Engine Mechanical: Other Infiniti EX35 I

Precaution for Procedure without Cowl Top Cover

When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc.

Scheme 220

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"

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 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 AIRBAG" and "SEAT BELT" of this Service Information.

PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS

Precaution Necessary for Steering Wheel Rotation after Battery Disconnect

Note. Before removing and installing any control units, first turn the push-button ignition switch to the LOCK position, then disconnect both battery cables. After finishing work, confirm that all control unit connectors are connected properly, then re-connect both battery cables. 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.

If turning the steering wheel is required with the battery disconnected or discharged, follow the procedure below before starting the repair operation.

Disconnecting Fuel Piping

1. Before starting work, check no fire or spark producing items are in the work area.
2. Release fuel pressure before disconnecting and disassembly.
3. After disconnecting pipes, plug openings to stop fuel leakage.

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

TOOL DESCRIPTION Tool number (Kent-Moore No.) Tool name Description KV10116200 (J-26336-A) Valve spring compressor KV10115900 (J-26336-20) Attachment KV10109220 (-) Adapter Disassembling valve mechanism Part (1) is a component of KV10116200 (J-26336-A), but Part (2) is not so. KV10107902 (J-38959) Valve oil seal puller Replacing valve oil seal KV10115600 (J-38958) Valve oil seal drift Installing valve oil seal Use side A (G). 20 (0.79) dia. 13 (0.51) dia. 10.3 (0.406) dia. 8 (0.31) dia. 10.7 (0.421) 5 (0.20) H: side B Unit: mm (in) EM03470000 (J-8037) Piston ring compressor Installing piston assembly into cylinder bore ST16610001 (J-23907) Pilot bushing puller Removing pilot converter KV10111100 (J-37228) Seal cutter Removing oil pan (lower and upper), front and rear timing chain case, etc. KV10112100 (BT8653-A) Angle wrench Tightening bolts for connecting rod bearing cap, cylinder head, etc. in angle KV10114400 (J-38365) Heated oxygen sensor wrench Loosening or tightening air fuel ratio sensor 1 22 mm (0.87 in) KV10118600 (J-48641) Ring gear stopper Removing and installing crankshaft pulley

Scheme 221

Scheme 222

Scheme 223

Scheme 224

Scheme 225

Commercial Service Tools

COMMERCIAL SERVICE TOOLS REFERENCE (Kent-Moore No.) Tool name Description (-) Tube presser Pressing the tube of liquid gasket (-) Power tool Loosening bolts and nuts (-) Manual lift table caddy Removing and installing engine (J-24239-01) Cylinder head bolt wrench Loosening and tightening cylinder head bolt, and used with the angle wrench [SST: KV10112100 (BT8653-A)] 13 mm (0.51 in) dia. 12 mm (0.47 in) 10 mm (0.39 in) (-) Compression gauge Adapter Checking compression pressure (-) Spark plug wrench Removing and installing spark plug 14 mm (0.55 in) (-) Valve seat cutter set Finishing valve seat dimensions (-) Piston ring expander Removing and installing piston ring (-) Valve guide drift Removing and installing valve guide Intake and Exhaust: 9.5 mm (0.374 in) dia. 5.5 mm (0.217 in) dia. (-) Valve guide reamer Reaming valve guide inner hole 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. (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 lubricant shown below. J-43897-18 [18 mm (0.71 in) dia.] for zirconia heated oxygen sensor and air fuel ratio sensor J-43897-12 [12 mm (0.47 in) dia.] for Titania heated oxygen sensor Mating surface shave cylinder Flutes (-) Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907) Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads

Scheme 226

Scheme 227

Scheme 228

Scheme 229

Scheme 230

Scheme 231

Scheme 232

Scheme 233

Checking

1. Check that the indicator (C) (notch on fixed side) of drive belt auto-tensioner is within the possible use range (A). NOTE: Check the drive belt auto-tensioner indication when the engine is cold. When new drive belt is installed, the indicator (notch on fixed side) should be within the range (B) in the figure.
2. Visually check entire drive belt for wear, damage or cracks.
3. If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.

Setting

Note. Explained here is how to disassemble with engine stand supporting transmission surface. When using different type of engine stand, note with difference in steps and etc.

Scheme 234

Scheme 235

Scheme 236

1. Remove the engine assembly from the vehicle. Refer to " «2WD : EXPLODED VIEW»(ref-368797-S25216674212010081300000) " (2WD models) or " «AWD : EXPLODED VIEW»(ref-368797-S34161627752010081300000) " (AWD models).
2. Remove the parts that may restrict installation of engine to widely use engine stand. NOTE: The procedure is described assuming that you use a widely use engine stand holding the surface, to which transmission is installed. Remove drive plate with power tool. Fix crankshaft with a ring gear stopper [SST: KV10118600 (J-48641)], and remove mounting bolts. Loosen mounting bolts in diagonal order. Check for deformation or damage drive plate. CAUTION: Never disassemble drive plate. Never place drive plate with signal plate facing down. When handling signal plate, take care not to damage or scratch it. Handle signal plate in a manner that prevents it from becoming magnetized.
3. Remove pilot converter using the pilot bushing puller [SST: ST16610001 (J-23907)] (A) if necessary.
4. Lift the engine with hoist to install it onto the widely use engine stand. CAUTION: Use an engine stand that has a load capacity [220 kg (485 lb) 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 " «EXPLODED VIEW»(ref-368797-S15585949212010081300000) ". Remove fuel injector and fuel tube assembly. Refer to " «EXPLODED VIEW»(ref-368797-S24186279832010081300000) ". Remove intake manifold. Refer to " «EXPLODED VIEW»(ref-368797-S39805602922010081300000) ". Remove ignition coil and rocker cover. Refer to " «EXPLODED VIEW»(ref-368797-S24620149682010081300000) ". Remove exhaust manifold. Refer to " «EXPLODED VIEW»(ref-368797-S19508390202010081300000) ". 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.
5. Drain engine oil. Refer to " «DRAINING»(ref-368815-S00680489972010081300000) ".
6. Drain engine coolant by removing water drain plugs (1) and (4) from cylinder block both sides as shown in the figure.

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 " CYLINDER BLOCK ".

Scheme 237

Piston Pin Outer Diameter

Measure the outer diameter of piston pin with a micrometer (A).

Standard : Refer to " CYLINDER BLOCK ".

Scheme 238

Piston to Piston Pin Oil Clearance

(Piston to piston pin oil clearance) = (Piston pin hole diameter) - (Piston pin outer diameter)

Standard : Refer to " CYLINDER BLOCK ".

1. If the calculated value is out of the standard, replace piston and piston pin assembly.
2. When replacing piston and piston pin assembly, Refer to " «DESCRIPTION»(ref-368797-S42715493472010081300000) ". NOTE: Piston is available together with piston pin as assembly. 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.

Scheme 239

1. Measure the side clearance of piston ring (1) and piston ring groove with a feeler gauge (C). Standard and limit : Refer to " «CYLINDER BLOCK»(ref-368797-S13500861732010081300000) ".
2. If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, replace piston also.

Scheme 240

1. Check that the cylinder bore inner diameter is within the specification. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-368797-S01320251792010081300000) ".
2. Lubricate with new engine oil to piston (1) and piston ring (2), and then insert piston ring until middle of cylinder with piston, and measure the piston ring end gap with a feeler gauge (B). Standard and limit : Refer to " «CYLINDER BLOCK»(ref-368797-S13500861732010081300000) ".
3. 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.

Scheme 241

1. Check with a connecting rod aligner. Bend limit : Refer to " «CYLINDER BLOCK»(ref-368797-S13500861732010081300000) ". Torsion limit
2. If it exceeds the limit, replace connecting rod assembly.

Scheme 242

1. Install connecting rod bearing cap without installing connecting rod bearing, and tightening connecting rod bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-368797-S01320251792010081300000) " for the tightening procedure.
2. Measure the inner diameter of connecting rod big end with an inside micrometer. Standard : Refer to " «CYLINDER BLOCK»(ref-368797-S13500861732010081300000) ".
3. 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).

Standard : Refer to " CYLINDER BLOCK ".

Scheme 243

Piston Pin Outer Diameter

Measure the outer diameter of piston pin with a micrometer (A).

Standard : Refer to " CYLINDER BLOCK ".

Connecting Rod Bushing Oil Clearance

(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) - (Piston pin outer diameter)

Standard and limit : Refer to " CYLINDER BLOCK ".

1. If the calculated value exceeds the limit, replace connecting rod assembly and/or piston and piston pin assembly.
2. If replacing piston and piston pin assembly, Refer to " «DESCRIPTION»(ref-368797-S42715493472010081300000) ".
3. If replacing connecting rod assembly, Refer to " «CONNECTING ROD BEARING»(ref-368797-S12497858202010081300000) " to select the connecting rod bearing.

Factory installed parts grading

Scheme 244

1. Service parts apply only to grade "0". PART GRADE REFERENCE Unit: mm (in) Grade 0 1 Connecting rod bushing inner diameter (1) 22.000 - 22.006 (0.8661 - 0.8664) 22.006 - 22.012 (0.8664 - 0.8666) Piston pin hole diameter 21.993 - 21.999 (0.8659 - 0.8661) 21.999 - 22. 005 (0.8661 - 0.8663) Piston pin outer diameter 21.989 - 21.995 (0.8657 - 0.8659) 21.995 - 22.001 (0.8659 - 0.8662) (1) After installing in connecting rod

Scheme 245

1. Using a 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.
2. 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 " «CYLINDER BLOCK»(ref-368797-S13500861732010081300000) ".
3. If it exceeds the limit, replace cylinder block.

Scheme 246

1. Install lower cylinder block (2) without installing main bearings, and tighten lower cylinder block bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-368797-S01320251792010081300000) " for the tightening procedure.
2. Measure the inner diameter of main bearing housing with a bore gauge. Standard : Refer to " «CYLINDER BLOCK»(ref-368797-S13500861732010081300000) ".
3. If out of the standard, replace cylinder block (1) and lower cylinder block as assembly. NOTE: 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

Scheme 247

Scheme 248

1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper at six different points on each cylinder. [(A) and (B) directions at (C), (D) and (E)] is in longitudinal direction of engine. f : 10 mm (0.39 in) g : 60 mm (2.36 in) h : 125 mm (4.92 in) Standard and limit : Refer to " «CYLINDER BLOCK»(ref-368797-S13500861732010081300000) ".
2. 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.
3. Oversize piston is provided. When using oversize piston, rebore 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

Measure the outer diameter of piston skirt with a micrometer (A).

Measure point Standard : Refer to " CYLINDER BLOCK ".

Scheme 249

Piston-to-Cylinder Bore Clearance

Calculate by piston skirt diameter and cylinder bore inner diameter [direction (B), position (D)].

1. A : Longitudinal direction
2. C : Top position
3. E : Bottom position
4. f : 10 mm (0.39 in)
5. g : 60 mm (2.36 in)
6. h : 125 mm (4.92 in)

(Clearance) = (Cylinder bore inner diameter) - (Piston skirt diameter).

Standard and limit : Refer to " CYLINDER BLOCK ".

1. If the calculated value exceeds the limit, replace piston and piston pin assembly. Refer to " «CYLINDER BLOCK»(ref-368797-S13500861732010081300000) ".

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, Piston skirt diameter as measured Piston to cylinder bore clearance (standard value) Honing allowance 0.02 mm (0.0008 in) Bored diameter
2. Install lower cylinder block, and tighten to the specified torque. Otherwise, cylinder bores may be distorted in final assembly.
3. Cut cylinder bores. NOTE: 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: Measurement should be done after cylinder bore cools down.

CRANKSHAFT MAIN JOURNAL DIAMETER

1. Measure the outer diameter of crankshaft main journals with a micrometer. Standard : Refer to " «CYLINDER BLOCK»(ref-368797-S13500861732010081300000) ".
2. If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to " «MAIN BEARING»(ref-368797-S41844485942010081300000) ".

Scheme 250

1. Measure the outer diameter of crankshaft pin journal with a micrometer (A). Standard : Refer to " «CYLINDER BLOCK»(ref-368797-S13500861732010081300000) ".
2. If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer to " «CONNECTING ROD BEARING»(ref-368797-S12497858202010081300000) ".

Scheme 251

1. Measure the dimensions at four different points as shown in the figure on each main journal and pin journal with a micrometer.
2. Out-of-round is indicated by the difference in the dimensions between (d) and (c) at (a) and (b).
3. Taper is indicated by the difference in the dimensions between. Limit : Refer to " «CYLINDER BLOCK»(ref-368797-S13500861732010081300000) ".
4. If the measured value exceeds the limit, correct or replace crankshaft.
5. 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 " «MAIN BEARING»(ref-368797-S41844485942010081300000) " and/or " «CONNECTING ROD BEARING»(ref-368797-S12497858202010081300000) ".

Scheme 252

1. Place V-block on precise flat table, and support the journals on the both end of crankshaft.
2. Place a dial indicator straight up on the No. 3 journal.
3. While rotating crankshaft, read the movement of the pointer on a dial indicator. (Total indicator reading) Standard and limit : Refer to " «CYLINDER BLOCK»(ref-368797-S13500861732010081300000) ".
4. If it exceeds the limit, replace crankshaft.

CONNECTING ROD BEARING OIL CLEARANCE

Method by Calculation

1. Install connecting rod bearings (1) to connecting rod (2) and connecting rod cap, and tighten connecting rod bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-368797-S01320251792010081300000) " for the tightening procedure.
2. 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 " CONNECTING ROD BEARING ".

Scheme 253

1. 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 " «DESCRIPTION»(ref-368797-S42715493472010081300000) ".

Method of Using Plastigage

Scheme 254

1. Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely.
2. Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
3. Install connecting rod bearings to connecting rod and connecting rod bearing cap, and tighten connecting rod bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-368797-S01320251792010081300000) " for the tightening procedure. CAUTION: Never rotate crankshaft.
4. 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 is delineated in "Method by Calculation" under «MAIN BEARING OIL CLEARANCE»(ref-368797-S01196411512010081300000) .

MAIN BEARING OIL CLEARANCE

Method by Calculation

1. 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 " «DISASSEMBLY AND ASSEMBLY»(ref-368797-S01320251792010081300000) " for the tightening procedure.
2. 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 " MAIN BEARING ".

Scheme 255

1. If the calculated value exceeds the limit, select proper main bearing according to main bearing inner diameter and crankshaft main journal diameter to obtain the specified bearing oil clearance. Refer to " «DESCRIPTION»(ref-368797-S42715493472010081300000) ".

Method of Using Plastigage

1. Remove engine oil and dust on crankshaft journal and the surfaces of each bearing completely.
2. Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
3. 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 " «DISASSEMBLY AND ASSEMBLY»(ref-368797-S01320251792010081300000) " for the tightening procedure. CAUTION: Never rotate crankshaft.
4. 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 delineated in the "Method by Calculation" under «MAIN BEARING CRUSH HEIGHT»(ref-368797-S35420072492010081300000) .

Scheme 256

1. 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 " «DISASSEMBLY AND ASSEMBLY»(ref-368797-S01320251792010081300000) " for the tightening procedure. Standard : There must be crush height.
2. If the standard is not met, replace main bearings.

CONNECTING ROD BEARING CRUSH HEIGHT

1. 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 " «DISASSEMBLY AND ASSEMBLY»(ref-368797-S01320251792010081300000) " for the tightening procedure. Standard : There must be crush height.
2. If the standard is not met, replace connecting rod bearings.

Scheme 257

1. Measure the outer diameters (c), (d) at two positions as shown in the figure.
2. If reduction appears in (a) range, regard it (c). Limit [(d) - (c)] : 0.11 mm (0.0043 in)
3. If it exceeds the limit (large difference in dimensions), replace lower cylinder block bolt with new one.

Scheme 258

1. Measure the outer diameters [(a), (b) and (c)] at the position shown in the figure.
2. Obtain a mean value (d) of (a) and (b).
3. Subtract (c) from (d). Limit [(d) - (c)] : 0.09 mm (0.0035 in)
4. If it exceeds the limit (large difference in dimensions), replace the bolt with new one.

Scheme 259

1. Check drive plate and signal plate for deformation or damage. CAUTION: Never disassemble drive plate. Never place drive plate with signal plate facing down. When handling signal plate, take care not to damage or scratch it. Handle signal plate in a manner that prevents it from becoming magnetized.
2. If anything is found, replace drive plate.

OIL JET

1. Check nozzle for deformation and damage.
2. Blow compressed air from nozzle, and check for clogs.
3. If it is not satisfied, clean or replace oil jet.

Scheme 260

1. Using a clean plastic stick, press check valve in oil jet relief valve. Check that valve moves smoothly with proper reaction force.
2. If it is not satisfied, replace oil jet relief valve.

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.

Scheme 261

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 " «CYLINDER BLOCK»(ref-368797-S13500861732010081300000) ".
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner diameter of the "PISTON SELECTION TABLE".
3. Select piston of the same grade.

PISTON SELECTION TABLE

PISTON GRADE CHART

Note. Piston is available together with piston pin as assembly. 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. No second grade mark is available on piston.

Scheme 262

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".
2. Apply crankshaft pin journal diameter grade stamped on crankshaft front side to the column in the "CONNECTING ROD BEARING SELECTION TABLE"
3. Read the symbol at the cross point of selected row and column in the "CONNECTING ROD BEARING SELECTION TABLE".
4. Apply the symbol obtained to the "CONNECTING ROD BEARING GRADE TABLE" to select connecting rod bearing.

WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED

1. Measure the connecting rod big end diameter. Refer to " «CYLINDER BLOCK»(ref-368797-S13500861732010081300000) ".
2. Check that the connecting rod big end diameter is within the standard value.
3. Measure the crankshaft pin journal diameter. Refer to " «CYLINDER BLOCK»(ref-368797-S13500861732010081300000) ".
4. 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".
5. Select connecting rod bearing of the same grade.

Scheme 263

CONNECTING ROD BEARING GRADE TABLE

Connecting rod bearing grade table : Refer to " CONNECTING ROD BEARING ".

Scheme 264

1. When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod bearings, use undersize (US) bearings.
2. 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)]. Bearing undersize table : Refer to " «CONNECTING ROD BEARING»(ref-368797-S02626367122010081300000) ".

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.
2. "MAIN BEARING SELECTION TABLE" columns correspond to journal diameter grade on front side of crankshaft.
3. Select main bearing grade at the point where selected row and column meet in "MAIN BEARING SELECTION TABLE".
4. Apply sign at crossing in above step 3 to "MAIN BEARING GRADE TABLE". NOTE: "MAIN BEARING GRADE TABLE" applies to all journals. 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 " «MAIN BEARING»(ref-368797-S41844485942010081300000) " and " «CYLINDER BLOCK»(ref-368797-S13500861732010081300000) ".
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 step 3 and later in "When New Cylinder Block and Crankshaft are Used".

Scheme 265

MAIN BEARING GRADE TABLE (ALL JOURNALS)

Main bearing grade table (All journals) : Refer to " MAIN BEARING ".

UNDERSIZE BEARING USAGE GUIDE

1. When the specified main bearing oil clearance is not obtained with standard size main bearings, use undersize (US) bearing.
2. 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: In grinding crankshaft main journal to use undersize bearings, keep the fillet R (A) [1.5 - 1.7 mm (0.059 - 0.067 in)]. Bearing undersize table : Refer to " «MAIN BEARING»(ref-368797-S36199960352010081300000) ".

DRIVE BELT

DRIVE BELT SERVICE DATA SPECIFICATION

SPARK PLUG

SPARK PLUG SERVICE DATA SPECIFICATION

INTAKE MANIFOLD

INTAKE MANIFOLD SERVICE DATA SPECIFICATION

EXHAUST MANIFOLD

EXHAUST MANIFOLD SERVICE DATA SPECIFICATION

CAMSHAFT

CAMSHAFT SERVICE DATA SPECIFICATION Unit: mm (in) Items Standard Limit Camshaft journal oil clearance No. 1 0.045 - 0.086 (0.0018 - 0.0034) 0.15 (0.0059) No. 2, 3, 4 0.035 - 0.076 (0.0014 - 0.0030) Camshaft bracket inner diameter No. 1 26.000 - 26.021 (1.0236 - 1.0244) - No. 2, 3, 4 23.500 - 23.521 (0.9252 - 0.9260) - Camshaft journal diameter No. 1 25.935 - 25.955 (1.0211 - 1.0218) - 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) Camshaft cam height "A" Intake 45.865 - 46.055 (1.8057 - 1.8132) 0.2 (0.008) (1) Exhaust 45.875 - 46.065 (1.8061 - 1.8136) 0.2 (0.008) (1) Camshaft runout [TIR (2) ] Less than 0.02 (0.0008) 0.05 (0.0020) Camshaft sprocket runout [TIR (2) ] - 0.15 (0.0059) (1) Cam wear limit (2) Total indicator reading

VALVE LIFTER

VALVE LIFTER SERVICE DATA SPECIFICATION

VALVE CLEARANCE

VALVE CLEARANCE SERVICE DATA SPECIFICATION

AVAILABLE VALVE LIFTER

AVAILABLE VALVE LIFTER SERVICE DATA SPECIFICATION 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 8.04 (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) 840 8.40 (0.3307)

CYLINDER HEAD

CYLINDER HEAD SERVICE DATA SPECIFICATION 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)

VALVE DIMENSIONS

VALVE DIMENSIONS SERVICE DATA SPECIFICATION Unit: mm (in) Valve head diameter "D" Intake 36.6 - 36.9 (1.441 - 1.453) Exhaust 30.2 - 30.5 (1.189 - 1.201) Valve length "L" Intake 97.13 (3.8240) Exhaust 94.67 (3.7272) Valve stem diameter "d" Intake 5.965 - 5.980 (0.2348 - 0.2354) Exhaust 5.962 - 5.970 (0.2347 - 0.2350) Valve seat angle "α" Intake 45°15' - 45°45' Exhaust Valve margin "T" Intake 1.1 (0.043) Exhaust 1.3 (0.051) Valve margin "T" limit 0.5 (0.020) Valve stem end surface grinding limit 0.2 (0.008)

Scheme 266

VALVE GUIDE

VALVE GUIDE SERVICE DATA SPECIFICATION Unit: mm (in) Items Standard Oversize (Service) [0.2 (0.008)] Valve guide Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029) 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 Valve guide clearance Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031) 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

VALVE SEAT SERVICE DATA SPECIFICATION Unit: mm (in) Items Standard Oversize (Service) [0.5 (0.02)] Cylinder head seat recess diameter "D" Intake 38.000 - 38.016 (1.4961 - 1.4967) 38.500 - 38.516 (1.5157 - 1.5164) Exhaust 31.600 - 31.616 (1.2441 - 1.2447) 32.100 - 32.116 (1.2638 - 1.2644) Valve seat outer diameter "d" Intake 38.097 - 38.113 (1.4999 - 1.5005) 38.597 - 38.613 (1.5196 - 1.5202) Exhaust 31.680 - 31.696 (1.2472 - 1.2479) 32.180 - 32.196 (1.2669 - 1.2676) Valve seat interference fit Intake 0.081 - 0.113 (0.0032 - 0.0044) Exhaust 0.064 - 0.096 (0.0025 - 0.0038) Diameter "d1" (1) Intake 34.6 (1.362) Exhaust 27.7 (1.091) Diameter "d2" (2) Intake 35.9 - 36.4 (1.413 - 1.433) Exhaust 29.3 - 29.8 (1.154 - 1.173) Angle "α1" Intake 60° Exhaust 60° Angle "α2" Intake 88°45' - 90°15' Exhaust 88°45' - 90°15' Angle "α3" Intake 120° Exhaust 120° Contacting width "W" (3) Intake 1.0 - 1.4 (0.039 - 0.055) Exhaust 1.2 - 1.6 (0.047 - 0.063) Height "h" Intake 5.9 - 6.0 (0.232 - 0.236) 5.05 - 5.15 (0.1988 - 0.2028) 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 "α1" and "α2" (2) Diameter made by intersection point of conic angles "α2" and "α3" (3) Machining data

VALVE SPRING

VALVE SPRING SERVICE DATA SPECIFICATION

VALVE SPRING SERVICE DATA SPECIFICATION

CYLINDER BLOCK

CYLINDER BLOCK SERVICE DATA SPECIFICATION Unit: mm (in) Surface flatness Standard Less than 0.03 (0.0012) Limit 0.1 (0.004) Main bearing housing inner diameter Standard 69.993 - 70.017 (2.7556 - 2.7566) Cylinder bore Inner diameter Standard Grade No. 1 95.500 - 95.510 (3.7598 - 3.7602) Grade No. 2 95.510 - 95.520 (3.7602 - 3.7606) Grade No. 3 95.520 - 95.530 (3.7606 - 3.7610) Wear limit 0.2 (0.008) Out-of-round Limit 0.015 (0.0006) Taper 0.010 (0.0004) Main bearing housing inner diameter grade (Without bearing) 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) Grade No. M 70.004 - 70.005 (2.7561 - 2.7561) 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 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 Standard Less than 0.03 (0.0012)

Scheme 267

AVAILABLE PISTON

PISTON SERVICE DATA SPECIFICATION Unit: mm (in) Items Standard Oversize (Service) [0.2 (0.008)] Piston skirt diameter "A" Grade No. 1 95.480 - 95.490 (3.7590 - 3.7594) - 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 Grade No. 0 21.993 - 21.999 (0.8659 - 0.8661) - Grade No. 1 21.999 - 22.005 (0.8661 - 0.8663) - Piston to cylinder bore clearance 0.010 - 0.030 (0.0004 - 0.0012) 0.08 (0.0031)

Scheme 268

PISTON RING

PISTON RING SERVICE DATA SPECIFICATION

PISTON PIN

PISTON PIN SERVICE DATA SPECIFICATION

CONNECTING ROD

CONNECTING ROD SERVICE DATA SPECIFICATION

CRANKSHAFT

CRANKSHAFT SERVICE DATA SPECIFICATION Unit: mm (in) Main journal diameter. "Dm" grade Standard 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) Grade No. M 64.964 - 64.963 (2.5576 - 2.5576) 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 (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) Pin journal diameter. "Dp" grade Standard 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) Grade No. J 53.966 - 53.965 (2.1246 - 2.1246) 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) Taper (Difference between "A" and "B") Limit 0.0025 (0.0001) Out-of-round (Difference between "X" and "Y") 0.0025 (0.0001) Crankshaft runout [TIR (1) ] Standard Less than 0.05 (0.0020) Limit 0.10 (0.0039) Crankshaft end play Standard 0.10 - 0.25 (0.0039 - 0.0098) Limit 0.30 (0.0118) (1) Total indicator reading

MAIN BEARING

MAIN BEARING SERVICE DATA SPECIFICATION Unit: mm (in) Grade number Thickness Width Identification color Remarks 0 2.500 - 2.503 (0.0984 - 0.0985) 19.9 - 20.1 (0.783 - 0.791) Black Grade is the same for upper and lower bearings. 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 4 2.512 - 2.515 (0.0989 - 0.0990) Blue 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 01 UPR 2.503 - 2.506 (0.0985 - 0.0987) Brown Grade and color are different for upper and lower bearings. LWR 2.500 - 2.503 (0.0984 - 0.0985) Black 12 UPR 2.506 - 2.509 (0.0987 - 0.0988) Green LWR 2.503 - 2.506 (0.0985 - 0.0987) Brown 23 UPR 2.509 - 2.512 (0.0988 - 0.0989) Yellow LWR 2.506 - 2.509 (0.0987 - 0.0988) Green 34 UPR 2.512 - 2.515 (0.0989 - 0.0990) Blue LWR 2.509 - 2.512 (0.0988 - 0.0989) Yellow 45 UPR 2.515 - 2.518 (0.0990 - 0.0991) Pink LWR 2.512 - 2.515 (0.0989 - 0.0990) Blue 56 UPR 2.518 - 2.521 (0.0991 - 0.0993) Purple LWR 2.515 - 2.518 (0.0990 - 0.0991) Pink 67 UPR 2.521 - 2.524 (0.0993 - 0.0994) White LWR 2.518 - 2.521 (0.0991 - 0.0993) Purple

UNDERSIZE

MAIN BEARING SERVICE DATA SPECIFICATION

MAIN BEARING OIL CLEARANCE SERVICE DATA SPECIFICATION

CONNECTING ROD BEARING

CONNECTING ROD BEARING SERVICE DATA SPECIFICATION

CONNECTING ROD BEARING SERVICE DATA SPECIFICATION

CONNECTING ROD BEARING OIL CLEARANCE SERVICE DATA SPECIFICATION