where they are exposed to magnetism JPBIA0454ZZ 5 Remove valve timing control cover as per the following Disconnect valve timing control solenoid valve harness connector b Loosen mounting bolts in the reverse order as shown in the fig ure w A Bank2 B Banki C Dowel pin hole CAUTION e Exercise care not to damage mating surfaces e Shaft is internally jointed with camshaft sprocket center hole When removing keep it horizontal until it is com pletely disconnected 6 Remove valve timing control solenoid valve INT and EXH if necessary CAUTION Valve timing control solenoid valve is not reusable Never remove it unless required 7 Remove O rings 1 from front cover JPBIA2117ZZ 8 Remove rocker cover Refer to EM 191 Exploded View 9 Obtain No 1 cylinder at TDC of its compression stroke Refer to EM 169 Inspection 10 Remove crankshaft pulley
237. limited portion as shown in the figure a 4 0 5 0 mm 0 157 0 197 in lt Engine front Use Genuine RTV Silicone Sealant or an equivalent Refer to GI 15 Recommended Chemical Products and Sealants CAUTION e For bolt holes with 4 marks 7 locations apply liquid gasket outside the holes Attaching must be done within 5 minutes after coating d Install oil pan upper CAUTION Install avoiding misalignment of O rings JPBIA0388ZZ Revision 2009 March EM 105 2009 FX35 FX50 OIL PAN UPPER lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR e Tighten mounting bolts in numerical order as shown in the fig ure lt Engine front e There are three types of mounting bolts Refer to the following for locating bolts M8 x 25 mm 0 98 in 3 6 8 9 11 12 14 15 16 M8 x 50 mm 1 97 in 72 M8 x 90 mm 3 54 in 1 4 5 7 10 13 3 Install oil strainer to oil pump 4 Install oil pan lower Refer to EM 47 Removal and Installation 5 Install oil pan drain plug e Refer to the figure of components of former page for installation direction of drain plug washer Refer to EM 103 AWD Exploded View 6 Install in the reverse order of removal after this step NOTE At least 30 minutes after oil pan is installed pour engine oil AWD Inspection INFOID 0000000003887385 INSPECTION AFTER REMOVAL Clean oil strainer if any object attached INSPECTION AFTER INSTALLATION 1 2 3 4
238. link Refer to FSU 32 Exploded View w Removal Work 1 Use a manual lift table caddy commercial service tool or an equivalently rigid tool such as a transmission jack Securely sup port bottom of suspension member and the transmission assem bly CAUTION Use a piece of wood or a similar item as the supporting sur face to secure a completely stable condition PBIC0804E 2 Loosen rear engine mounting member mounting bolts Loosen front suspension member mounting bolts Refer to FSU 37 Exploded View 4 Carefully lower jack or raise lift to remove the engine the transmission assembly and front suspension member When performing work observe the following caution items CAUTION w Revision 2009 March EM 198 2009 FX35 FX50 ENGINE ASSEMBLY lt UNIT REMOVAL AND INSTALLATION gt VK50VE e Confirm there is no interference with the vehicle e Check that all connection points have been disconnected Keep in mind that the center of gravity of the vehicle changes If necessary use jack s to sup port the vehicle at rear jacking point s to prevent it from falling off the lift Separation Work 1 Install engine slingers into front of cylinder head bank 1 and i rear of cylinder head bank 2 1 Engine front slinger bank 1 2 Engine rear slinger bank 2 lt 2 Engine front Slinger bolts O 45 0 N m 4 6 kg m 33 ft lb 2 Hang the lifting hook of a two point engine lifter co
239. ls in the figure Re m oval a n d n stal lat i O n INFOID 0000000003887348 REMOVAL WARNING Perform the work when the exhaust and cooling system have completely cooled down NOTE When removing bank 1 side parts only step 2 5 and 10 are unnecessary 1 N D Ole ON Remove engine undercover with power tool Drain engine coolant Refer to CO 8 Draining Remove engine cover with power tool Refer to EM 27 Exploded View Remove air cleaner case and air duct Refer to EM 29 Exploded View Remove heater pipe and water hose Refer to CO 24 Exploded View Remove exhaust front tube Refer to EX 5 Exploded View Disconnect heated oxygen sensor 2 harness connectors bank 1 and bank 2 and remove harness clip Revision 2009 March EM 36 2009 FX35 FX50 EXHAUST MANIFOLD lt REMOVAL AND INSTALLATION gt VQ35HR 8 Using heated oxygen sensor wrench SST KV10114400 J 38365 C removal heated oxygen sensor 2 A Bank 2 B Bank 1 lt o __ Vehicle front 9 Remove three way catalysts bank 1 and bank 2 10 Disconnect steering lower joint at power steering gear assembly side and release steering lower shaft 11 Disconnect air fuel ratio sensor 1 harness connectors bank 1 and bank 2 and remove harness clip 12 Using the heated oxygen sensor wrench SST KV10114400 J 38365 C remove air fuel ratio sensor 1 bank 1 and bank 2 A Bank2 B Bank 1 CAUTION Be careful not to damage air
240. ly if it is splashed 5 Perform the following inspection if engine oil does not come out from intake valve timing control solenoid valve oil hole of the cylinder head e Remove oil filter and then clean it Refer to EM 53 Exploded View e Clean oil groove between oil strainer and intake valve timing control solenoid valve Refer to LU 3 Engine Lubrication System and LU 3 Engine Lubrication System Schematic 6 Remove components between intake valve timing control solenoid valve and camshaft sprocket INT and then check each oil groove for clogging e Clean oil groove if necessary Refer to LU 3 Engine Lubrication System and LU 3 Engine Lubrica tion System Schematic 7 After inspection install removed parts in the reverse order Inspection for Leakage The following are procedures for checking fluids leakage lubricates leakage 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 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 leak age 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 NOTE If hydraulic pressure inside timing chain tensioner drops after rem
241. m this step when engine is cold e Never spill engine coolant on drive belt b Disconnect water hoses from electric throttle control actuator When engine coolant is not drained from radiator attach plug to water hoses to prevent engine coolant leakage c Disconnect harness connector d Loosen mounting bolts in reverse order as shown in the figure NOTE e When removing only intake manifold collector move electric throttle control actuator without disconnecting the water hose e The figure shows the electric throttle control actuator bank 1 viewed from the air duct side e Viewed from the air duct side order of loosening mounting bolts of electric throttle control actuator bank 2 is the same as that of the electric throttle control actuator bank 1 CAUTION Handle carefully to avoid any impact to electric throttle con trol actuator 4 Disconnect vacuum hose PCV hose and EVAP hose from intake manifold collector JPBIAO011ZZ 5 Remove EVAP canister purge volume control solenoid valve and EVAP tube assembly from intake mani fold collector 6 Loosen mounting bolts and nuts with power tool in the reverse order as shown in the figure to remove intake manifold collector lt Engine front INSTALLATION Note the following item and install in the reverse order of removal INTAKE MANIFOLD COLLECTOR e If stud bolts were removed install them and tighten to the specified torque below 10 8 N m 1 1 k
242. margin T Exhaust 1 3 0 051 Valve margin T limit 0 5 0 020 Valve stem end surface grinding limit 0 2 0 008 VALVE GUIDE Unit mm in SEM950E Items Standard Oversize Service 0 2 0 008 Wai Outer diameter 10 023 10 034 0 3946 0 3950 10 223 10 234 0 4025 0 4029 alve guide 3 Inner diameter Finished size 6 000 6 018 0 2362 0 2369 Cylinder head valve guide hole diameter 9 975 9 996 0 3927 0 3935 10 175 10 196 0 4006 0 4014 Interference fit of valve guide 0 027 0 059 0 0011 0 0023 Items Standard Limit Intake 0 020 0 053 0 0008 0 0021 0 08 0 0031 Valve guide clearance Exhaust 0 030 0 056 0 0012 0 0022 0 09 0 0035 Projection length L 12 6 12 8 0 496 0 504 VALVE SEAT Unit mm in PBIC2745E Items Standard Oversize Service 0 5 0 02 f Intake 38 000 38 016 1 4961 1 4967 38 500 38 516 1 5157 1 5164 Cylinder head seat recess diameter D Exhaust 31 600 31 616 1 2441 1 2447 32 100 32 116 1 2638 1 2644 Intake 38 097 38 113 1 4999 1 5005 38 597 38 613 1 5196 1 5202 Valve seat outer diameter d Exhaust 31 680 31 696 1 2472 1 2479 32 180 32 196 1 2669 1 2676 Intake 0 081 0 113 0 0032 0 0044 Valve seat interference fit Exhaust 0 064 0 096 0 0025 0 0038 Revision 2009 March EM 146 2009 FX35 FX50 SERVICE DATA AND SP
243. marks 0 2 483 2 486 0 0978 0 0979 Black 1 2 486 2 489 0 0979 0 0980 Brown 2 2 489 2 492 0 0980 0 0981 Green 3 2 492 2 495 0 0981 0 0982 Yellow ides thesanie 4 2 495 2 498 0 0982 0 0983 Blue for upper and lower 5 2 498 2 501 0 0983 0 0985 Pink bearings 6 2 501 2 504 0 0985 0 0986 Purple 7 2 504 2 507 0 0986 0 0987 White 8 2 507 2 510 0 0987 0 0988 Red ji UPR 2 483 2 486 0 0978 0 0979 Black LWR 2 486 2 489 0 0979 0 0980 Brown UPR 2 486 2 489 0 0979 0 0980 Brown ia LWR 2 489 2 492 0 0980 0 0981 ee Green 0 783 0 791 35 UPR 2 489 2 492 0 0980 0 0981 Green LWR 2 492 2 495 0 0981 0 0982 Yellow UPR 2 492 2 495 0 0981 0 0982 Yellow i LWR 2 495 2 498 0 0982 0 0983 Blue Grade and color are different for upper j UPR 2 495 2 498 0 0982 0 0983 Blue and lower bearings LWR 2 498 2 501 0 0983 0 0985 Pink UPR 2 498 2 501 0 0983 0 0985 Pink i LWR 2 501 2 504 0 0985 0 0986 Purple a UPR 2 501 2 504 0 0985 0 0986 Purple LWR 2 504 2 507 0 0986 0 0987 White os UPR 2 504 2 507 0 0986 0 0987 White LWR 2 507 2 510 0 0987 0 0988 Red UNDERSIZE Unit mm in Items Thickness Main journal diameter 0 25 0 0098 2 618 2 626 0 1031 0 1034 Grind so that bearing clearance is the specified value MAIN BEARING OIL CLEARANCE Unit mm in Items Standard Limit Main bearing oil clearanc
244. ming chain case the dowel pin of magnet retarder may not be aligned with the dowel pin holes of cover In this case return to step b d Being careful not to move seal ring from the installation groove align dowel pins on front timing chain case with holes to install valve timing control covers e Tighten mounting bolts in numerical order as shown in the fig ure A Bank1 B Bank2 C Dowel pin hole Tightening torque Refer to EM 53 Exploded View e After all bolts are tightened tighten No 1 bolt to the specified torque again JPBIA0041ZZ 12 Install oil pan lower Refer to EM 46 Exploded View Revision 2009 March EM 67 2009 FX35 FX50 TIMING CHAIN lt REMOVAL AND INSTALLATION gt VQ35HR 13 Install rocker covers bank 1 and bank 2 Refer to EM 50 Exploded View 14 Install crankshaft pulley as per the following a Fix crankshaft using the ring gear stopper SST KV10118600 J 48641 b Install crankshaft pulley taking care not to damage front oil seal e When press fitting crankshaft pulley with plastic hammer tap on its center portion not circumference c Tighten crankshaft pulley bolt O 44 1 N m 4 5 kg m 33 ft lb d Place a matching mark A on crankshaft pulley 2 aligning with the matching mark C of crankshaft pulley bolt 1 Tighten the bolt 90 degrees one marks b e Rotate crankshaft pulley in normal direction clockwise when viewed from front to confirm
245. mmercial ser vice tool A from the front and rear engine slingers to hoist engine and flywheel housing assembly For the flywheel housing side use a webbing slinger B or an equivalent to hoist the assembly horizontally CAUTION Always hoist the engine by using a two point engine lifter i e hoisting the front and rear slingers from one point in the air or the rocker cover and parts around the engine may be damaged due to the fall of the engine slinger JPBIA2509ZZ 3 Remove power steering oil pump from engine side Refer to ST 40 VK50VE Exploded View Remove engine mounting insulators RH and LH under side nuts with power tool 5 Lift with hoist and separate the engine transmission transfer and front final drive assembly from front suspension member CAUTION Before and during this lifting always check that any harnesses are left connected e Never damage engine mounting insulator and avoid oil grease smearing or spills onto engine mounting insulator gt A 6 Remove alternator Refer to CHG 28 VK50VE Exploded View 7 Separate the engine from the transmission assembly Refer to TM 384 Exploded View 8 Remove front propeller shaft Refer to DLN 109 VK50VE Exploded View 9 Remove the front final drive assembly from oil pan upper Refer to DLN 149 VK50VE Exploded View 10 ie ii each engine mounting insulator and each engine mounting bracket from the engine with power tool INSTAL
246. n place to protect removed crankshaft pul ley from dropping 3 Remove front oil seal using a suitable tool CAUTION Be careful not to damage front cover and crankshaft INSTALLATION 1 Install front oil seal on front cover lt Engine inside 4 Engine outside e Apply new engine oil to both oil seal lip A and dust seal lip B e Install it so that each seal lip is oriented as shown in the figure CAUTION Be careful not to scratch or make burrs on circumference of oil seal JPBIA0054ZZ e Using a suitable drift outer diameter 56 mm 2 20 in press fit oil seal until it becomes flush with front cover end face e Check the garter spring is in position and seal lips are not inverted 2 Install in the reverse order of removal REAR OIL SEAL Revision 2009 March EM 194 2009 FX35 FX50 INFOID 0000000003733437 OIL SEAL lt REMOVAL AND INSTALLATION gt VKSOVE REAR OIL SEAL Removal and Installation ihre nacondaseeeaess REMOVAL 1 Remove transmission assembly Refer to TM 384 Exploded View 2 Remove drive plate Refer to EM 255 Exploded View 3 Remove rear oil seal with a suitable tool CAUTION Be careful not to damage crankshaft and cylinder block Oil seal retainer INSTALLATION 1 Install rear oil seal e Install rear oil seal so that each seal lip is oriented as shown in the figure A Oil seal lip B Dust seal lip lt Engine inside Engine outside JPBIA0054ZZ e Press in rear oil
247. nd Staal szg ena 1 Exploded VieW susoni a E 227 INSPOCTION e aae T RRA 178 Disassembly and Assembly sssssssssccseseeeessssseee 228 INTAKE MANIFOLD cccccccccccccccccececececcceccecees 179 Inspec sarraa aA es 236 Exploded VEW e enee a dines 179 CYLINDER HEAD ec cet n Ona ia 245 Removal gid NIST AOD sisichapa 120 Exploded View areneks ia aS 245 Revision 2009 March EM 3 2009 FX35 FX50 Disassembly and Assembly ccceeeeeeeee 246 SERVICE DATA AND SPECIFICATIONS WAS POCUON staves ett dasa tinea E toed 251 SDS sccscveusscetarsnunnatocteseseddateranieonneceatieueid 282 E ee aorta E E me SERVICE DATA AND SPECIFICATIONS AP OSS v TON eneee cia Magee ag SDS na A 282 Disassembly and ASSeEMDIYy sacha eaiekish clea 256 fa Specification cc cccccesssecceeeessteeeeeeeaes 282 INSpECHON ate ecteceas at aati estate eetatin teehee tei 265 Drive Belts iiiaio iS 282 HOW TO SELECT PISTON AND BEARING 274 Spark Plug sooteneeeneeneeeeeneeeeeeneenseettaneenetaneeneeanetnass 282 Descriptions esna a E R 274 Exhaust Manifold 0 reesei ens ETES Wiese EAA TAE EE T 274 Camshaft eeereseeesseeceeeeeceeeeeeenteeenneeennntecenneeennaten 283 Connecting Rod Bearing s s 275 Cylinder Head oo cistl cant e S 285 Main Bearing rite escunin iccncane uscchs etoedsAcncs uate ates 277 vance Seger capes acca aaa a Connecting Rod Bearing ccccesceeeteeeteeees 292 EM 4 Revision 2009 March 2009 FX35 FX50 NOISE VIBRATION AND HARSHN
248. ne oil or engine coolant passages 2 At each of several locations on bottom surface of cylinder head measure the distortion in six directions A B C D E and F Limit Refer to EM 145 Cylinder Head e If it exceeds the limit replace cylinder head INSPECTION AFTER DISASSEMBLY Valve Dimensions e Check the dimensions of each valve For the dimensions refer to EM 145 Cylinder Head e If dimensions are out of the standard replace valve and check valve seat contact Refer to VALVE SEAT CONTACT Valve Guide Clearance Valve Stem Diameter e Measure the diameter of valve stem with micrometer A Standard Refer to EM 145 Intake and exhaust Cylinder Head Valve Guide Inner Diameter f e Measure the inner diameter of valve guide with bore gauge Standard Refer to EM 145 Intake and exhaust Cylinder Head JPBIAO183ZZ Revision 2009 March EM 114 2009 FX35 FX50 CYLINDER HEAD lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR Valve Guide Clearance a f f e Valve guide clearance Valve guide inner diameter Valve stem diameter Val i l TEUER TE Refer to EM 145 Cylinder Head Standard and limit Intake and exhaust EM e If the calculated value exceeds the limit replace valve and or valve guide When valve guide must be replaced refer to EM 107 Disassembly and Assembly Valve Seat Contact e After confirming that the dimensions of valve guides and valves are within the
249. nesrnnnnnseeennens 15 CHECKING ieena t TE E N 15 EXHAUST MANIFOLD 2 00 ccccececcccecccececcececececees 36 Tension Adjustment c cesses 15 Exploded VIEW sci snisieecsaniesinvahachiatucsednaetesteaniabieeesate 36 Removal and Installation 0 00 0 eeeeeeeeesteeeeeeeeee 15 Removal and Installation ccccccccccccccccccccccecceecseseeeees 36 INSPOCHION 0 seessseesesetteeseseetees tenets eeteseteseeneteaneas 16 Inspechone d ar e A 38 EM 1 Revision 2009 March 2009 FX35 FX50 FUEL INJECTOR AND FUEL TUBE 40 OIL PAN UPPER a iiicccaiisteecsetasaderducdentvcrecunnetes 100 Exploded View ccccesssecceteesseeeeeeeeseneeeteeseneeeeees 40 Removal and Installation Sade tte toca SB Slates Naps toa 40 2WD Serer e rrr rrr rrr rrr rr trey nannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 100 WAS DE CHOI dieen ania a E aa 45 2WD Exploded View nssssssssssssssrnsnrrinrsnsennnnnnns 100 2WD Disassembly and Assembly aa 100 OIL PAN LOWER AND OIL STRAINER 46 QWD Inspection 0 0 ee eeeeee eee eeeeteeeeeeeeeteteeeteeeees 102 Exploded VIEW ar E 46 Remova and naO a a a 47 AWD coseeeaseeeaseeeaenensecaneeeaneeeaneeeeseeenaeenaaeeenaeeenaeeeaaees 102 IMSPOCUION 14 erioa bese eee E hte testes 49 aidia Exploded NN oa e et el nee on 103 AWD Disassembly and Assembly n 103 IGNITION COIL SPARK PLUG AND ROCK AWD Inspection 0 2 22 cee eeeeeeeeeeeceeceeeeeeeeeeeeeeeeeee 106 ER COVER TTE 50 CYLIND
250. new engine oil Never clean O ring with solvent e Check that O ring and its mating part are free of foreign material When installing O ring be careful not to scratch it with tool or fingernails Also be careful not to twist or stretch O ring If O ring was stretched while it was being attached never insert it quickly into fuel tube e Insert new O ring straight into fuel tube Never decenter or twist it Install spacer A to fuel damper Insert fuel damper straight into fuel tube bank 1 CAUTION Insert straight check that the axis is lined up Insert fuel damper at 130 N 13 3 kg 29 2 Ib or less to pre JPBIA2087ZZ vent damage to the parts Insert fuel damper until the rim C reaches the cap flange B Tighten mounting bolts evenly in turn e After tightening mounting bolts check that there is no gap between flange and fuel tube bank 1 Install fuel feed damper Revision 2009 March EM 184 2009 FX35 FX50 FUEL INJECTOR AND FUEL TUBE lt REMOVAL AND INSTALLATION gt VK50VE e Handling procedure of O ring is the same as that of fuel damper e Insert fuel feed damper straight into fuel tube bank 2 CAUTION Insert fuel feed damper at 147 N 15 kg 33 1 Ib or less to prevent damage to the parts Tighten mounting bolts evenly in turn EM e After tightening mounting bolts check that there is no gap between flange and fuel tube bank 2 3 Install new O rings to fuel injector paying attention t
251. ng procedure A Crush height Standard There must be crush height e If the standard is not met replace main bearings JPBIA0233ZZ CONNECTING ROD BEARING CRUSH HEIGHT e When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings 1 installed the tip end of bearing must protrude Refer to EM 118 Disassem bly and Assembly for the tightening procedure A Crush height Standard There must be crush height If the standard is not met replace connecting rod bearings JPBIA0233ZZ LOWER CYLINDER BLOCK BOLT OUTER DIAMETER e Measure the outer diameters c d at two positions as shown in the figure a 20 mm 0 79 in b lt 30 mm 1 181 Z TBB e 10 mm 0 39 in e If reduction appears in a range regard it c Limit d c 0 11 mm 0 0043 in e If it exceeds the limit large difference in dimensions replace JPBIA0234ZZ lower cylinder block bolt with new one CONNECTING ROD BOLT OUTER DIAMETER Revision 2009 March EM 134 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR 1 Measure the outer diameters a b and c at the position shown in the figure a Value at the end of the smaller diameter of the bolt b Value at the end of the smaller diameter of the bolt opposite side of a c Value of the smallest diameter of the smaller of the bolt 2 Obtain a mean value d of a and b
252. nger side kicking plate and dash side finisher Refer to INT 17 Exploded View 2 Disconnect engine room harness connectors at unit sides and other 3 Disengage intermediate fixing point Pull out engine room harnesses to engine room side and temporarily secure them on engine CAUTION When pulling out harnesses take care not to damage harnesses and connectors After temporarily securing cover connectors with vinyl or similar material to protect against for eign material adhesion Vehicle Underbody 1 Remove A T fluid cooler hoses and power steering oil pump oil cooler hoses Revision 2009 March EM 83 2009 FX35 FX50 ENGINE ASSEMBLY lt UNIT REMOVAL AND INSTALLATION gt VQ35HR w 8 9 10 11 e Install plug to avoid leakage of A T fluid and power steering fluid Disconnect heated oxygen sensor 2 harness Remove three way catalyst and exhaust front tube Refer to EX 5 Exploded View Disconnect steering lower joint at power steering gear assembly side and release steering lower shaft Refer to ST 17 WITHOUT ELECTRIC MOTOR Exploded View or ST 20 WITH ELECTRIC MOTOR Exploded View Remove rear propeller shaft Refer to DLN 116 Exploded View Disengage A T control rod at A T shift selector side Then temporarily secure it on the transmission assembly so that it does not sag Refer to TM 187 Exploded View Preparation for the separation work of transaxle is as per the following e Remove rear pl
253. ngine front a F as es OL O o 1st step 2 0 N m 0 2 kg m 18 in Ib 2nd step 8 3 N m 0 85 kg m 73 in Ib JPBIA2093ZZ e Because of the limited working space use adapter A and torque wrench B assembly SST KV10119300 to tighten bolts on the No 7 and No 8 cylinders to the specified torque lt __ ENgine front 5 Install spark plug Refer to EM 167 Removal and Installation 6 Install ignition coil e Install Ignition coil marked with an identification mark A on cylinder No 7 and 8 lt Engine front JPBIA2363ZZ 7 Install in the reverse order of removal Revision 2009 March EM 193 2009 FX35 FX50 lt REMOVAL AND INSTALLATION gt OIL SEAL VK50VE OIL SEAL FRONT OIL SEAL FRONT OIL SEAL Removal and Installation REMOVAL 1 Remove the following parts e Engine undercover with power tool e Drive belts Refer to EM 163 Exploded View Cooling fan assembly Refer to CO 39 Exploded View e Front cross bar Refer to FSU 34 Exploded View 2 Remove crankshaft pulley as per the following a Remove rear plate cover Refer to EM 188 Exploded View b Set the ring gear stopper SST KV10119200 J 49277 A as shown in the figure lt Engine front c Loosen crankshaft pulley bolt and then pull crankshaft pulley with both hands to remove it CAUTION Never remove crankshaft pulley bolt Keep loosened crank shaft pulley bolt i
254. ngine front 7 Remove axle pipe if necessary e Remove axle pipe from oil pan upper using a suitable drift A outer diameter 37 mm 1 46 in JPBIA0028ZZ INSTALLATION 1 Install axle pipe 3 to oil pan upper if removed e Lubricate O ring groove of axle pipe O rings 1 2 and O ring joint of oil pan with new engine oil Unit mm in Items O ring inner diameter Final drive side right side 31 4 1 236 Axle pipe flange side left side 33 6 1 323 JPBIA0452ZZ Revision 2009 March EM 104 2009 FX35 FX50 OIL PAN UPPER lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR e Install axle pipe 1 to oil pan upper from axle pipe flange side left side using a suitable drift A outer diameter 43 to 57 mm 1 69 to 2 24 in CAUTION Insert it with care to prevent O ring from sliding 2 Install oil pan upper as per the following a Use a scraper A to remove old liquid gasket from mating sur faces CAUTION Never scratch or damage the mating surfaces when clean ing off old liquid gasket Also remove old liquid gasket from mating surface of lower cyl inder block e Remove old liquid gasket from the bolt holes and threads b Install new O rings 2 on the bottom of lower cylinder block 1 and oil pump 3 lt Engine front c Apply a continuous bead of liquid gasket with the tube presser commercial service tool to the cylinder block mating surface of oil pan upper to a
255. nit mm in Items Standard Limit Grade No 0 21 989 21 995 0 8657 0 8659 Piston pin outer diameter Grade No 1 21 995 22 001 0 8659 0 8662 Piston to piston pin oil clearance 0 002 0 006 0 0001 0 0002 Connecting rod bushing oil clearance CONNECTING ROD Items 0 005 0 017 0 0002 0 0007 Standard 0 030 0 0012 Unit mm in Limit Center distance 144 15 144 25 5 68 5 68 Bend per 100 3 94 0 15 0 0059 Torsion per 100 3 94 0 30 0 0118 Grade No 0 22 000 22 006 0 8661 0 8664 Connecting rod bushing inner diameter Grade No 1 22 006 22 012 0 8664 0 8666 Grade No A 57 000 57 001 2 2441 2 2441 Grade No B 57 001 57 002 2 2441 2 2442 Grade No C 57 002 57 003 2 2442 2 2442 Grade No D 57 003 57 004 2 2442 2 2442 Grade No E 57 004 57 005 2 2442 2 2443 Grade No F 57 005 57 006 2 2443 2 2443 Se rod big end diameter Without Grade No G 57 006 57 007 2 2443 2 2444 Grade No H 57 007 57 008 2 2444 2 2444 Grade No J 57 008 57 009 2 2444 2 2444 Grade No K 57 009 57 010 2 2444 2 2445 Grade No L 57 010 57 011 2 2445 2 2445 Grade No M 57 011 57 012 2 2445 2 2446 Grade No N 57 012 57 013 2 2446 2 2446 Items Standard Limit Side clearance After
256. nt final drive assembly with front suspension member facing downward Then separate the engine from transmission Preparation 1 Remove engine cover engine room cover RH and LH battery cover and brake master cylinder cover Refer to EM 174 Exploded View 2 Release fuel pressure Refer to EC 1228 Inspection 3 Remove the following parts e Engine undercover power tool e Front road wheel and tires power tool e Cowl top cover Refer to EXT 22 Exploded View e Air duct air cleaner case assembly and PCV hose Refer to EM 177 Exploded View e Drive belts Refer to EM 164 Removal and Installation e Front cross bar Refer to FSU 34 Exploded View 4 Disconnect both battery cables Refer to PG 120 Exploded View 5 Drain engine coolant from radiator Refer to CO 33 Draining CAUTION Perform this step when engine is cold 6 Discharge refrigerant from A C circuit Refer to HA 81 Collection and Charge 7 Remove radiator hoses upper and lower Refer to CO 39 Exploded View Engine Room LH 1 Disconnect heater hose at engine side and fit a plug onto hose end to prevent engine coolant leakage 2 Disconnect A C piping from A C compressor and temporarily fasten it on vehicle with a rope Refer to HA 108 Exploded View 3 Disconnect vacuum hose from brake booster Refer to EM 179 Exploded View 4 Disconnect ground cable Engine Room RH 1 Disconnect all clips and connectors of the engine room harne
257. nt mark 4 0 Cylinder head side Paint mark color Yellowish green JPBIAO179ZZ 7 Install valve spring retainer 8 Install valve collet e Compress valve spring with the valve spring compressor SST KV10116200 J 26336 A A the attachment SST KV10115900 J 26336 20 C and the adapter SST KV10116200 _ B Install valve collet with a magnet hand CAUTION When working take care not to damage valve lifter holes e Tap valve stem edge lightly with plastic hammer after installa tion to check its installed condition 4 PA lt Z aa i1 DS O JPBIA0180ZZ 9 Install spark plug tube e Press fit spark plug tube as per the following a Remove old locking sealant adhering to cylinder head mounting hole b Apply sealant to area within approximately 12 mm 0 47 in from edge of spark plug tube press fit side Use Genuine high strength thread locking sealant or an equivalent Refer to GI 15 Recom mended Chemical Products and Sealants c Using drift press fit spark plug tube so that its height A is as specified in the figure B High strength thread locking sealant application area Standard press fit height 37 7 38 7 mm 1 484 1 524 in CAUTION When press fitting take care not to deform spark plug tube After press fitting wipe out liquid gasket protruding onto cylinder head upper face 10 Install new cylinder head gaskets 11 Turn crankshaft until
258. o the driver and front passenger for certain types of collision This system includes seat belt switch inputs and dual stage front air bag modules The SRS system uses the seat belt switches to determine the front air bag deployment and may only deploy one front air bag depending on the severity of a collision and whether the front occupants are belted or unbelted Information necessary to service the system safely is included in the SRS AIR BAG and SEAT BELT of this Service Manual WARNING To avoid rendering the SRS inoperative which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation all maintenance must be performed by an authorized NISSAN INFINITI dealer Improper maintenance including incorrect removal and installation of the SRS can lead to personal injury caused by unintentional activation of the system For removal of Spiral Cable and Air Bag Module see the SRS AIR BAG Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual SRS wiring harnesses can be identified by yellow and or orange harnesses or har ness connectors PRECAUTIONS WHEN USING POWER TOOLS AIR OR ELECTRIC AND HAMMERS WARNING When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the ignition ON or engine running DO NOT use air or electric power tools or strike near the sensor s
259. o the following caution CAUTION Upper and lower O ring are different Be careful not to confuse them Fuel tube side Black Nozzle side Green Handle O ring with bare hands Never wear gloves Lubricate O ring with new engine oil Never clean O ring with solvent Check that O ring and its mating part are free of foreign material When installing O ring be careful not to scratch it with tool or fingernails Also be careful not to twist or stretch O ring If O ring was stretched while it was being attached never insert it quickly into fuel tube Insert O ring straight into fuel injector Never decenter or twist it 4 Install fuel injector 3 to fuel tube 1 as per the following 2 O ring black 4 O ring green a Insert clip 5 into clip mounting groove B on fuel injector e Insert clip so that protrusion C of fuel injector matches cutout E of clip CAUTION Never reuse clip Replace it with a new one Be careful to keep clip from interfering with O ring If interference occurs replace O ring b Insert fuel injector into fuel tube with clip attached e Insert it while matching it to the axial center e Insert fuel injector so that protrusion G of fuel tube matches cutout F of clip e Check that fuel tube flange A is securely fixed in flange fixing groove D on clip CAUTION Insert fuel injector at 147 N 15 kg 33 1 Ib or less to pre vent damage to the parts c Check that ins
260. o the position as shown in the figure B Cylinder block rear end face a 0 0 5 mm 0 0 020 in I JPBIAO152ZZ e Using a suitable drift A press fit until the height of rear oil seal is level with the mounting surface Suitable drift outer diameter 100 mm 3 94 in inner diameter 85 mm 3 35 in CAUTION Be careful not to damage crankshaft and cylinder block Press fit straight and avoid causing burrs or tilting oil seal JPBIA0O153ZZ 2 Install in the reverse order of removal after this step Revision 2009 March EM 81 2009 FX35 FX50 ENGINE ASSEMBLY lt UNIT REMOVAL AND INSTALLATION gt VQ35HR UNIT REMOVAL AND INSTALLATION ENGINE ASSEMBLY 2WD 2WD 7 Explod ed View INFOID 0000000003887368 SEC 112 0 92 5 9 4 68 0 49 0 5 0 36 0 92 5 9 4 68 0 49 0 5 0 36 JPBIA0528GB Engine mounting bracket RH 2 Engine mounting insulator RH 3 Engine mounting bracket LH Engine mounting insulator LH 5 Rear engine mounting member 6 Engine mounting insulator rear Dynamic damper Pa e A Front mark Refer to GI 4 Components for symbols in the figure 2WD Removal and Installation Fei neoninanaeaRaeE WARNING e Situate the vehicle on a flat and solid surface e Place chocks at front and back of rear wheels e For engines not equipped with engine slingers attach proper slingers and bolts described in PARTS CATALOG CAUTION Always be careful to
261. ololo cone EEEE EE EEEE diameter AIAJ AJAJAJA AJAJAJA Unit mm in 7 Nlalalala la NIA ala eal er E slsis sisieieisisisis pit feumal SS HMMNIM NM MBIE i 5 YP ATA A ow LINJN A D e AN Alalalalalalalalalala nit mm in E lalol o o ire olola Golo e 8 8 S 8 s sls NINI N I INI NIJIN N O O V mM wM w w S o s S s 8s 5 Axle diameter S S a o a a NININ I INI NIJIN N moO mi mm mM Ww to 1 1 57 008 57 009 a alo EREA En a a l a a a N a x a f a l a l e EA N E w ho PM P w W N NIN Y N nm Ph N N WO WO OINININININ I NH ee e elele efe fo e r v0 7 ro ro 57 009 57 010 wo wo F lele o gt e s s s 57010 57 01 a w w AJAJ ao fo foo foo fo o rm rm mw mw w 57 006 57 007 2 2443 2 2444 G JPBIA2287GB Revision 2009 March EM 276 2009 FX35 FX50 HOW TO SELECT PISTON AND BEARING lt UNIT DISASSEMBLY AND ASSEMBLY gt VK50VE CONNECTING ROD BEARING GRADE TABLE Connecting rod bearing grade table Refer to EM 292 Connecting Rod Bearing UNDERSIZE BEARING USAGE GUIDE EM e When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod bearings use undersize US bearings e When using undersize US bearing measure the connecting rod bearing inner diameter with bea
262. olt as it will be used as a supporting point for suitable puller e Place suitable puller tab on holes of crankshaft pulley and pull crankshaft pulley through CAUTION Never put suitable puller tab on crankshaft pulley periphery as this will damage internal damper 26 Remove oil pan lower Refer to EM 46 Exploded View 27 Loosen two mounting bolts in front of oil pan upper with power tool in reverse order as shown in the figure lt Engine front JPBIA0047ZZ 28 Remove front timing chain case as per the following Revision 2009 March EM 56 2009 FX35 FX50 TIMING CHAIN lt REMOVAL AND INSTALLATION gt VQ35HR a Loosen mounting bolts in reverse order as shown in the figure b Insert a suitable tool A into the notch at the top of front timing chain case as shown c Pry off case by moving the suitable tool as shown e Use the seal cutter SST KV10111100 J 37228 to cut liquid gasket for removal CAUTION Never use a screwdriver or something similar After removal handle front timing chain case carefully so it does not tilt cant or warp under a load 29 Remove front oil seal from front timing chain case using a suit able tool e Use a screwdriver for removal CAUTION Be careful not to damage front timing chain case 30 Remove O rings 1 from rear timing chain case A Bank 1 B Bank2 31 Remove timing chain tensioner primary as per the following Revision 2009 March
263. on and connecting rod assembly check the connecting rod side clearance Refer to EM 147 Cylinder Block 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 Remove connecting rod bearing cap Using a 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 PBIC2940E 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 e Identify installation positions and store them without mixing them up Remove piston rings from piston e Before removing piston rings check the piston ring side clearance Refer to EM 147 Cylinder Block e Use a piston ring expander commercial service tool A CAUTION e When removing piston rings be careful not to damage piston Be careful not to damage piston rings by expanding them excessively JPBIA0194ZZ Remove piston from connecting rod as per the following Revision 2009 March EM 118 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR a Using a snap ring pliers A remove snap rings JPBIAO195ZZ b Heat piston to
264. on direction of drain plug washer Refer to EM 46 Exploded View 4 Install in the reverse order of removal after this step NOTE At least 30 minutes after oil pan is installed pour engine oil n S p e ct i O n INFOID 0000000003887356 INSPECTION AFTER REMOVAL Clean oil strainer if any object attached INSPECTION AFTER INSTALLATION Check the engine oil level and adjust engine oil Refer to LU 6 Inspection Start engine and check there is no leakage of engine oil Stop engine and wait for 10 minutes Check the engine oil level again Refer to LU 6 Inspection PON or Revision 2009 March EM 49 2009 FX35 FX50 IGNITION COIL SPARK PLUG AND ROCKER COVER lt REMOVAL AND INSTALLATION gt IGNITION COIL SPARK PLUG AND ROCKER COVER Exploded View SEC 1119118 fg 7 0 erie aM 19 6 2 0 Q 2 5 0 26 2 aD i S lt 1 PCV hose 4 Spark plug 7 Rocker cover gasket bank 1 Camshaft position sensor PHASE 10 bank 1 13 Exhaust valve timing control position sensor bank 2 16 PCV hose A To intake manifold collector D To air duct 11 14 17 s Clamp PCV valve Rocker cover bank 1 Exhaust valve timing control position sensor bank 1 Rocker cover gasket bank 2 Oil filler cap Refer to EM 50 Refer to Gl 4 Components for symbols in the figure Removal and Installation REMOVAL 1 Remove the following parts e Engine cover Refer to EM 27 Explode
265. on ring compressor SST EM03470000 J 8037 A or suitable tool install piston with the front mark on the pis ton 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 PBIC3244J 15 Install connecting rod bearing cap e Match the stamped cylinder number marks on connecting rod with those on connecting rod bearing cap to install A Sample codes B Bearing stopper groove C Small end diameter grade D Big end diameter grade E Weight grade F Cylinder No G Management code JPBIA2273ZZ Revision 2009 March EM 263 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE 16 a b C 17 18 19 20 e Be sure that front mark H on connecting rod bearing cap is facing the front of the engine Tighten connecting rod bolts as per the following Inspect the outer diameter of connecting rod bolt Refer to EM 265 Inspection Apply engine oil to the threads and seats of connecting rod bolts Tighten connecting rod bolts O 28 4 N m 2 9 kg m 21 ft lb Completely loosen connecting rod bolts O 0 N m 0 kg m 0 ft Ib Tighten connecting rod bolts 0 24 5 N m 2 5 kg m 18 ft Ib Tighten connecting rod bolts clockwise Angle tightening 90 degrees CAUTION Always use the angle wrench SST KV10112100 BT8653 A Never
266. onnect heated oxygen sensor 2 harness 4 Remove three way catalyst and exhaust front tube Refer to EM 205 Exploded View and EX 10 Exploded View 5 Remove rear propeller shaft Refer to DLN 132 Exploded View 6 Disconnect lower joint at power steering gear assembly side and release lower shaft Refer to ST 17 WITHOUT ELECTRIC MOTOR Exploded View or ST 20 WITH ELECTRIC MOTOR Exploded View 7 Disengage A T control rod at A T shift selector side Then temporarily secure it on the transmission assembly so that it does not sag Refer to TM 187 Exploded View 8 Preparation for the separation work of transaxle is as per the following e Remove rear plate cover from oil pan upper Then remove bolts fixing drive plate to torque converter Refer to EM 188 Exploded View e Remove transmission joint bolts that pierce at oil pan upper lower rear side Refer to EM 188 Exploded View 9 Remove front stabilizer connecting rod Refer to FSU 36 Exploded View 10 Remove front wheel sensor for ABS from steering knuckle Refer to BRC 133 FRONT WHEEL SENSOR Exploded View 11 Remove brake caliper assembly with piping connected from steering knuckle Temporarily secure it on the vehicle side with a rope to avoid load on it Refer to BR 47 BRAKE CALIPER ASSEMBLY 4 PISTON TYPE Exploded View 12 Separate upper link from steering knuckle Refer to FSU 32 Exploded View 13 Separate shock absorber from transverse
267. oolant and engine oil If less than required quantity fill to the specified level Refer to MA 12 Fluids and Lubricants e 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 leak age at connection points Start engine With engine speed increased check again for fuel leakage at connection points e Run engine to check for unusual noise and vibration e Warm up engine thoroughly to check there is no leakage of fuel exhaust gases or any oil fluids including engine oil and engine coolant e Bleed air from lines and hoses of applicable lines such as in cooling system e 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 Items 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 Transmission transaxle CVT fluid power steering fluid brake fluid etc AWD Revision 2009 March EM 86 2009 FX35 FX50 ENGINE ASSEMBLY lt UNIT REMOVAL AND INSTALLATION gt VQ35HR AWD S Exploded View INFOID 0000000003887371 0 49 0 5 0 36 5 49 0 6 0 26 0 49 0 5 0 36 0 49 0 5 0 36 WAN e
268. or and temporarily fasten it on vehicle with a rope Refer to HA 40 Exploded View 3 Disconnect brake booster vacuum hose 4 Disconnect ground cables Engine Room RH 1 Disconnect battery positive cable vehicle side and temporarily fasten it on engine 2 Disconnect all clips and connectors of the engine room harness from engine back side 3 Disconnect fuel feed hose with damper and EVAP hose Refer to EM 40 Exploded View CAUTION Fit plugs onto disconnected hoses to prevent fuel leakage 4 Remove reservoir tank of power steering oil pump and piping from vehicle and temporarily secure them on engine Refer to ST 47 VQ35HR Exploded View CAUTION When temporarily securing keep the reservoir tank upright to avoid a fluid leakage Vehicle Inside Follow procedure below to disconnect engine room harness connectors at passenger room side and tempo rarily secure them on engine 1 Remove passenger side kicking plate and dash side finisher Refer to INT 17 Exploded View 2 Disconnect engine room harness connectors at unit sides and other 3 Disengage intermediate fixing point Pull out engine room harnesses to engine room side and temporarily secure them on engine CAUTION When pulling out harnesses take care not to damage harnesses and connectors After temporarily securing cover connectors with vinyl or similar material to protect against for eign material adhesion Vehicle Underbody 1 Remove A T fluid
269. oval installation slack in the guide may generate a pounding noise during and just after engine start However this is normal Noise will stop after hydraulic pressure rises Warm up engine thoroughly to check there is no leakage of fuel 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 Items 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 Transmission transaxle CVT fluid power steering fluid brake fluid etc Revision 2009 March EM 78 2009 FX35 FX50 OIL SEAL lt REMOVAL AND INSTALLATION gt OIL SEAL VALVE OIL SEAL VALVE OIL SEAL Removal and Installation REMOVAL 1 Remove camshaft relating to valve oil seal to be removed Refer to 2 Remove valve lifters Refer to EM 70 Exploded View VQ35HR INFOID 0000000003887365 em Exploded View 3 Turn crankshaft until the cylinder requiring new oil seals is at TDC This will prevent valve from dropping into cylinder 4 Remove valve collet Compress valve spring with the valve spring compressor SST KV10116200 J 26336
270. parts Fix control shaft to prevent the interference of the stopper surface JPBIA2143ZZ 7 Install new VVEL control shaft position sensor as per the following CAUTION Regarding replacement because VVEL actuator sub assembly and VVEL control shaft position sensor are controlled on a one on one basis replace them as a set a Apply engine oil to O ring or contact surface of O ring Revision 2009 March EM 235 2009 FX35 FX50 CAMSHAFT lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE b Align matching marks B of VVEL control shaft position sensor and upper housing e Face connector toward matching mark A JPBIA2142ZZ c Temporarily tighten bolt d Adjust VVEL control shaft position sensor after setting the engine assembly in the vehicle Refer to EC 584 VVEL CONTROL SHAFT POSITION SENSOR ADJUSTMENT Description CAUTION Be sure to adjust VVEL control shaft position sensor e After adjusting VVEL control shaft position sensor tighten bolts to the specified torque 8 Install actuator cover 9 Inspect the valve clearance Refer to EM 169 Inspection 10 Install in the reverse order of removal n S pect i O n INFOID 0000000003733452 CAMSHAFT EXH VALVE CLEARANCE ADJUSTMENT e Perform adjustment depending on selected head thickness of valve lifter EXH 1 Measure the valve clearance Refer to EM 169 Inspection 2 Remove VVEL ladder assembly and camshaft EXH Refer to EM 228 Disassem
271. perature sensor To Electric throttle control actuator A Refer to EM 246 B bank 1 Refer to Gl 4 Components for symbol marks in the figure CAUTION VK50VE INFOID 0000000003733453 JPBIA2290GB Valve spring retainer EXH Valve guide EXH Valve collet INT Valve spring with valve spring seat INT Valve seat EXH Oil filter for VVEL ladder assembly Cylinder head gasket bank 1 Water pipe A high degree of precision is required for a valve on the intake side Never remove the valve related parts unless necessary Revision 2009 March EM 245 2009 FX35 FX50 CYLINDER HEAD lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE NOTE e As for replacement of parts on the intake side as shown in the exploded view replace VVEL ladder assem bly amp cylinder head assembly Only valve oil seals are replaceable as a single part e VVEL ladder assembly cannot be replaced as a single part because it is machined together with cylinder head assembly Disassembly and Assembly INFOID 0000000003738454 DISASSEMBLY 1 Remove the following parts e Rocker cover and spark plug Refer to EM 191 Exploded View e Intake manifold Refer to EM 179 Exploded View e Exhaust manifold Refer to EM 205 Exploded View e Water inlet and thermostat housing Refer to CO 46 Exploded View e Water pipe and heater pipe Refer to CO 46 Exploded View e Timing chain Refer to EM 212 Exploded View
272. pump side nut 1 Oil pump sprocket oil pump side CAUTION Secure the oil pump unit shaft with the two flat parts JPBIA2298ZZ 20 Remove oil pump drive chain tensioner 21 Remove timing chain tensioner bank 1 as per the following Revision 2009 March EM 215 2009 FX35 FX50 TIMING CHAIN lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE NOTE To remove timing chain and related parts start with those on bank 1 The procedure for removing parts on bank 2 is omitted because it is the same as that for bank 1 a Push both sides of spring A against spring tension and then press in plunger with a slack guide 2 1 Timing chain tensioner bank 1 b Insert a stopper pin A into the body hole and then fix it with the plunger pushed in 22 Remove tension guide and slack guide 23 Remove timing chain and crankshaft sprocket CAUTION After removing timing chain never turn crankshaft and camshaft separately or valves will strike the piston head 24 Remove camshaft sprocket INT and EXH as per the following Exhaust side e Secure the hexagonal portion of camshaft EXH using a wrench to loosen mounting bolt Refer to EM 227 Exploded View Intake side e Secure the hexagonal portion located in between journal No 1 and journal No 2 of drive shaft A using a wrench B to loosen mounting bolt Refer to EM 227 Exploded View lt Engine front NOTE The figure shows an example of bank
273. pump sprocket so that its flange side the larger diameter side without teeth A faces in the direction shown in the figure 1 Oil pump sprocket crankshaft side 2 Oil pump sprocket oil pump side 3 Oil pump 4 Crankshaft NOTE There is no matching mark in the oil pump related parts JPBIA2108ZZ Hold the two flat parts of oil pump shaft and then tighten the oil pump sprocket oil pump side nut 1 Oil pump sprocket oil pump side CAUTION Secure the oil pump shaft with the two flat parts Securely pull out the stopper pin A after installing the oil pump drive chain e Check that the tension is applied to the oil pump drive chain 1 after installing JPBIA2303ZZ Install front oil seal on front cover Refer to EM 194 FRONT OIL SEAL Removal and Installation Revision 2009 March EM 221 2009 FX35 FX50 TIMING CHAIN lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE 9 Install timing chain tensioner cover 2 to front cover 1 a 63 4 4 4 mm 0 134 0 173 in e Apply a continuous bead of liquid gasket with tube presser commercial service tool to front cover as shown in the figure Use Genuine RTV Silicone Sealant or an equivalent Refer to GI 15 Recommended Chemical Products and Seal ants JPBIA2113ZZ 10 Install oil filter for valve timing control solenoid valve 1 in the direction shown in the figure if removed e Check that the oil filter does not protrude from the
274. r head assem bly replacement are required VVEL Ladder Assembly DRIVE SHAFT OPERATIONAL CHECK e 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 JPBIA2135ZZ CONTROL SHAFT OPERATIONAL CHECK e 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 a pear shaft from dropping off Ara faye fi OF SO SS T H JPBIA2136ZZ RINK CHECK FOR BACK LASH BONDING Revision 2009 March EM 242 2009 FX35 FX50 CAMSHAFT lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE Check that the link and the shaft of drive shaft and control shaft are not fixed e Check this by moving drive shaft and control shaft in the axial and rotation directions JPBIA2137ZZ e If there is an unusualness related to the above three items replace VVEL ladder assembly amp cylinder head assembly NOTE VVEL ladder assembly cannot be replaced as a single part because it is machined together with cylinder head assembly INSPECTION AFTER ASSEMBLY Inspection of Camshaft Sprocket INT Oil Groove CAUTION Perform this inspection only when DTC P0011 P0012 is detected in self diagnostic results of CON SULT III and it is directed according to inspection procedure of EC section Re
275. r may have not be installed correctly Check connection again NOTE Figure shows an example fuel feed damper side JPBIA2379ZZ 7 Install in the reverse order of removal n S pect i O n INFOID 0000000003733428 INSPECTION AFTER INSTALLATION Check for Fuel Leakage 1 Turn ignition switch ON with the engine stopped With fuel pressure applied to fuel piping check that there is no fuel leakage at connection points NOTE Use mirrors for checking at points out of clear sight 2 Start the engine With engine speed increased check again that there is no fuel leakage at connection points CAUTION Never touch the engine immediately after it is stopped because the engine is extremely hot Revision 2009 March EM 187 2009 FX35 FX50 OIL PAN LOWER AND OIL STRAINER lt REMOVAL AND INSTALLATION gt VKSOVE OIL PAN LOWER AND OIL STRAINER Exploded View INFOID 0000000003733429 SEC 110 150 213 fg 8 8 0 90 78 fel s s 0 90 78 2 5 18 0 21 6 2 2 16 0 21 6 2 2 16 l p m 8 8 0 90 78 5S JPBIA2088GB 1 Oil level gauge 2 Oil level gauge guide 3 O ring 4 Oil cooler 5 Connector bolt 6 Oil filter Drain plug washer 8 Oil pan lower 9 Oil strainer 10 Gasket 11 Oil temperature sensor 12 Oil pressure switch 13 O ring 14 Axle pipe 15 O ring 16 Rear plate cover 17 Crankshaft position sensor POS 18 O ring 19 O ring 20 Baffle plate 21 Baffle plate A Refer to LU 29 B
276. rage Jack and Safety Stand and 2 Pole Lift REMOVAL Revision 2009 March EM 87 2009 FX35 FX50 ENGINE ASSEMBLY lt UNIT REMOVAL AND INSTALLATION gt VQ35HR Outline At first remove the engine the transmission assembly the transfer assembly and the front final drive assem bly with front suspension member downward Then separate the engine the transmission assembly the trans fer and the front final drive assembly Preparation 1 Release fuel pressure Refer to EC 567 Inspection 2 Disconnect both battery terminals Refer to PG 120 Exploded View 3 Drain engine coolant from radiator Refer to CO 8 Draining CAUTION Perform this step when engine is cold e Never spill engine coolant on drive belt 4 Remove the following parts Radiator reservoir tank Refer to CO 14 Exploded View e Engine cover Refer to EM 27 Exploded View e Front road wheel and tires power tool Engine undercover power tool Front cross bar Refer to FSU 15 Exploded View e Cowl top cover Refer to EXT 22 Exploded View e Air duct and air cleaner case assembly Refer to EM 29 Exploded View 5 Discharge refrigerant from A C circuit Refer to HA 25 Collection and Charge 6 Remove radiator hoses upper and lower Refer to CO 14 Exploded View Engine Room LH 1 Disconnect heater hose from vehicle side and fit a plug onto hose end to prevent engine coolant leakage 2 Disconnect A C piping from A C compress
277. rake fluid etc Revision 2009 March EM 91 2009 FX35 FX50 ENGINE STAND SETTING lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR UNIT DISASSEMBLY AND ASSEMBLY ENGINE STAND SETTING S ett i n g INFOID 0000000003887374 NOTE Explained here is how to disassemble with engine stand supporting transmission surface When using differ ent type of engine stand note with difference in steps and etc 1 Remove the engine assembly from the vehicle Refer to EM 82 2WD Exploded View 2WD models or EM 87 AWD Exploded View AWD models 2 Remove crankshaft pulley Refer to EM 53 Exploded View NOTE The drive plate is fixed with a ring gear stopper SST KV10118600 J 48641 Loosen the crankshaft pul ley mounting bolts before installing the engine stand 3 Remove the parts that may restrict installation of engine to a widely use engine stand e Fix crankshaft with a ring gear stopper SST KV10118600 J 48641 Loosen drive plate mounting bolt with power tool e Check for deformation or damage of drive plate Refer to EM 117 Exploded View NOTE The procedure is described assuming that you use a widely use engine stand holding the surface to which transmission is installed 4 Remove pilot converter using the pilot bushing puller SST ST16610001 J 23907 A if necessary JPBIA0193ZZ 5 Lift the engine with hoist to install it onto the widely use engine stand CAUTION Use an engine stand that has a load capacity 2
278. ring installed and grind crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard CAUTION In grinding crankshaft pin to use undersize bearings keep the fillet R A 1 5 1 7 mm 0 059 0 067 in JPBIA0216ZZ Bearing undersize table Refer to EM 292 Connecting Rod Bearing M ai n Bea ri n g INFOID 0000000003733462 WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE USED 1 MAIN BEARING SELECTION TABLE rows correspond to bearing housing grade on rear side of cylinder block Bearing housing grade No 1 Bearing housing grade No 2 Bearing housing grade No 3 Bearing housing grade No 4 Bearing housing grade No 5 Cylinder bore grade No 1 Cylinder bore grade No JPBIA2284ZZ Cylinder bore grade No Cylinder bore grade No Cylinder bore grade No Cylinder bore grade No SFrarAc TAT moO gt 2 3 4 Cylinder bore grade No 5 6 7 8 Cylinder bore grade No if Engine front 2 MAIN BEARING SELECTION TABLE columns correspond to journal diameter grade on front side of crankshaft Pin diameter grade No 1 an OPACA Pin diameter grade No 2 Pin diameter grade No 3 Pin diameter grade No 4 Journal diameter grade No 1 Journal diameter grade No 2 onmo gt Journal diameter grade No 3 JPBIA2283ZZ Revision 2009 March EM 277 2009 FX35 FX50 HOW TO SELECT PISTON AND BEARING lt UNIT DISASSEMBLY AND ASSEMBLY
279. rocket EXH bank 2 Oil pump drive chain Oil pump sprocket crankshaft side Camshaft sprocket INT bank 1 Tension guide bank 2 Matching mark copper link Matching mark notched e The above figure shows the relationship between the matching mark on each timing chain and that on the corresponding sprocket with the components installed e Parts with an identification mark R or L should be installed on the corresponding bank according to the mark Camshaft sprocket INT camshaft sprocket EXH Tension guide Slack guide e To install timing chain and related parts start with those on bank 2 The procedure for installing parts on bank 1 is omitted because it is the same as that for installation on bank 2 e There is no matching mark in the oil pump related parts Revision 2009 March EM 218 2009 FX35 FX50 TIMING CHAIN lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE 1 Check that crankshaft key 1 and dowel pin A of each cam shaft are located as shown in the figure Camshaft dowel pin At cylinder head upper face side in each bank Crankshaft key Straight up NOTE Though camshaft does not stop at the position as shown in the figure for the placement of cam nose it is generally accepted JPBIAZ10922 camshaft is placed for the same direction of the figure 2 Install camshaft sprockets INT and EXH e Install onto correct side by checking with identification mark A on surface JPBIA2110ZZ
280. rp under a load JPBIA0088ZZ Revision 2009 March EM 96 2009 FX35 FX50 REAR TIMING CHAIN CASE lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR 5 Remove O rings 1 from cylinder block lt Engine front JPBIA0090ZZ 6 Remove timing chain tensioners secondary from cylinder head as per the following if necessary Remove camshaft brackets No 1 Refer to EM 70 Exploded View b Remove timing chain tensioners secondary with a stopper pin A attached JPBIAO095ZZ As S e m b y INFOID 0000000003887379 1 Install timing chain tensioners secondary to cylinder head as per the following if removed Refer to EM 70 Exploded View a Install timing chain tensioners secondary with a stopper pin attached and new O rings Install camshaft brackets No 1 Refer to EM 70 Exploded View Measure difference in levels between front end faces of cam shaft bracket No 1 and cylinder head Standard 0 14 to 0 14 mm 0 0055 to 0 0055 in e Measure two positions both intake and exhaust side for a single bank e If the measured value is out of the standard re install cam shaft bracket No 1 EMQ0044D 2 Install rear timing chain case as per the following a Install new O rings 1 onto cylinder block lt 3 Engine front N C t ANN E rr i 01x ian JPBIA0090ZZ Revision 2009 March EM 97 2009 FX35 FX50 REAR TIMING CHAIN CASE lt UNIT DISASSEMBLY AND
281. s of the No 3 journal housing on cylinder block A No 1 B No 2 C No 3 D No 4 F Thrust bearing installation position lt Engine front e Install thrust bearings with the oil groove E facing crankshaft arm outside c Install main bearings paying attention to the direction A Cylinder block side D Lower cylinder block side lt Engine front e Main bearing with oil hole B and groove C goes on cylinder block The one without them goes on lower cylinder block e 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 e When installing align main bearing stopper protrusion to cut out of cylinder block and lower cylinder block e Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned 5 Install crankshaft to cylinder block e While turning crankshaft by hand check that it turns smoothly 6 Install lower cylinder block NOTE Lower cylinder block cannot be replaced as a single part because it is machined together with cylinder block JPBIA0200ZZ Revision 2009 March EM 121 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR e Apply a continuous bead of liquid gasket with the tube presser commercial service tool to lower cylinder block as shown in the figure B Apply to end a 04 0 5 0 mm 0 157 0 197 in Use Genuine R
282. shaft main journal diameter Standard and limit Refer to EM 151 Main Bearing e If the calculated value exceeds the limit select proper main bear ing according to main bearing inner diameter and crankshaft main JPBIA0232ZZ journal diameter to obtain the specified bearing oil clearance Refer to EM 139 Main Bearing Method of Using Plastigage e Remove engine oil and dust on crankshaft journal and the surfaces of each bearing completely e Cut a plastigage slightly shorter than the bearing width and place it in crankshaft axial direction avoiding oil holes e Install main bearing to cylinder block and lower cylinder block and tighten lower cylinder block bolts with lower cylinder block to the specified torque Refer to EM 118 Disassembly and Assembly for the tightening procedure CAUTION Revision 2009 March EM 133 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR Never rotate crankshaft e Remove lower cylinder block 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 JPBIA0231ZZ MAIN BEARING CRUSH HEIGHT e When lower cylinder block is removed after being tightened to the specified torque with main bearings 1 installed the tip end of bearing must protrude Refer to EM 118 Disassembly and Assembly for the tighteni
283. signal plate EXH 8 Camshaft sensor bracket bank 1 10 Camshaft signal plate INT 11 Camshaft INT bank 1 13 eee tensioner secondary 44 Cylinder head bank 1 16 Cylinder head bank 2 17 Camshaft sensor bracket bank 2 19 Camshaft signal plate EXH 20 Camshaft signal plate INT 22 Camshaft bracket No 1 bank 2 A Refer to EM 70 Refer to Gl 4 Components for symbols in the figure Removal and Installation REMOVAL 1 Remove front timing chain case camshaft sprocket and timing chain 2 Remove fuel sub tube Refer to EM 40 Exploded View Revision 2009 March EM 70 15 18 21 VQ35HR INFOID 0000000003887362 A G O be vo JPBIA1901GB Seal washer Camshaft EXH bank 1 Dowel pin Valve lifter Timing chain tensioner secondary bank 2 Camshaft EXH bank 2 Camshaft INT bank 2 INFOID 0000000003887363 Refer to EM 53 Exploded View 2009 FX35 FX50 CAMSHAFT lt REMOVAL AND INSTALLATION gt VQ35HR 3 Remove camshaft sensor bracket e Loosen camshaft sensor bracket bolts in reverse order as shown in the figure lt 1 Engine front NOTE The order of loosening bolts is the same for bank 1 and bank 2 JPBIA1960ZZ 4 Remove camshaft brackets e Mark camshafts camshaft brackets and bolts so they are placed in the same position and direction for installation e Equally loosen camshaft bracket bolts in several steps in reverse order as shown in the fig
284. sor if necessary Remove rear plate cover Remove oil pan lower Refer toEM 188 Exploded View Remove oil strainer Refer to EM 188 Exploded View Remove oil pan upper as per the following Loosen mounting bolts in the reverse order as shown in the fig ure with power tool to remove POO ANO E lt Engine front NOTE Disregard No 12 17 when loosening b Insert a suitable tool into the notch at oil pan upper 1 as shown e Pry off case by moving a suitable tool lt Engine front CAUTION Be careful not to damage the mating surfaces JPBIA2299ZZ 10 Remove O ring from bottom of cylinder block and oil pump 11 Remove baffle plate if necessary 12 Remove axle pipe from oil pan upper if necessary e Pull axle pipe from oil pan upper using a suitable drift ASSEMBLY 1 Install axle pipe 1 to oil pan upper if removed O ring O ring with identification paint gt wD Front final drive side B Drive shaft LH side e Lubricate O ring groove of axle pipe O ring and O ring joint of oil pan with new engine oil e Install axle pipe to oil pan upper from drive shaft LH side CAUTION Insert it with care to prevent O ring from sliding JPBIA2122ZZ Revision 2009 March EM 209 2009 FX35 FX50 OIL PAN UPPER lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE 2 Install oil pan upper as per the following a Use a scraper A to remove old liquid gasket from m
285. ss from engine side 2 Disconnect fuel feed hose and EVAP service port hose Refer to EM 182 Exploded View CAUTION Fit plugs onto disconnected hoses to prevent fuel leakage 3 Remove reservoir tank of power steering oil pump and piping from vehicle and temporarily secure them on engine Refer to ST 48 VK50VE Exploded View CAUTION When temporarily securing keep the reservoir tank upright to avoid fluid leakage Revision 2009 March EM 197 2009 FX35 FX50 ENGINE ASSEMBLY lt UNIT REMOVAL AND INSTALLATION gt VKSOVE Vehicle Inside Follow the procedure below to disconnect engine room harness connectors at passenger room side and tem porarily secure them on engine 1 Remove glove box assembly and instrument assist lower panel Refer to P 11 Exploded View 2 Disconnect engine room harness connectors at unit sides and other locations 3 Disengage intermediate fixing point Pull out engine room harnesses to engine room side and temporarily secure them on engine CAUTION When pulling out harnesses take care not to damage harnesses and connectors After temporarily securing cover connectors with vinyl or similar material to protect against adhesion of foreign materials Vehicle Underbody 1 Remove A T fluid cooler hoses and power steering oil pump oil cooler hoses e Install plug to avoid leakage of A T fluid and power steering fluid 2 Disconnect ground cable from exhaust manifold cover bank 2 Disc
286. ston to connecting rod e Using an industrial use drier 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 e Assemble so that the front mark on the piston head and the cylinder number on connecting rod are positioned as shown in the figure A Piston grade number B Front mark C Pin grade number D Cylinder number E Front mark lt 2 Engine front JPBIA0203ZZ c Install new snap ring to the groove of the piston front side e Insert it fully into groove to install e After installing check that connecting rod moves smoothly 10 Using a piston ring expander commercial service tool A install piston rings CAUTION e When installing piston rings be careful not to damage piston Be careful not to damage piston rings by expending them excessively JPBIA0194ZZ e If there is stamped mark on ring mount it with marked side up Stamped mark Top ring A 1N Second ring B 2N JPBIA1720ZZ e Position each ring with the gap as shown in the figure referring to the piston front mark D Top ring gap Oil ring upper or lower rail gap either of them Second ring and oil ring spacer gap 90 degrees 45 degrees ov nmo JPBIA0205ZZ Revision 2009 March EM 123 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35H
287. sure remains at low level despite the addition of engine oil valves may be mal functioning Check valves for damage Replace valve or valve seat accordingly Refer to EM 256 Dis assembly and Assembly If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil cylinder head gaskets are leaking In such a case replace cyl inder head gaskets Refer to EM 246 Disassembly and Assembly 9 After inspection is completed install removed parts 10 Start the engine and check that the engine runs smoothly 11 Perform trouble diagnosis If DTC appears erase it Refer to EC 731 Description Revision 2009 March EM 173 2009 FX35 FX50 ENGINE ROOM COVER lt REMOVAL AND INSTALLATION gt VKSOVE REMOVAL AND INSTALLATION ENGINE ROOM COVER Exp loded View INFOID 00000000037334 11 Engine room cover JPBIA2359ZZ 1 Battery cover 2 Engine room cover RH 3 Air duct inlet 4 Engine room cover LH 5 Brake master cylinder cover 6 Engine cover A Clip Refer to GI 4 Components for symbols in the figure Engine cover SEC 140 JPBIA2072GB Revision 2009 March EM 174 2009 FX35 FX50 ENGINE ROOM COVER lt REMOVAL AND INSTALLATION gt VK50VE 1 Engine cover 2 Grommet 3 Bracket 4 Bracket rear Refer to Gl 4 Components for symbols in the figure EM Removal and Installation INFOID 0000000003733412 em REMOVA
288. t lt Q Insertion direction of feeler gauge on the bank 2 4a Insertion direction of feeler gauge on the bank 1 e Refer to the figure for the insertion direction of the feeler gauge since the direction depends on the bank JPBIA2297ZZ a SetNo 1 cylinder at TDC of its compression stroke Revision 2009 March EM 169 2009 FX35 FX50 CAMSHAFT VALVE CLEARANCE lt PERIODIC MAINTENANCE gt VKSOVE e Rotate crankshaft pulley clockwise to align timing mark grooved line without color B with timing indicator A e Check that exhaust cam nose on No 1 cylinder engine front side of bank 1 is located as shown in the figure 1 Camshaft EXH bank 1 lt Engine front If not turn crankshaft one revolution 360 degrees and align as shown in the figure By referring to the figure measure the valve clearances at locations marked x as shown in the table below locations indicated in the figure Tee Sete NOP lt 2 Engine front Ga we I e No 1 cylinder at compression TDC CP Ale Halse Hale AFEN ced Erie VEE AL HAL Measuring position bank 2 A bra Se ori r No 1 cylinder at com EXH x C pression TDC INT x D x E Measuring position bank 1 B oe oe ki xA No 1 cylinder at com INT x F x G pression TDC EXH x H x I JPBIA2067ZZ NOTE Revision 2009 March EM 170 2009 FX35 FX50 CAMSHAFT VALVE CLEARANCE lt PERIODIC MAINTENANCE gt VK50VE To
289. t locations marked x as shown in the table below locations indicated in the figure lt Engine front e No 6 cylinder at compression TDC Measuring position bank 2 A ce P gt a No 6 cylinder at com EXH x B x C JPBIA2069ZZ pression TDC INT x D 3 Perform adjustment or replacement if the measured value is out of the standard e If a valve clearance on the exhaust side is out of specification adjust the valve clearance Refer to EM 236 Inspection e If a valve clearance on the intake side is out of specification replace VVEL ladder assembly amp cylinder head assembly Refer to EM 227 Exploded View CAUTION Never adjust valve clearance on the intake side NOTE Since the valve lifter INT cannot be replaced by the piece VVEL ladder assembly amp cylinder head assembly replacement are required Revision 2009 March EM 172 2009 FX35 FX50 COMPRESSION PRESSURE lt PERIODIC MAINTENANCE gt VK50VE COMPRESSION PRESSURE n S pect i O n INFOID 0000000003733410 1 Warm up engine thoroughly Then stop it 2 Release fuel pressure Refer to EC 1228 Inspection 3 Disconnect fuel pump fuse 1 from IPDM E R 2 to avoid fuel injection during measurement JMBIA1552ZZ Remove engine cover Refer to EM 174 Exploded View Remove ignition coil and spark plug from each cylinder Refer to EM 191 Exploded View Connect engine tachometer not required in use of CONSULT II
290. t 0 5 0 020 Valve stem end surface grinding limit 0 2 0 008 VALVE GUIDE Revision 2009 March EM 285 2009 FX35 FX50 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS VK50VE Unit mm in SEM950E Items Standard Oversize Service 0 2 0 008 on a Outer diameter 10 023 10 034 0 3946 0 3950 10 223 10 234 0 4025 0 4029 alve guide Inner diameter Finished size 6 000 6 018 0 2362 0 2369 Cylinder head valve guide hole diameter 9 975 9 996 0 3927 0 3935 10 175 10 196 0 4006 0 4014 Interference fit of valve guide 0 027 0 059 0 0011 0 0023 Items Standard Limit Intake 0 020 0 053 0 0008 0 0021 0 08 0 003 Valve guide clearance Exhaust 0 030 0 063 0 0012 0 0025 0 09 0 004 Intake 12 6 12 8 0 496 0 504 Projection length L Exhaust 11 9 12 1 0 469 0 476 Parts settings are for exhaust side only VALVE SEAT Unit mm in PBIC2745E Items Standard Oversize Service 0 5 0 02 4 Cylinder head seat recess di Intake 38 000 38 016 1 4961 1 4967 ameter D Exhaust 31 600 31 616 1 2441 1 2447 32 100 32 116 1 2638 1 2644 4 Intake 38 097 38 113 1 4999 1 5005 Valve seat outer diameter d Exhaust 31 680 31 696 1 2472 1 2479 32 180 32 196 1 2669 1 2676 4 Intake 0 081 0 113 0 0032 0 0044
291. t from centralized under floor piping 3 CAUTION Pull quick connector holding position A as shown in the figure Never pull with lateral force applied O ring inside quick connector may be damaged Prepare container and cloth beforehand as fuel will leak out Avoid fire and sparks Spence Keep parts away from heat source Especially be careful when welding is performed around them Never expose parts to battery electrolyte or other acids Never bend or twist connection between quick connector and fuel feed hose with damper dur ing installation removal To keep the connecting portion clean and to avoid dam age and foreign materials cover them completely with plastic bags etc A or something similar JPBIA0135ZZ 8 Remove fuel sub tube mounting bolt 9 Disconnect harness connector from fuel injector Revision 2009 March EM 41 2009 FX35 FX50 FUEL INJECTOR AND FUEL TUBE lt REMOVAL AND INSTALLATION gt VQ35HR 10 Loosen mounting bolts in reverse order as shown in the figure and remove fuel tube and fuel injector assembly lt 1 Engine front CAUTION Never tilt fuel tube or remaining fuel in pipes may flow out from pipes 11 Remove fuel injector 2 from fuel tube 4 as per the following 3 O ring A __ Installed condition B Clip mounting groove a Open and remove clip 1 b Remove fuel injector from fuel tube by pulling straight CAUTION Be careful with remaining fuel that may go o
292. t is machined together with VVEL ladder assembly Camshaft Sprocket EXH Runout 1 Put V block on precise flat table and support No 2 and 5 journals of camshaft EXH CAUTION Never support No 1 journal on the side of camshaft sprocket because it has a different diameter from the other four locations 2 Measure the camshaft sprocket EXH runout with a dial indica tor Total indicator reading Limit Refer to EM 283 Camshaft 3 If it exceeds the limit replace camshaft sprocket EXH PBIC0930E Valve Lifter EXH e Check if surface of valve lifter has any wear or crack e If wear or crack is found replace valve lifter EXH Refer to EM 283 Camshaft 4 KBIA0182E Valve Lifter Clearance EXH VALVE LIFTER OUTER DIAMETER Revision 2009 March EM 239 2009 FX35 FX50 CAMSHAFT lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE e Measure the outer diameter at 1 2 height of valve lifter with a micrometer A since valve lifter is in barrel shape Standard Refer to EM 283 Camshaft JPBIAO1252Z VALVE LIFTER HOLE DIAMETER e Measure the inner diameter of valve lifter hole of cylinder head with an inside micrometer Standard Refer to EM 283 Camshaft VALVE LIFTER CLEARANCE e Valve lifter clearance Valve lifter hole diameter Valve lifter outer diameter Standard Refer to EM 283 Camshaft e If the calculated value is out of the standard referring to each st
293. t onto the widely used engine stand CAUTION Use an engine stand that has a load capacity 240 kg 529 Ib or more large enough for supporting the engine weight If the load capacity of the stand is not adequate remove the following parts beforehand to reduce the potential risk of overturning the stand Remove intake manifold Refer to EM 179 Exploded View Remove fuel injector and fuel tube assembly Refer to EM 182 Exploded View Remove ignition coil Refer to EM 191 Exploded View Remove rocker cover Refer to EM 191 Exploded View Remove exhaust manifold Refer to EM 205 Exploded View Other removable brackets NOTE The figure shows an example of widely used engine stand A that can hold mating surface of transmission with drive plate removed CAUTION Before removing the hanging chains check the engine stand is stable and there is no risk of overturning JPBIA0190ZZ 6 Drain engine oil Refer to LU 26 Draining Revision 2009 March EM 202 2009 FX35 FX50 ENGINE STAND SETTING lt UNIT DISASSEMBLY AND ASSEMBLY gt VK50VE 7 Drain engine coolant by removing water drain plug 3 from both sides of the cylinder block as shown in the figure Washer Plug o os 00 S Pg IESALA 1 2 4 Plug 5 Washer lt 1 Engine front JPBIA2121ZZ Revision 2009 March EM 203 2009 FX35 FX50 ENGINE UNIT lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE ENGINE UNIT D i sasse m b ly INF
294. tallation is complete by checking that fuel injector does not rotate or come off e Check that protrusions of fuel injectors and fuel tube are aligned with cutouts of clips after installation 5 Install fuel tube and fuel injector assembly e Tighten mounting bolts a first Then tighten mounting bolts b shown in the figure JPBIA2095ZZ 1 Fuel tube bank 2 2 Fuel tube bank 1 lt Engine front 1ststep 10 1 N m 1 0 kg m 7 ft lb 2nd step 23 6 N m 2 4 kg m 17 ft lb CAUTION Be careful not to let tip of injector nozzle come in contact with other parts JPBIA2086ZZ Revision 2009 March EM 185 2009 FX35 FX50 FUEL INJECTOR AND FUEL TUBE lt REMOVAL AND INSTALLATION gt VK50VE Insert fuel injector at 147 N 15 kg 33 1 Ib or less to prevent damage to the parts 6 Install quick connecters as per the following e Unless otherwise indicated the installation to the engine side and centralized under floor piping side is exactly alike a Check no foreign substances are deposited in and around fuel piping and quick connector and no dam age on them Thinly apply new engine oil around fuel piping from tip end to spool end c Align center to insert quick connector straightly into fuel piping Fuel hose center and centralized under floor piping side e Visually confirm that the two retainer tabs A are connected to the quick connector B CAUTION e Carefully align center to avoid inclined ins
295. ter EM 162 Checking compression pressure 2009 FX35 FX50 DRIVE BELTS lt PERIODIC MAINTENANCE gt VK50VE PERIODIC MAINTENANCE DRIVE BELTS Exp loded View INFOID 0000000003733400 JPBIA2065ZZ Auto tensioner for alternator water 1 Water pump 2 pump and A C compressor belt 3 Alternator Auto tensioner for power steering oil 4 Power steering oil pump belt 5 Power steering oil pump 6 pump belt 7 Crankshaft pulley 8 Idler pulley 9 A C compressor 10 Alternator water pump and A C com pressor belt A Indicator B Possible use range C Range when new drive belt is installed D ViewD E ViewE Checki ng INFOID 0000000003733401 WARNING Be sure to perform the these steps when engine is stopped e Remove air duct inlet when inspecting alternator water pump and A C compressor belt e Remove engine undercover with power tool when inspecting power steering oil pump belt e Check that the indicator A notch on fixed side of each auto tensioner is within the possible use range B NOTE e Check the each auto tensioners indication when the engine is cold e When new drive belts is installed the indicator notch on fixed side should be within the range C in the figure e Visually check all drive belts for wear damage or cracks e If the indicator notch on fixed side is out of the possible use range or drive belts are damaged replace drive belts Revision 2009 March EM 163 200
296. th bare hands Never wear gloves e Lubricate O ring with new engine oil JPBIAO316ZZ Revision 2009 March EM 42 2009 FX35 FX50 FUEL INJECTOR AND FUEL TUBE lt REMOVAL AND INSTALLATION gt VQ35HR Never clean O ring with solvent e Check that O ring and its mating part are free of foreign material When installing O ring be careful not to scratch it with tool or fingernails Also be careful not to twist or stretch O ring If O ring was stretched while it was being attached never insert it quickly into fuel tube EM Insert new O ring straight into fuel tube Never decenter or twist it e Insert fuel sub tube straight into fuel tube e Tighten mounting bolts evenly in turn e After tightening mounting bolts check that there is no gap between flange and fuel tube 3 Install new O rings to fuel injector paying attention to the following CAUTION Upper and lower O ring are different Be careful not to confuse them Fuel tube side Black Nozzle side Green Handle O ring with bare hands Never wear gloves Lubricate O ring with new engine oil Never clean O ring with solvent Check that O ring and its mating part are free of foreign material When installing O ring be careful not to scratch it with tool or fingernails Also be careful not to twist or stretch O ring If O ring was stretched while it was being attached never insert it quickly into fuel tube e Insert O ring straight into fuel injector
297. the crankshaft as instructed in the removal procedure Refer to EM 194 FRONT OIL SEAL Removal and Installation a Install crankshaft pulley taking care not to damage front oil seal b Apply engine oil onto threaded parts of crankshaft pulley bolt and seating area e Lightly tapping its center with plastic hammer insert crankshaft pulley CAUTION Never tap crankshaft pulley on the side surface where belt is installed outer circumference c Tighten crankshaft pulley bolt 157 N m 16 kg m 116 ft Ib d Puta paint mark A on crankshaft pulley 1 aligning with angle mark B on crankshaft pulley bolt e Tighten crankshaft pulley bolt clockwise Angle tightening 90 degrees c e Check the tightening angle by referencing to the notches The angle between two notches is 90 degrees JPBIA2066ZZ 18 Rotate crankshaft pulley in normal direction clockwise when viewed from engine front to confirm it turns smoothly 19 Install in the reverse order of removal n S pect i O n INFOID 0000000003733436 INSPECTION AFTER DISASSEMBLY Timing Chain Check for cracks and any excessive wear at link plates and roller links of timing chain Replace timing chain if necessary A Crack B Wear JPBIA0091ZZ INSPECTION AFTER ASSEMBLY Inspection for Leakage The following are procedures for checking fluid leakage lubricant leakage e Before starting engine check oil fluid levels including engine coolant
298. the following Revision 2009 March EM 223 2009 FX35 FX50 TIMING CHAIN lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE a Install new O rings 1 on front cover JPBIA2117ZZ b Install new seal rings 1 in shaft grooves CAUTION When replacing seal ring replace all rings with new ones c Apply a continuous bead of liquid gasket with tube presser commercial service tool to valve timing control covers as shown in the figure A Bank 1 B Bank2 c 03 4 4 4 mm 0 134 0 173 in Use Genuine RTV Silicone Sealant or equivalent Refer to GI 15 Recommended Chemical Products and Sealants JPBIA2104ZZ d Being careful not to move seal ring from the installation groove align dowel pins on front cover with dowel pin holes C to install valve timing control covers A Bank2 B Banki e Tighten mounting bolts in numerical order as shown in the fig ure JPBIA2118ZZ Revision 2009 March EM 224 2009 FX35 FX50 TIMING CHAIN lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE 13 Install camshaft position sensor and valve timing control solenoid valve RH and LH to valve timing con trol cover if removed e Be sure to tighten mounting bolts with flanges completely seated 14 Install oil pan lower and oil strainer Refer to EM 188 Exploded View 15 Install oil pan upper Refer to EM 208 Exploded View 16 Install water pump pulley Refer to CO 44 Exploded View 17 Install crankshaft pulley e Fix
299. tion With the sleeve side B of quick connector release A facing to quick connector D install quick connector release onto fuel feed hose 1 Fuel feed damper C Insert and retain Insert quick connector release into quick connector until sleeve contacts and goes no further Hold quick connector release on that position CAUTION Inserting quick connector release hard will not disconnect quick connector Hold quick connector release where it contacts and goes no further Pull out quick connector straight from fuel feed damper CAUTION Pull quick connector holding position E as shown in the figure e Never pull with lateral force applied O ring inside quick connector may be damaged Prepare container and cloth beforehand as fuel will leak out Avoid fire and sparks Keep parts away from heat source Especially be careful when welding is performed around them Never expose parts to battery electrolyte or other acids Never bend or twist connection between quick connector and fuel feed hose during installation removal To keep the connecting portion clean and to avoid dam age and foreign materials cover them completely with plastic bags A or something similar JPBIA2083ZZ JPBIA2084ZZ Remove air duct Refer to EM 177 Exploded View Remove electric throttle control actuator Refer to EM 179 Exploded View Remove fuel hose center e The procedure for removing the quick connector is the same
300. tion sensor b Fix two flat areas C of control shaft with a wrench to remove mounting bolts of control shaft A Bank 2 B Bank 1 lt Engine front CAUTION During the operation never allow a wrench to interfere with other parts e Fix control shaft to prevent the interference of the stopper surface JPBIA2143ZZ c Remove VVEL actuator sub assembly e Loosen mounting bolts in the reverse order as shown in the figure A Bank1 B Bank2 CAUTION When removing prepare wastes because oil spills e When installing be careful with VVEL actuator sub assembly bank 1 mounting bolt No 4 because its length is different d Remove actuator bracket rear e Loosen mounting bolts in the reverse order as shown in the figure A Bank 2 B Bank 1 lt 1 Engine front JPBIA21252ZZ 3 Remove front cover camshaft sprockets and timing chains Refer to EM 212 Exploded View 4 Remove VVEL ladder assembly Revision 2009 March EM 229 2009 FX35 FX50 CAMSHAFT lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE e Loosen mounting bolts gold color in the reverse order as shown in the figure A Bank2 B Bank 1 lt Engine front CAUTION e Never loosen adjusting bolts and mounting bolts black color e When removing VVEL ladder assembly hold the drive shaft from below so as not to drop it JPBIA2128ZZ 5 Remove camshaft EXH 6 Remove valve lifter if necessary e Ident
301. tions of Bank Names INFOID 0000000003739334 e In this manual each bank name is defined as per the following A Bank 2 The conventional right bank B Bank 1 The conventional left bank lt 2 Engine front e For cylinder numbers and bank layout refer to the figure Bank1 The bank side including cylinder No 1 odd numbered cylinder side Bank 2 The other bank side of the above JPBIA2064ZZ even numbered cylinder side Revision 2009 March EM 158 2009 FX35 FX50 lt PREPARATION gt PREPARATION PREPARATION Special Service Tool PREPARATION VK50VE INFOID 0000000003733473 Tool number Kent Moore No Description Tool name KV10116200 Disassembling valve mechanism J 26336 A Part 1 is a component of KV10116200 Valve spring compressor 1 KV10115900 J 26336 20 Attachment 2 KV10109220 C MY Adapter a She A B 1 i l 1 Se PBIC1650E J26336 A but part 2 is not so KV10107902 J 38959 Valve oil seal puller S NTO11 Removing valve oil seal KV10115600 J 38958 Valve oil seal drift JPBIAO396ZZ Installing valve oil seal Use side A G a 20 0 79 dia d 8 0 31 dia b 13 0 51 dia e 10 7 0 421 c 10 3 0 406 dia f 5 0 20 H Side B Unit mm in EM03470000 J 8037 Piston ring compressor S NT044 Installing piston assembly into cylinder bore KV10111100 Removing steel oil pan and front cover J 37228
302. to piston pin oil clearance Piston pin hole diameter Piston pin outer diameter Standard Refer to EM 147 Cylinder Block e If the calculated value is out of the standard replace piston and piston pin assembly e When replacing piston and piston pin assembly refer to EM 136 Description NOTE e Piston is available together with piston pin as assembly e Piston pin piston pin hole grade is provided only for the parts installed at the plant For service parts no piston pin grades can be selected Only 0 grade is available PISTON RING SIDE CLEARANCE Revision 2009 March EM 127 2009 FX35 FX50 CYLINDER BLOCK lt UNIT DISASSEMBLY AND ASSEMBLY gt VQ35HR e Measure the side clearance of piston ring 1 and piston ring groove with a feeler gauge C A OK B NG Standard and limit Refer to EM 147 Cylinder Block e If the measured value exceeds the limit replace piston ring and measure again If it still exceeds the limit replace piston also JPBIA0219ZZ PISTON RING END GAP e Check that the cylinder bore inner diameter is within the specification Refer to EM 118 Disassembly and Assembly e Lubricate with new engine oil to piston 1 and piston ring 2 and then insert piston ring until middle of cylinder with piston and mea sure the piston ring end gap with a feeler gauge B A Press fit C Measuring point Standard and limit Refer to EM 147 Cylinder Block
303. tor e Tighten in numerical order as shown in the figure NOTE e The figure shows the electric throttle control actuator bank 1 viewed from the air duct side e Viewed from the air duct side the order of tightening mounting bolts of electric throttle control actuator bank 1 is the same as that of the electric throttle control actuator bank 2 Perform the Throttle Valve Closed Position Learning when har ness connector of electric throttle control actuator is disconnected Refer to EC 582 THROTTLE VALVE CLOSED POSITION LEARNING Description Perform the Idle Air Volume Learning and Throttle Valve Closed Position Learning when electric throttle control actuator is replaced Refer to EC 583 IDLE AIR VOLUME LEARNING Description and EC 582 THROTTLE VALVE CLOSED POSITION LEARNING Description Water Hose Insert hose by 27 to 32 mm 1 06 to 1 26 in from connector end JPBIA2362ZZ Vacuum Hose Refer to EC 1229 Inspection Revision 2009 March EM 181 2009 FX35 FX50 FUEL INJECTOR AND FUEL TUBE lt REMOVAL AND INSTALLATION gt VK50VE FUEL INJECTOR AND FUEL TUBE Exploded View INFOID 0000000003733426 SEC 164 JPBIA2081GB 1 Quick connector cap 2 Fuel hose bracket 3 Fuel feed hose 4 Quick connector cap 5 Fuel hose bracket 6 Quick connector cap 7 Fuel hose center 8 O ring 9 Fuel tube bank 1 10 O ring 11 Fuel damper 12 Fuel damper cap 13 O ring green 14
304. tube presser commercial service tool to the oil pan lower as shown in the figure a 7 5 9 5 mm 0 295 0 374 in b 64 0 5 0 mm 0 157 0 197 in lt Engine front fa 1 Use Genuine RTV Silicone Sealant or an equivalent Refer 1 to GI 15 Recommended Chemical Products and Sealants Z Z CAUTION Attaching must be done within 5 minutes after coating JPBIA2091ZZ Install oil pan lower e Tighten mounting bolts in numerical order as shown in the fig ure lt Engine front JPBIA2090ZZ Install oil pan drain plug e Refer to the figure of the components of on the prior page for installation direction of drain plug washer Refer to EM 188 Exploded View Install in the reverse order of removal after this step NOTE Wait at least 30 minutes after oil pan is installed before pouring engine oil n S pect i O n INFOID 0000000003733431 INSPECTION AFTER REMOVAL Clean oil strainer if any object is attached INSPECTION AFTER INSTALLATION 1 2 3 4 Check the engine oil level and adjust engine oil Refer to LU 25 Inspection Start engine and check there is no leakage of engine oil Stop engine and wait for 15 minutes Check the engine oil level again Refer to LU 25 Inspection Revision 2009 March EM 190 2009 FX35 FX50 lt REMOVAL AND INSTALLATION gt VK50VE IGNITION COIL SPARK PLUG AND ROCKER COVER Removal and Installation Exploded View IGNITION COIL SPARK PL
305. uator Refer to EM 31 Exploded View 4 Remove ignition coil Refer to EM 50 Removal and Installation Revision 2009 March EM 18 2009 FX35 FX50 SPARK PLUG lt PERIODIC MAINTENANCE gt VQ35HR 5 Remove spark plug with a spark plug wrench commercial ser vice tool a 14 mm 0 55 in JPBIA0030ZZ INSTALLATION Installation is the reverse order of removal n S p e ct i O n INFOID 0000000003887332 INSPECTION AFTER REMOVAL Use the standard type spark plug for normal condition Spark plug Standard type Refer to EM 143 Spark Plug CAUTION Never drop or impact spark plug Never use a wire brush for cleaning If plug tip is covered with carbon spark plug cleaner may be used Cleaner air pressure Less than 588 kPa 6 kg cm 85 psi Cleaning time Less than 20 seconds SMA773C Measure spark plug gap When it exceeds the limit replace spark plug even if it is within the speci fied replacement mileage Refer to EM 143 Spark Plug e Spark plug gap adjustment is not required between replace ment intervals JPBIA0031ZZ Revision 2009 March EM 19 2009 FX35 FX50 CAMSHAFT VALVE CLEARANCE lt PERIODIC MAINTENANCE gt VQ35HR CAMSHAFT VALVE CLEARANCE Inspection and Adjustment INFOID 0000000003887388 INSPECTION Perform inspection as follows after removal installation or replacement of camshaft or valve related parts or if there is unusual engine conditions regard
306. uel pressure applied to fuel piping check for fuel leak age 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 NOTE If hydraulic pressure inside chain tensioner drops after removal installation slack in guide may generate a pounding noise during and just after the engine start However this does not indicate an unusualness Noise will stop after hydraulic pressure rises Warm up engine thoroughly to check there is no leakage of fuel 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 Items 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 Transmission transaxle CVT fluid power steering fluid brake fluid etc Revision 2009 March EM 69 2009 FX35 FX50 CAMSHAFT lt REMOVAL AND INSTALLATION gt CAMSHAFT Exploded View SEC 1119130 0 55 0 5 6 41 a 1 Camshaft bracket No 3 4 2 Camshaft bracket No 2 4 Camshaft bracket No 1 bank 1 5 Dowel pin Camshaft
307. ure lt Engine front JPBIA0257ZZ 5 Remove camshaft 6 Remove valve lifter e Identify installation positions and store them without mixing them up 7 Remove timing chain tensioners Secondary 1 from cylinder head A Bank1 B Bank2 e Remove timing chain tensioners secondary with its stopper pin C attached NOTE Stopper pin should be attached when timing chain secondary is removed JPBIAO121ZZ INSTALLATION 1 Install timing chain tensioners secondary on both sides of cylinder head Revision 2009 March EM 71 2009 FX35 FX50 CAMSHAFT lt REMOVAL AND INSTALLATION gt VQ35HR e Install timing chain tensioners 1 with its stopper pin C attached Bank 1 side A Sliding part facing downward Bank 2 side B Sliding part facing upward aay JPBIA0121ZZ 2 Install valve lifter e Install it in the original position 3 Install camshafts e Follow your identification marks made during removal or fol low the identification marks that are present on new camshafts for proper placement and direction lt _ Engine front i Paint marks vee Bank INT EXH Dowel pin Identification 1 M1 E M2 F M3 D mark C Light i 2 ib 3 blue ME JPBIA1191ZZ 1 INT A Yes Green No Light 1E blue INT A Yes Green No Light 1G blue i Ligh EXH B Yes No Green ight 1H blue e Install camshaft so that dowel pin A on front end face are pos
308. ut from fuel tube Be careful not to damage injector nozzles during removal Never bump or drop fuel injector e Never disassemble fuel injector JPBIAO036ZZ 12 Remove fuel sub tube and fuel damper if necessary INSTALLATION 1 Install fuel damper 4 as per the following a Install new O ring 2 to fuel tube 1 as shown When handling new O ring be careful of the following caution CAUTION Handle O ring with bare hands Never wear gloves e Lubricate O ring with new engine oil e Never clean O ring with solvent e Check that O ring and its mating part are free of foreign material When installing O ring be careful not to scratch it with tool or fingernails Also be careful not to twist or stretch O ring If O ring was stretched while it was being attached never insert it quickly into fuel tube Insert new O ring straight into fuel tube Never twist it Install spacer 3 to fuel damper c Insert fuel damper straight into fuel tube CAUTION Insert straight checking sure that the axis is lined up Insert fuel damper at 130 N 13 3 kg 29 2 Ib or less to pre vent damage to the parts Insert fuel damper until B is touching A of fuel tube d Tighten bolts evenly in turn e After tightening bolts check that there is no gap between fuel damper cap 5 and fuel tube 2 Install fuel sub tube e When handling new O rings be careful of the following caution CAUTION Handle O ring wi
309. ver Refer to EM 174 Exploded View 2 Remove ignition coil Refer to EM 191 Exploded View Revision 2009 March EM 167 2009 FX35 FX50 SPARK PLUG lt PERIODIC MAINTENANCE gt VKSOVE 3 Remove spark plug with a spark plug wrench commercial ser vice tool a 14 mm 0 55 in JPBIA0030ZZ INSTALLATION Installation is the reverse order of removal n S pect i O n INFOID 0000000003733408 INSPECTION AFTER REMOVAL Use the standard type spark plug for normal condition Spark plug Standard type Refer to EM 282 Spark Plug CAUTION e Never drop or impact spark plug Never use a wire brush for cleaning e If plug tip is covered with carbon use spark plug cleaner to clean Cleaner air pressure Less than 588 kPa 6 kg cm 85 psi Cleaning time Less than 20 seconds SMA773C e Measure spark plug gap When it exceeds the limit replace spark plug even if it is within the speci fied replacement mileage Refer to EM 282 Spark Plug e Spark plug gap adjustment is not required between replace ment intervals JPBIA0031ZZ Revision 2009 March EM 168 2009 FX35 FX50 CAMSHAFT VALVE CLEARANCE lt PERIODIC MAINTENANCE gt VK50VE CAMSHAFT VALVE CLEARANCE n S pect i O n INFOID 0000000003733409 INSPECTION Check valve clearance if applicable to the following cases Intake side e At the removal and installation of VVEL ladder assembly or valve related parts or at the occurrence
310. wever this does not indicate a malfunction The noise will stop after hydraulic pressure rises e Warm up engine thoroughly to check that there is no leakage of fuel or any oil fluids including engine oil and engine coolant e Bleed air from lines and hoses of applicable lines such as in cooling system e After cooling down engine again check oil fluid levels including engine oil and engine coolant Refill them to the specified level if necessary Summary of the inspection items Items Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluids Level Leakage Level Fuel Leakage Leakage Leakage Transmission transaxle CVT fluid power steering fluid brake fluid etc Revision 2009 March EM 244 2009 FX35 FX50 CYLINDER HEAD lt UNIT DISASSEMBLY AND ASSEMBLY gt CYLINDER HEAD Exploded View SEC 111 130 220 9 22 0 2 2 16 t x Ce 7 90 0 24 5 2 5 18 p nao lt 1 Valve lifter EXH 2 Valve collet EXH 3 4 Valve oil seal EXH 5 Valve spring with valve spring seat 6 EXH 7 Spark plug 8 Valve seat INT 9 10 Valve spring retainer INT 11 Valve oil seal INT 12 13 Cylinder head bolt 14 Cylinder head bank 2 15 16 Valve EXH 17 Cylinder head gasket bank 2 18 19 Cylinder block 20 Valve INT 21 22 Cylinder head bank 1 23 Gasket 24 25 Engine coolant tem
311. work safely avoid forceful or uninstructed operations Never start working until exhaust system and engine coolant are cool enough If items or work required are not covered by the engine section refer to the applicable sections Always use the support point specified for lifting e Use either 2 pole lift type or separate type lift as best you can If board on type is used for unavoid able reasons support at rear axle jacking point with transmission jack or similar tool before starting work in preparation for the backward shift of center of gravity Revision 2009 March EM 82 2009 FX35 FX50 ENGINE ASSEMBLY lt UNIT REMOVAL AND INSTALLATION gt VQ35HR e For supporting points for lifting and jacking point at rear axle refer to GI 26 Garage Jack and Safety Stand and 2 Pole Lift REMOVAL Outline EM At first remove the engine and the transmission assembly with front suspension member downward Then em separate the engine from transmission Preparation 1 Release fuel pressure Refer to EC 567 Inspection 2 Disconnect both battery cables Refer to PG 120 Exploded View 3 Drain engine coolant from radiator Refer to CO 8 Draining CAUTION e Perform this step when engine is cold e Never spill engine coolant on drive belt 4 Remove the following parts e Radiator reservoir tank Refer to CO 14 Exploded View e Engine cover Refer to EM 27 Exploded View e Front road wheel and tires power tool Engine
312. xceeds the limit Replace valve spring with valve spring seat EXH Refer to EM 245 Exploded View Exhaust side Replace VVEL ladder assembly amp cylinder head assembly Refer to EM 227 Exploded View Intake side NOTE Since the valve spring with valve spring seat INT cannot be replaced by the piece VVEL ladder assembly amp cylinder head assembly replacement are required JPBIAO189ZZ Valve Spring Dimensions and Valve Spring Pressure Load e Check the valve spring with valve spring seat pressure at speci fied spring height Standard Refer to EM 285 Cylinder Head e If the installation load or load with valve open is out of the stan dard Replace valve spring with valve spring seat EXH Refer to EM 245 Exploded View Exhaust side Replace VVEL ladder assembly amp cylinder head assembly Refer to EM 227 Exploded View Intake side NOTE Since the valve spring with valve spring seat INT cannot be replaced by the piece VVEL ladder assembly amp cylinder head assembly replacement are required INSPECTION AFTER ASSEMBLY Inspection for Leakage The following are procedures for checking fluid leakage lubricant leakage e Before starting engine check oil fluid levels including engine coolant and engine oil If any are less than the required quantity fill them to the specified level Refer to MA 12 Fluids and Lubricants Follow the procedure below to check for
313. y for easy troubleshooting and assembly e 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 Precaution for Inspection Repair and Replacement InFo10 0000000008733481 Before repairing or replacing thoroughly inspect parts Inspect new replacement parts in the same way and replace if necessary Precaution for Assembly and Installation InFo10 0000000008733482 Use torque wrench to tighten bolts or nuts to specification 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 specified 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 Dowel pins are used for several parts alignment When replacing and reassembling parts with dowel pins check that dowel pins are installed in the original position 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 st
314. ylinder block e While turning crankshaft by hand check that it turns smoothly Install main bearing caps as per the following e Align the identification number to the journal position to install lt Engine front e Install it with the front mark indicated by stamping facing the front of engine e 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 8 Install each main bearing cap bolts as per the following CAUTION Remove dust dirt and engine oil on bearing mating surfaces of cylinder block and main bearing caps BD OV gang C j IQR Y 2 SSS JPBIA2148ZZ JPBIA2380ZZ If main bearing cap bolts and sub bolts are re used check their outer diameters before installa tion Refer to EM 265 Inspection Revision 2009 March EM 260 2009 FX35 FX50 lt UNIT DISASSEMBLY AND ASSEMBLY gt VKSOVE a Apply new engine oil to threads and seat surfaces of main bearing cap bolts and sub bolts b Tighten all bolts in order of No 1 30 temporarily lt Engine front c Tighten main bearing cap bolts M12 in order of No 1 10 O 53 9 N m 5 5 kg m 40 ft Ib d Tighten main bearing cap sub bolts M9 in order of No 11 20 O 19 6 N m 2 0 kg m 14 ft Ib e Tighten main bearing cap bolts M12 in order of No 1 10 clockwise

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