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EM-2
Revision: 2004 November 2004 FX35/FX45
FUEL INJECTOR AND FUEL TUBE ........................45
Removal and Installation ........................................45
REMOVAL ...........................................................46
INSTALLATION ....................................................47
INSPECTION AFTER INSTALLATION ................49
ROCKER COVER .....................................................51
Removal and Installation ........................................51
REMOVAL ...........................................................51
INSTALLATION ....................................................52
FRONT TIMING CHAIN CASE .................................54
Removal and Installation ........................................54
REMOVAL ...........................................................54
INSTALLATION ....................................................58
INSPECTION AFTER INSTALLATION ................62
TIMING CHAIN ..........................................................63
Removal and Installation ........................................63
REMOVAL ...........................................................64
INSPECTION AFTER REMOVAL ........................71
INSTALLATION ....................................................71
INSPECTION AFTER INSTALLATION ................80
CAMSHAFT ...............................................................82
Removal and Installation ........................................82
REMOVAL ...........................................................83
INSPECTION AFTER REMOVAL ........................84
INSTALLATION ....................................................87
Valve Clearance ......................................................89
INSPECTION .......................................................89
ADJUSTMENT ....................................................92
OIL SEAL ..................................................................94
Removal and Installation of Valve Oil Seal .............94
REMOVAL ...........................................................94
INSTALLATION ....................................................94
Removal and Installation of Front Oil Seal .............95
REMOVAL ...........................................................95
INSTALLATION ....................................................96
Removal and Installation of Rear Oil Seal ..............96
REMOVAL ...........................................................96
INSTALLATION ....................................................96
CYLINDER HEAD .....................................................98
On-Vehicle Service .................................................98
CHECKING COMPRESSION PRESSURE .........98
Removal and Installation ........................................99
REMOVAL ...........................................................99
INSPECTION AFTER REMOVAL ......................100
INSTALLATION ..................................................101
Disassembly and Assembly ..................................102
DISASSEMBLY .................................................103
ASSEMBLY .......................................................103
Inspection After Disassembly ...............................104
VALVE DIMENSIONS ........................................104
VALVE GUIDE CLEARANCE ............................105
VALVE GUIDE REPLACEMENT .......................105
VALVE SEAT CONTACT ...................................107
VALVE SEAT REPLACEMENT .........................107
VALVE SPRING SQUARENESS .......................108
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD ..............................109
ENGINE ASSEMBLY ...............................................110
Removal and Installation .......................................110
2WD MODEL .....................................................110
REMOVAL .......................................................... 111
INSTALLATION ..................................................113
INSPECTION AFTER INSTALLATION ..............113
AWD MODEL .....................................................115
REMOVAL ..........................................................115
INSTALLATION ..................................................118
INSPECTION AFTER INSTALLATION ..............118
CYLINDER BLOCK .................................................120
Disassembly and Assembly ..................................120
DISASSEMBLY ..................................................121
ASSEMBLY ........................................................126
How to Select Piston and Bearing ........................131
DESCRIPTION ..................................................131
HOW TO SELECT PISTON ...............................131
HOW TO SELECT CONNECTING ROD BEAR-
ING .....................................................................132
HOW TO SELECT MAIN BEARING ..................133
Inspection After Disassembly ................................136
CRANKSHAFT END PLAY ................................136
CONNECTING ROD SIDE CLEARANCE .........136
PISTON TO PISTON PIN OIL CLEARANCE .....136
PISTON RING SIDE CLEARANCE ...................137
PISTON RING END GAP ..................................137
CONNECTING ROD BEND AND TORSION .....138
CONNECTING ROD BEARING HOUSING
DIAMETER (BIG END) ......................................138
CONNECTING ROD BUSHING OIL CLEAR-
ANCE (SMALL END) .........................................138
CYLINDER BLOCK DISTORTION ....................139
MAIN BEARING HOUSING INNER DIAMETER .140
PISTON TO CYLINDER BORE CLEARANCE ..140
CRANKSHAFT MAIN JOURNAL DIAMETER ...141
CRANKSHAFT PIN JOURNAL DIAMETER ......142
CRANKSHAFT OUT-OF-ROUND AND TAPER .142
CRANKSHAFT RUNOUT ..................................142
CONNECTING ROD BEARING OIL CLEAR-
ANCE .................................................................142
MAIN BEARING OIL CLEARANCE ...................143
MAIN BEARING CRUSH HEIGHT ....................144
CONNECTING ROD BEARING CRUSH
HEIGHT .............................................................144
MAIN BEARING CAP BOLT OUTER DIAMETER .144
CONNECTING ROD BOLT OUTER DIAMETER .144
DRIVE PLATE ....................................................145
OIL JET ..............................................................145
OIL JET RELIEF VALVE ....................................145
SERVICE DATA AND SPECIFICATIONS (SDS) ....146
Standard and Limit ................................................146
GENERAL SPECIFICATIONS ...........................146
DRIVE BELT ......................................................147
INTAKE MANIFOLD COLLECTOR, INTAKE
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