Engine Mechanical: Other Infiniti FX45 I

PRECAUTIONS FOR DISCONNECTING FUEL PIPING

1. Before starting work, make sure 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.

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Scheme 157

Use the chart below to help you find the cause of the symptom. (Scheme 158)

1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.

If necessary, repair or replace these parts.

Scheme 158

Scheme 159

Intake Manifold (Lower)

Tighten in numerical order as shown in the figure.

Scheme 160

1. There are two types of mounting bolts. Refer to the following for locating bolts. M8 x 90 mm (3.54 in): 7,8 M8 x 35 mm (1.38 in) Except the above

Intake Manifold (Upper)

Tighten in numerical order as shown in the figure.

Scheme 161

1. There are two types of mounting bolts. Refer to the following for locating bolts. M8 x 80 mm (3.15 in): 4,5,6,7 M8 x 25 mm (0.98 in): Except the above

Electric Throttle Control Actuator

1. Install intake manifold adapter gasket and electric throttle control actuator gasket so that three protrusions for installation identification do not face downward.
2. Tighten mounting bolts of electric throttle control actuator equally and diagonally in several steps.
3. After installation perform procedure in «INSPECTION AFTER INSTALLATION»(ref-158963-S08627609562005020300000) .

Water Hose

Insert hose 27 to 32 mm (1.06 to 1.26 in) from connector end.

Vacuum Hose

Refer to VACUUM DIAGRAMS .

Exhaust Manifold Gasket

Install exhaust manifold gasket with its directional protrusion set upward.

see scheme 25

Scheme 162

1. Install exhaust manifold in numerical order as shown in figure. NOTE: Tighten nuts No. 1 to No. 4 in two steps. The numerical order No. 9 to No. 12 show second steps.

Heated Oxygen Sensor

Scheme 163

Check on Fuel Leakage

1. Turn ignition switch "ON" (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. NOTE: Use mirrors for checking at points out of clear sight.
2. Start engine. With engine speed increased, check again for fuel leakage at connection points. CAUTION: Do not touch engine immediately after stopped, as engine becomes extremely hot.

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Scheme 166

1. Remove engine cover with power tool. Refer to «ENGINE ROOM COVER»(ref-158963-S06074735262005020300000) .
2. Refer to the following for incidental works related to left bank. Remove air duct (inlet), air cleaner case and mass air flow sensor assembly, air duct and resonator assembly. Refer to «AIR CLEANER AND AIR DUCT»(ref-158963-S32645370962005020300000) . Move harness on upper rocker cover and its peripheral aside. Remove harness brackets from camshaft bracket (No. 6). Refer to «CAMSHAFT»(ref-158963-S21071505232005020300000) . Remove electric throttle control actuator. Refer to «INTAKE MANIFOLD»(ref-158963-S18903985172005020300000) . Remove ignition coil. Refer to «IGNITION COIL»(ref-158963-S35156859472005020300000) . Remove PCV hose from PCV valve.
3. Refer to the following for incidental works related to right bank. Move harness on upper rocker cover and its peripheral aside. Remove ignition coil «IGNITION COIL»(ref-158963-S35156859472005020300000) . Remove PCV hose from PCV valve.
4. Remove grommets from right and left cowl top panel. Remove right side grommet as follows: Remove battery. Remove battery tray. Remove grommet.
5. Loosen bolts in reverse order as shown in the figure. CAUTION: Do not hold oil filler neck (right bank) not to damage it. NOTE: Loosen No. 10 bolt of the right bank and No. 10 and No. 12 bolts of the left bank from cowl top panel hole using tool.
6. Use scraper to remove all traces of liquid gasket from cylinder head and camshaft bracket.

Scheme 167

Scheme 168

1. Apply liquid gasket to joint part of cylinder head and camshaft bracket as follows: NOTE: The figure shows an example of left bank side [zoomed in shows camshaft bracket (No. 1)]. Apply only to camshaft bracket (No. 1) for right bank side. Refer to the figure "a" to apply liquid gasket to joint part of camshaft bracket (both No. 1 and No. 6) and cylinder head. Refer to the figure "b" to apply liquid gasket in 90 degrees to the figure "a". Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS .
2. Install rocker cover. Check if rocker cover gasket is not dropped from installation groove of rocker cover.
3. Tighten bolts in two steps separately in numerical order as shown in the figure. CAUTION: Do not hold oil filler neck (right bank) not to damage it. NOTE: Tighten No. 10 bolt of the right bank and No. 10 and No. 12 bolts of the left bank from cowl top panel hole with using tool. 1st step: 2.0 N.m (0.2 kg-m, 18 in-lb) 2nd step: 8.3 N.m (0.85 kg-m, 73 in-lb)
4. Install in the reverse order of removal after this step.

Scheme 169

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Scheme 181

1. Remove engine assembly from vehicle. Refer to «ENGINE ASSEMBLY»(ref-158963-S21545795282005020300000) .
2. Remove the following components and related parts: Drive belt auto tensioner and idler pulley; Refer to «DRIVE BELT AUTO TENSIONER AND IDLER PULLEY»(ref-158963-S27340166892005020300000) . Thermostat housing and hoses; Refer to «THERMOSTAT AND WATER CONTROL VALVE»(ref-172394-S06367148102005022800000) . Ignition coil; Refer to «IGNITION COIL»(ref-158963-S35156859472005020300000) . Rocker cover; Refer to «ROCKER COVER»(ref-158963-S03766277342005020300000) .
3. If necessary, remove intake valve timing control position sensor (right and left bank) and camshaft position sensor (PHASE) from intake valve timing control cover and front cover. CAUTION: Handle carefully to avoid dropping and shocks. Do not disassemble.
4. If necessary, remove intake valve timing control solenoid valve from intake valve timing control cover. CAUTION: Handle components and parts carefully to avoid dropping and shocks. Do not disassemble. Do not allow metal powder to adhere to magnetic part at sensor tip. Do not place sensors in a location where they are exposed to magnetism.
5. Remove intake valve timing control cover as follows: Loosen and remove mounting bolts in the reverse order as shown in the figure. Use seal cutter [SST: KV10111100 (J37228)] or equivalent tool to cut liquid gasket for removal. CAUTION: Exercise care not to damage mating surfaces. Pull out cover keeping levelness without an angle, as inner part of cover is engaged with the center of camshaft sprocket (INT).
6. Remove O-rings from front cover.
7. Obtain No. 1 cylinder at TDC of its compression stroke as follows: Rotate crankshaft pulley clockwise to align the TDC identification notch (without paint mark) with timing indicator on front cover. Make sure that both intake and exhaust cam noses of No. 1 cylinder (engine front side of left bank) are located as shown in the figure. If not, turn crankshaft pulley one revolution (360 degrees) and align as shown in the figure.
8. Remove crankshaft pulley as follows: Remove rear plate cover, and set ring gear stopper (SST). Loosen crankshaft pulley bolt, and then pull crankshaft pulley with both hands to remove it. CAUTION: Do not remove crankshaft pulley bolt. Keep loosened crankshaft pulley bolt in place to protect removed crankshaft pulley from dropping. Do not remove balance weight (inner hexagon bolt) at the front of crankshaft pulley.
9. Remove oil pan and oil strainer. Refer to «OIL PAN AND OIL STRAINER»(ref-158963-S07521548342005020300000) .
10. Remove front cover as follows: Loosen mounting bolts in reverse order as shown in the figure. Use seal cutter [SST: KV10111100 (J37228)] or equivalent tool to cut liquid gasket for removal. CAUTION: Exercise care not to damage mating surfaces. After removal, handle front cover carefully so it does not tilt, cant, or warp under a load.
11. Remove front oil seal from front cover using suitable tool. Use flat-blade screwdriver for removal. CAUTION: Be careful not to damage front cover.
12. Remove O-rings from cylinder heads (right and left bank) and cylinder block.
13. Remove chain tensioner cover from front cover. Use seal cutter [SST: KV10111100 (J37228)] or equivalent tool to cut liquid gasket for remove.
14. Remove oil pump drive spacer. Set bolts in the two bolt holes [M6 x pitch 1.0 mm (0.04 in)] on front surface. Using suitable puller, pull oil pump drive spacer off from crankshaft. NOTE: The dimension between the centers of the two bolt holes is 33 mm (1.30 in). In the figure, a commercial steering puller is used.
15. Remove oil pump. Refer to OIL PUMP .
16. Remove chain tensioner (left bank) as follows: NOTE: To remove timing chain and related parts, start with those on left bank. The procedure for removing parts on right bank is omitted because it is the same as that for left bank. Press tab in the direction of arrow (or turn lever in the direction of arrow) to unlock the locking with the groove that stops tensioner plunger from returning. Lightly press tensioner plunger to release the tension of spring for this operation. Push in tensioner plunger to align the hole on lever and that on pump main body. Pushing in tensioner too far does not allow the holes to align. Therefore, push in plunger to the degree at which the start of stopper groove and tab engages. Insert stopper pin [hard wire with approx. 0.5 mm (0.020 in) diameter or similar tool] to fix plunger. With plunger fixed, remove chain tensioner.
17. Remove chain tension guide and timing chain slack guide.
18. Remove timing chain and crankshaft sprocket. CAUTION: After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike the piston head.
19. With hexagonal part of camshaft locked with wrench, loosen bolts securing camshaft sprocket to remove camshaft sprocket.
20. Perform same procedure as for left bank, remove timing chain and related parts on right side.
21. Use scraper to remove all traces of old liquid gasket from front cover and opposite mating surfaces. Remove oil liquid gasket from bolt hole and thread.
22. Use scraper to remove all trace of liquid gasket from chain tensioner cover and intake valve timing control covers.

Timing Chain

Check for cracks and any excessive wear at the roller links and link plates. Replace timing chain as necessary.

Scheme 182

Scheme 183

Note. The above figure shows the relationship between the mating mark on each timing chain and that on the corresponding sprocket, with the components installed. Parts with an identification mark (R or L) should be installed on the corresponding bank according to the mark. Parts with an identification mark: Camshaft sprocket (INT) Dowel pin groove of camshaft sprocket (EXH) (camshaft sprocket is same part both banks) Chain tension guide Chain slack guide Because of parallel manufacture, there are two types of mark (link colors) for timing chain. To install timing chain and related parts, start with those on right bank. The procedure for installing parts on left bank is omitted because it is the same as that for installation on right bank.

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1. Make sure that crankshaft key and dowel pin of each camshaft 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 left bank
2. Install camshaft sprockets. Install onto correct side by checking with identification mark on surface. Install camshaft sprocket (EXH) by selectively using the groove of dowel pin according to the bank. (Common part used for both banks.) Lock the hexagonal part of camshaft in the same procedure as for removal, and tighten mounting bolts.
3. Install crankshaft sprockets for both banks. Install each crankshaft sprocket so that its flange side (the larger diameter side without teeth) faces in the direction shown in the figure. NOTE: The same parts are used but facing directions are different.
4. Install timing chains and related parts. Align the mating mark on each sprocket and timing chain for installation. CAUTION: For the above reason, after the mating marks are aligned, keep them aligned by holding them with a hand. NOTE: Before installing chain tensioner, it is possible to change the position of mating mark on timing chain for that on each sprocket for alignment. Install slack guides and tension guides onto correct side by checking with identification mark on surface. Install chain tensioner with plunger fixed as described in its removal. CAUTION: Before and after the installation of chain tensioner, make sure that the mating mark on timing chain is not out of alignment. After installing chain tensioner, remove stopper pin to release tensioner. Make sure tensioner is released. To avoid chain-link skipping of timing chain, do not move crankshaft or camshafts until front cover is installed.
5. Perform the same procedure as for right bank, install timing chain and related parts on left side.
6. Install oil pump. Refer to OIL PUMP.
7. Install oil pump drive spacer as follows: Insert oil pump drive spacer according to the directions of crankshaft key and the two flat surfaces of oil pump inner rotor. If the positional relationship does not allow the insertion, rotate oil pump inner rotor with a finger to allow spacer. After confirming that the position of each part is in correct condition to allow for spacer, force fit spacer by lightly tapping with plastic hammer until it contacts and does not go further.
8. Install front oil seal on front cover. Apply new engine oil to both oil seal lip and dust seal lip. 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. Using suitable drift, press fit until the height of front oil seal is level with the mounting surface. Suitable drift Outer diameter: 56 mm (2.20 in) Inner diameter: 49 mm (1.93 in) Make sure the garter spring is in position and seal lips not inverted.
9. Install chain tensioner cover to front cover. Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( - )] to front cover as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS.
10. Install front cover as follows: Install new O-rings onto cylinder heads (right and left bank) and cylinder block. Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( - )] to front cover as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS. Make sure again that the mating marks on timing chain and that on each sprocket are aligned. Then, install front cover. CAUTION: Be careful to avoid interference with the front end of oil pump drive spacer. Such interference may damage front oil seal. Tighten mounting bolts in numerical order as shown in the figure. There are four type mounting bolts. After all bolts are tightened, retighten them in numerical order (Scheme 194) CAUTION: Be sure to wipe off any excessive liquid gasket leaking onto surface mating with oil pan.
11. Install intake valve timing control cover as follows: At the back of intake valve timing control cover, install new seal rings (three for each bank) to the area to be inserted into camshaft sprocket (INT). CAUTION: Do not spread seal ring excessively to avoid breaks and deformation. Install new O-rings on front cover. Apply a continuous bead of liquid gasket with tube presser [SST: WS3930000 ( - )] to intake valve timing control covers as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS. Tighten mounting bolts in numerical order as shown in the figure.
12. Install intake valve timing control position sensor, intake valve timing control solenoid valve and camshaft position sensor (PHASE) to intake valve timing control cover and front cover if removed. Be sure to tighten bolts with flanges completely seated.
13. Install oil pan and oil strainer. Refer to «OIL PAN AND OIL STRAINER»(ref-158963-S07521548342005020300000).
14. Install crankshaft pulley as follows: Fix crankshaft with ring gear stopper [SST: J-45476]. Install crankshaft pulley, taking care not to damage front oil seal. Install according to dowel pin of oil pump drive spacer. Lightly tapping its center with plastic hammer, insert pulley. CAUTION: Do not tap pulley on the side surface where belt is installed (outer circumference). Apply engine oil onto threaded parts of crankshaft pulley bolt and seating area. Tighten crankshaft pulley bolt. 93.1 N.m (9.5 kg-m, 69 ft-lb) Put a paint mark on crankshaft pulley aligning with angle mark on crankshaft pulley bolt. Further tighten by 90 degrees. (Angle tightening) Check the tightening angle by referencing the notches. The angle between two notches is 90 degrees.
15. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to confirm it turns smoothly.
16. Install in the reverse order of removal after this step. NOTE: If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in guide may generate a pounding noise during and just after engine start. However, this does not indicate an unusualness. Noise will stop after hydraulic pressure rises.

Camshaft Journal Oil Clearance

1. (Oil clearance) = (Camshaft bracket inner diameter) - (Camshaft journal diameter). Standard: No. 1 : 0.045 - 0.083 mm (0.0018 - 0.0033 in) No. 2, 3, 4 : 0.030 - 0.068 mm (0.0012 - 0.0027 in)
2. If out of the standard, replace either or both camshaft and cylinder head. NOTE: Camshaft brackets cannot be replaced as a single part, because it is machined together with cylinder head. Replace whole cylinder head assembly.

Scheme 200

Scheme 201

1. Install dial indicator in thrust direction on front end of camshaft. Measure end play of dial indicator when camshaft is moved forward/backward (in direction to axis). Standard : 0.115 - 0.188 mm (0.0045 - 0.0074 in)
2. Measure the following parts if out of the limit. Dimension "A" for camshaft No. 1 journal Standard : 30.500 - 30.548 mm (1.2008 - 1.2027 in) Dimension "B" for cylinder head No. 1 journal Standard : 30.360 - 30.385 mm (1.1953 - 1.1963 in)
3. Refer to the standards above, and then replace camshaft and/or cylinder head.

Scheme 202

1. Put V-block on precise flat table, and support No. 2 and No. 5 journal of camshaft. CAUTION: Do not support journal No. 1 (on the side of camshaft sprocket) because it has a different diameter from the other three locations.
2. Measure camshaft sprocket runout with dial indicator. (Total indicator reading) Limit : 0.15 mm (0.0059 in) If it exceeds the limit, replace camshaft sprocket.

Valve Lifter and Adjusting Shim

Check if surface of valve lifter and adjusting shim has any wear or cracks.

Scheme 203

1. If anything above is found, replace valve lifter.
2. When replacing adjusting shim, refer to «ADJUSTMENT»(ref-158963-S39009489342005020300000) .

Scheme 204

1. Measure outer diameter of valve lifter with micrometer. Standard : 33.965 - 33.975 mm (1.3372 - 1.3376 in)

Scheme 205

1. Measure inner diameter of valve lifter hole of cylinder head with inside micrometer. Standard : 34.000 - 34.016 mm (1.3386 - 1.3392 in)

Valve Lifter Clearance

1. (Valve lifter clearance) = (Valve lifter hole diameter) - (Valve lifter outer diameter) Standard : 0.025 - 0.51 mm (0.0010 - 0.0020 in)
2. If it exceeds 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.

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1. Install valve lifters and adjusting shims if removed. Install it in the original position.
2. Install camshafts. Follow your identification marks made during removal, or follow the identification marks that are present on new camshafts for proper placement and direction. Install camshafts so that dowel pin on front end face are positioned as shown in the figure. (No. 1 cylinder TDC on its compression stroke) NOTE: Though camshaft does not stop at the position as shown, 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
3. Install camshaft brackets. Remove foreign material completely from camshaft bracket backside and from cylinder head installation face. Install by referring to installation location mark on upper surface and front mark. Install so that installation location mark can be correctly read when viewed from the side of left exhaust bank. Apply liquid gasket to mating surface of camshaft bracket (No. 1) as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS . CAUTION: After installation, be sure to wipe off any excessive liquid gasket leaking from part "A" and "B" (both on right and left sides). Remove completely any excess of liquid gasket inside bracket. Apply liquid gasket to mating surface of camshaft bracket (No. 6) on left bank intake as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS . CAUTION: After installation, be sure to wipe off any excessive liquid gasket leaking from part "A" and "B" (both on right and left sides). Remove completely any excess of liquid gasket inside bracket.
4. Tighten camshaft bracket bolts in the following steps, in numerical order as shown in the figure. Tighten No. 9 to 12 in numerical order as shown. 1.96 N.m (0.2 kg-m, 1 ft-lb) Tighten No. 1 to 8 in numerical order as shown. 1.96 N.m (0.2 kg-m, 1 ft-lb) Tighten No. 13 to 14 in numerical order as shown. (Left bank only) 1.96 N.m (0.2 kg-m, 1 ft-lb) Tighten all bolts in numerical order as shown. 5.88 N.m (0.6 kg-m, 4 ft-lb) Tighten No. 1 to 12 in numerical order as shown. 10.41 N.m (1.1 kg-m, 8 ft-lb) Tighten No. 13 to 14 in numerical order as shown. (Left bank only) 31.35 N.m (3.2 kg-m, 23 ft-lb) CAUTION: After tightening mounting bolts of camshaft brackets, be sure to wipe off excessive liquid gasket from the parts listed below. Mating surface of rocker cover Mating surface of front cover
5. Install camshaft sprockets. Install by checking with identification mark on surface. Install camshaft sprocket (EXH) by selectively using the groove of dowel pin according to the bank. (Common part used for both banks.) Lock the hexagonal part of camshaft in the same way as for removal, and tighten mounting bolts.
6. Check and adjust valve clearance. Refer to «VALVE CLEARANCE»(ref-158963-S29581479042005020300000) .
7. Install in the reverse order of removal after this step.

Cylinder Head Distortion

Note. When performing this inspection, cylinder block distortion should be also checking. Refer to CYLINDER BLOCK DISTORTION .

Scheme 214

1. Using scraper, wipe off oil, scale, gasket, sealant and carbon deposits from surface of cylinder head. CAUTION: Do not allow gasket fragments to enter engine oil or engine coolant passages.
2. At each of several locations on bottom surface of cylinder head, measure distortion in six directions. Limit : 0.1 mm (0.004 in) If it exceeds the limit, replace cylinder head.

Scheme 215

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1. Install cylinder head gasket.
2. Turn crankshaft until No. 1 piston is set at TDC. Crankshaft key should line up with the left bank cylinder center line as shown in the figure.
3. Install cylinder head and follow the steps below to tighten cylinder head bolts in numerical order as shown in the figure. CAUTION: If cylinder head bolts are re-used, check their outer diameters before installation. Refer to «CYLINDER HEAD BOLTS OUTER DIAMETER»(ref-158963-S00226879112005020300000) . Apply engine oil to threads and seating surface of cylinder head bolts. Tighten all bolts. 98.1 N.m (10 kg-m, 72 ft-lb). 98.1 N.m (10 kg-m, 72 ft-lb) Completely loosen all bolts. 0 N.m (0 kg-m, 0 ft-lb) CAUTION: In step "c", loosen bolts in reverse order of that indicated in the figure. Tighten all bolts to 44.1 N.m (4.5 kg-m, 33 ft-lb). 44 N.m (4.5 kg-m, 33 ft-lb) Turn all bolts 60 degrees clockwise. (Angle tightening) CAUTION: Check and confirm the tightening angle by using angle wrench (SST) and cylinder head bolt wrench (commercial service tool). Avoid judgment by visual inspection without SST. Turn all bolts 60 degrees clockwise again. (Angle tightening)
4. Install in the reverse order of removal after this step.

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Scheme 220

1. Remove spark plug with spark plug wrench (commercial service tool).
2. Remove adjusting shim and valve lifter. Identify installation positions, and store them without mixing them up.
3. Remove valve collet. Compress valve spring with valve spring compressor, attachment and adapter (SST). Remove valve collet with magnetic hand. CAUTION: When working, take care not to damage valve lifter holes.
4. Remove valve spring retainer and valve spring. CAUTION: Do not remove valve spring seat from valve spring.
5. Push valve stem to combustion chamber side, and remove valve. Identify installation positions, and store them without mixing them up.
6. Remove valve oil seal with valve oil seal puller (SST).
7. If valve seat must be replaced, refer to «VALVE SEAT REPLACEMENT»(ref-158963-S07060372312005020300000) .
8. If valve guide must be replaced, refer to «VALVE GUIDE REPLACEMENT»(ref-158963-S21607327342005020300000) .
9. Remove spark plug tube, as necessary. Using pair of pliers, pull spark plug tube out of cylinder head. CAUTION: Take care not to damage cylinder head. Once removed, spark plug tube will be deformed and cannot be reused. Do not remove it unless absolutely necessary.

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Scheme 224

1. When valve guide is removed, install it. Refer to «VALVE GUIDE REPLACEMENT»(ref-158963-S21607327342005020300000) .
2. When valve seat is removed, install it. Refer to «VALVE SEAT REPLACEMENT»(ref-158963-S07060372312005020300000) .
3. Install valve oil seal. Install with valve oil seal drift (SST) to match dimension in the figure.
4. Install valve. Install in the original position. NOTE: Larger diameter valves are for intake side.
5. Install valve spring. Install smaller pitch (valve spring seat side) to cylinder head side.
6. Install valve spring retainer.
7. Install valve collet. Compress valve spring with valve spring compressor, attachment and adapter (SST). Install valve collet with magnetic hand. CAUTION: When working, take care not to damage valve lifter holes. Tap stem edge lightly with plastic hammer after installation to check its installed condition.
8. Install valve lifter and adjusting shim. Install in the original position.
9. Install spark plug tube. Press-fit spark plug tube following procedure below. Remove old liquid gasket adhering to cylinder-head mounting hole. Apply liquid gasket to area within approximately 12 mm (0.47 in) form edge of spark plug tube press-fit side. Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS . Using drift, press-fit spark plug tube so that its height "H" is as specified in the figure. Standard press-fit height "H": 38.4 - 39.4 mm (1.512 - 1.551 in) CAUTION: When press-fitting, take care not to deform spark plug tube. After press-fitting, wipe off liquid gasket protruding onto cylinder-head upper face.
10. Install spark plug with spark plug wrench (commercial service tool).

Scheme 225

1. Check dimensions of each valve. For dimensions (Scheme 281)
2. If dimensions are out of the standard, replace valve. (Scheme 281)

Valve Stem Diameter

Measure diameter of valve stem with micrometer.

Scheme 226

1. Standard Intake : 5.972 - 5.980 mm (0.2351 - 0.2354 in) Exhaust : 5.962 - 5.970 mm (0.2347 - 0.2350 in)

Valve Guide Inner Diameter

Measure inner diameter of valve guide with inside micrometer.

1. Standard Intake and Exhaust : 6.000 - 6.018 mm (0.2362 - 0.2369 in)

Valve Guide Clearance

(Valve guide clearance) = (Valve guide inner diameter) - (Valve stem diameter).

1. Valve guide clearance: Standard Intake : 0.020 - 0.046 mm (0.0008 - 0.0018 in) Exhaust : 0.030 - 0.056 mm (0.0012 - 0.0022 in) Limit Intake : 0.08 mm (0.003 in) Exhaust : 0.1 mm (0.004 in) If it exceeds the limit, replace valve and/or valve guide.

Outline

At first, remove engine, transmission assembly and front final drive with front suspension member downward. Then separate engine from transmission.

Preparation

1. Release fuel pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-151810-S21305829172003010800000) .
2. Drain engine coolant from radiator. Refer to «DRAINING ENGINE COOLANT»(ref-172394-S36492838212005022800000) .
3. Disconnect both battery terminals.
4. Remove crankshaft position sensor (POS) from transmission. CAUTION: Handle carefully to avoid dropping and shocks. Do not disassemble. Do not allow metal powder to adhere to magnetic part at sensor tip. Do not place sensors in a location where they are exposed to magnetism.
5. Remove the following parts: Hood assembly; Refer to HOOD . Engine cover; Refer to «ENGINE ROOM COVER»(ref-158963-S06074735262005020300000) . Front and rear engine undercover Air duct (inlet), air duct and air cleaner case assembly; Refer to «AIR CLEANER AND AIR DUCT»(ref-158963-S32645370962005020300000) . Drive belts; Refer to «DRIVE BELTS»(ref-158963-S21592309282005020300000) . Radiator and radiator hoses (upper and lower); Refer to «REMOVAL AND INSTALLATION»(ref-172394-S31028763572005022800000) . Front road wheels and tires
6. Discharge refrigerant from A/C circuit. Refer to «REFRIGERANT LINES»(ref-171325-S33575650812005020800000) .

Engine Room LH

1. Disconnect engine room harness from the engine side and set it aside for easier work.
2. Disconnect heater hoses, and install plugs to avoid leakage of engine coolant.
3. Disconnect ground cable from exhaust manifold cover to vehicle.
4. Disconnect vacuum hose between vehicle and engine and set it aside.
5. Remove A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope. Refer to «COMPONENTS»(ref-171325-S14788335622005020800000) .

Engine Room RH

1. Disconnect fuel feed hose and EVAP hose. Refer to «FUEL INJECTOR AND FUEL TUBE»(ref-158963-S14867697182005020300000) . CAUTION: Fit plugs onto disconnected hose to prevent fuel leak.
2. Disconnect engine room harness from the engine side and set it aside for easier work.
3. Disconnect ground cable from exhaust manifold cover to vehicle.
4. Disconnect vacuum hose between vehicle and engine and set it aside.
5. Disconnect reservoir tank of power steering oil pump from engine, and move it aside for easier work. CAUTION: When temporarily securing, keep reservoir tank upright to avoid a fluid leak.

Vehicle Underbody

1. Remove front cross bar. Refer to «REMOVAL & INSTALLATION»(ref-166182-S14780889182004091500000) .
2. Disconnect power steering oil pump from engine. Move it from its location and secure with a rope for easier work. Refer to «REMOVAL AND INSTALLATION (VK45DE MODELS)»(ref-172959-S03591239322005030800000) .
3. Remove A/T fluid cooler tube. Refer to «REMOVAL AND INSTALLATION (AWD MODELS)»(ref-171001-S14766714062005012500000) .
4. Remove exhaust front tube and center muffler with power tool. Refer to EXHAUST SYSTEM .
5. Remove RH and LH transverse link mounting bolts and nuts. Refer to «TRAVERSE LINK & BALL JOINT»(ref-166182-S29506703952004091500000) .
6. Disconnect stabilizer connecting rod lower. Refer to «REMOVAL & INSTALLATION»(ref-166182-S14780889182004091500000) .
7. Remove A/T control rod at control device assembly side. Then temporarily secure it on transmission, so that it does not sag. Refer to «SHIFT CONTROL DEVICE»(ref-166548-S31711463872005020300000) .
8. Remove rear plate cover, then remove drive plate to torque converter connecting bolts. Refer to «REMOVAL AND INSTALLATION (AWD MODELS)»(ref-171001-S14766714062005012500000) .
9. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Refer to STEERING COLUMN .
10. Remove rear propeller shaft. Refer to «REMOVAL AND INSTALLATION»(ref-172647-S13459453942005030200000) . After disconnection, plug the opening on transmission side.
11. Remove front drive shaft (both side). Refer to «AXLE SHAFT»(ref-165270-S38183230462004082400000) .
12. Remove front propeller shaft. Refer to FRONT PROPELLER SHAFT .
13. Remove three way catalyst (both bank). Refer to «EXHAUST MANIFOLD AND THREE WAY CATALYST»(ref-158963-S19526898532005020300000) .

Scheme 227

Scheme 228

1. Install engine slingers into front of left bank cylinder head and front of right bank cylinder head. Slinger bolts: 33.4 N.m (3.4 kg-m, 25 ft-lb)
2. Lift with hoist and secure engine in position.
3. Use manual lift table caddy (commercial service tool) or equivalently rigid tool such as transmission jack. Securely support bottom of suspension member and transmission. CAUTION: Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.
4. Remove front suspension member mounting nuts with power tool. Refer to «REMOVAL & INSTALLATION»(ref-166182-S14780889182004091500000) .
5. Carefully lower jack, or raise lift to remove engine, transmission front final drive and front suspension member assembly. When performing work, observe the following caution: CAUTION: Confirm there is no interference with vehicle. Make sure that all connection points have been disconnected. Keep in mind the center of vehicle gravity changes. If necessary, use jack(s) to support vehicle at rear jacking point(s) to prevent it from falling it off the lift.

Scheme 229

1. Change engine slinger installing to cylinder head (right bank). NOTE: In order to keep secure position when hoisting engine. Slinger bolts: 33.4 N.m (3.4 kg-m, 25 ft-lb)
2. Remove engine mounting insulators (RH and LH) under side nut with power tool.
3. Lift with hoist and separate engine and transmission assembly from front suspension member. CAUTION: Before and during this lifting, always check if any harnesses are left connected. Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
4. Remove alternator. Refer to «GENERATOR»(ref-166067-S04166173422004091000000) .
5. Remove starter motor. Refer to «REMOVAL & INSTALLATION»(ref-167750-S19717379932004102000000) .
6. Separate engine from transmission assembly. Refer to «REMOVAL AND INSTALLATION (AWD MODELS)»(ref-171001-S14766714062005012500000) .
7. Remove front final drive from engine. Refer to FRONT FINAL DRIVE ASSEMBLY .
8. Remove engine mounting insulators (RH and LH) and brackets (RH and LH) from engine with power tool.
9. Remove engine rear member and engine mounting insulator (rear) from transmission.

When New Cylinder Block Is Used

Check the cylinder bore grade ("0", "1" or "2") on the rear upper side between cylinder block banks, and select piston of the same grade.

Scheme 230

Scheme 231

Note. Piston is available with piston pin as a set for the service part. (Only "0" grade piston pin is available.)

When Cylinder Block Is Reused

1. Measure the cylinder bore inner diameter. Refer to «CYLINDER BORE INNER DIAMETER»(ref-158963-S18556000282005020300000) .
2. Determine the bore grade by comparing the measurement with the values the "Cylinder bore inner diameter" of the "Piston Selection Table". Select piston of the same grade.

Scheme 232

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.

When New Connecting Rod And Crankshaft Are Used

Check pin diameter grade ("0", "1" or "2") on front of crankshaft, and select connecting rod bearing of the same grade.

Note. There is no grading for connecting rod big end diameter.

Scheme 233

When Crankshaft And Connecting Rod Are Reused

1. Measure the connecting rod big end diameter. Refer to «CONNECTING ROD BIG END DIAMETER»(ref-158963-S13768170482005020300000) .
2. Make sure that the connecting rod big end diameter is within the standard value.
3. Measure the crankshaft pin journal diameter. Refer to «CRANKSHAFT PIN JOURNAL DIAMETER»(ref-158963-S13164466702005020300000) .
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»(ref-158963-S15298712672005020300000) .
5. Select connecting rod bearing of the same grade.

Scheme 234

Scheme 235

Under Size Bearings Usage Guide

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 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.

Scheme 236

Scheme 237

Scheme 238

Scheme 239

1. «MAIN BEARING SELECTION TABLES»(ref-158963-S35399465172005020300000) rows correspond to main bearing housing grade on rear upper side between cylinder block banks.
2. «MAIN BEARING SELECTION TABLES»(ref-158963-S35399465172005020300000) columns correspond to main 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 TABLES»(ref-158963-S35399465172005020300000) . CAUTION: 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. Do not confuse.
4. Apply sign at crossing in above step 3 to «MAIN BEARING GRADE TABLE (ALL JOURNALS)»(ref-158963-S39160665052005020300000) . NOTE: «MAIN BEARING GRADE TABLE (ALL JOURNALS)»(ref-158963-S39160665052005020300000) applies to all journals. 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 «MAIN BEARING HOUSING INNER DIAMETER»(ref-158963-S06132624012005020300000) and «CRANKSHAFT MAIN JOURNAL DIAMETER»(ref-158963-S04026253072005020300000) .
2. Correspond the measured dimension in «MAIN BEARING HOUSING INNER DIAMETER»(ref-158963-S06132624012005020300000) row of «MAIN BEARING SELECTION TABLES»(ref-158963-S35399465172005020300000) .
3. Correspond the measured dimension in «CRANKSHAFT MAIN JOURNAL DIAMETER»(ref-158963-S04026253072005020300000) column of «MAIN BEARING SELECTION TABLES»(ref-158963-S35399465172005020300000) .
4. Follow step 3 and later in «WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE USED»(ref-158963-S02949081522005020300000) .

Scheme 240

Scheme 241

Scheme 242

Scheme 243

1. When the specified main bearing oil clearance is not obtained with standard size main bearings, use underside (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 [1.5 mm (0.059 in)].

Scheme 244

Scheme 245

1. Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with dial indicator. Standard : 0.10 -- 0.25 mm (0.0039 -- 0.0098 in) Limit : 0.30 mm (0.0118 in)
2. If the measured value exceeds the limit, replace thrust bearings, and measure again. If it still exceeds the limit, replace crankshaft also.

Scheme 246

1. Measure side clearance between connecting rod and crankshaft arm with feeler gauge. Standard : 0.20 -- 0.35 mm (0.0079 -- 0.0138 in) Limit : 0.40 mm (0.0157 in)
2. If the measured value exceeds the limit, replace connecting rod, and measure again. If it still exceeds the limit, replace crankshaft also.

Piston Pin Hole Diameter

Measure the inner diameter of piston pin hole with inside micrometer.

Scheme 247

1. Standard : 21.993 -- 22.005 mm (0.8659 -- 0.8663 in)

Piston To Piston Pin Oil Clearance

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

1. Standard : 0.0001 -- 0.0002 in) If clearance is out of the standard, replace piston and piston pin assembly. When replacing piston and piston pin assembly, refer to «PISTON TO CYLINDER BORE CLEARANCE»(ref-158963-S02986247712005020300000) . 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 248

1. Measure side clearance of piston ring and piston ring groove with feeler gauge. Standard: Top ring : 0.045 -- 0.080 mm (0.0018 -- 0.0031 in) 2nd ring : 0.030 -- 0.070 mm (0.0012 -- 0.0028 in) Oil ring : 0.065 -- 0.135 mm (0.0026 -- 0.0053 in) Limit: Top ring : 0.11 mm (0.0043 in) 2nd ring : 0.1 mm (0.004 in)
2. If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, replace piston also.

Scheme 249

1. Make sure that cylinder bore inner diameter is within specification. Refer to «CYLINDER BORE INNER DIAMETER»(ref-158963-S18556000282005020300000) .
2. Lubricate with new engine oil to piston and piston ring, and then insert piston ring until middle of cylinder with piston, and measure piston ring end gap with feeler gauge. Standard: Top ring : 0.22 -- 0.32 mm (0.0087 -- 0.0126 in) 2nd ring : 0.22 -- 0.32 mm (0.0087 -- 0.0126 in) Oil ring : 0.20 -- 0.60 mm (0.0079 -- 0.0236 in) Limit: Top ring : 0.56 mm (0.0220 in) 2nd ring : 0.56 mm (0.0220 in) Oil ring : 0.96 mm (0.0378 in)
3. If the measured value exceeds the limit, replace piston ring and measure again. If it still exceeds the limit, re-bore cylinder and use oversize piston and piston rings.

Scheme 250

1. Check with connecting rod aligner. Bend: Limit : 0.15 mm (0.0059 in) per 100 mm (3.94 in) length Torsion: Limit : 0.30 mm (0.0118 in) per 100 mm (3.94 in) length
2. If it exceeds the limit, replace connecting rod assembly.

Scheme 251

1. Install connecting rod cap without installing connecting rod bearing, and tightening connecting rod bolts to the specified torque. Refer to «ASSEMBLY»(ref-158963-S21089060012005020300000) for the tightening procedure.
2. Measure the inner diameter of connecting rod big end with inside micrometer. Standard : 55.000 - 55.013 mm (2.1654 - 2.1659 in)
3. If out of the standard, replace connecting rod assembly.

Connecting Rod Bushing Inner Diameter

Measure the inner diameter of connecting rod bushing with inside micrometer.

Scheme 252

1. Standard : 22.000 - 22.012 mm (0.8661 - 0.8666 in)

Connecting Rod Bushing Oil Clearance

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

1. Standard : 0.005 - 0.017 mm (0.0002 - 0.0007 in)
2. Limit : 0.030 mm (0.0012 in)

Scheme 253

1. If the measured 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 «PISTON TO CYLINDER BORE CLEARANCE»(ref-158963-S02986247712005020300000) .
3. If replacing connecting rod assembly, refer to «CONNECTING ROD BEARING OIL CLEARANCE»(ref-158963-S18679914572005020300000) to select the connecting rod bearing.

Scheme 254

Scheme 255

1. Service parts apply only to grade "0".

Scheme 256

1. Using 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 with straightedge and feeler gauge. Limit : 0.1 mm (0.004 in)
3. If it exceeds the limit, replace cylinder block.

Scheme 257

1. Install main bearing caps and main bearing beam without installing main bearings, and tighten main bearing cap bolts to the specified torque. Refer to «ASSEMBLY»(ref-158963-S21089060012005020300000) for the tightening procedure.
2. Measure the inner diameter of main bearing housing with bore gauge. Standard : 68.944 - 68.968 mm (2.7143 - 2.7153 in)
3. If out of the standard, replace cylinder block and main bearing caps as assembly. NOTE: Cylinder block cannot be replaced as single part, because it is machined together with main bearing caps.

Scheme 258

Scheme 259

1. Using bore gauge, measure cylinder bore for wear, out-of-round and taper at six different points on each cylinder. ("X" and "Y" directions at "A", "B" and "C") ("Y" is in longitudinal direction of engine). Standard inner diameter: 93.000 - 93.030 mm (3.6614 - 3.6626 in) Wear limit: 0.2 mm (0.008 in) Out-of-round (Difference between "X" and "Y"): 0.015 mm (0.0006 in) Taper limit (Difference between "A" and "C"): 0.01 mm (0.0004 in)
2. 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.
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 it for all cylinders with oversize piston rings. Oversize (OS) : 0.2 mm (0.008 in)

Scheme 260

Scheme 261

1. Measure outer diameter of piston skirt with micrometer. Standard : 92.980 - 93.010 mm (3.6606 - 3.6618 in)
2. Measure point "H" (Distance from the top) : 42 mm (1.65 in)

Piston To Cylinder Bore Clearance

Calculate by piston skirt diameter and cylinder bore inner diameter (direction "X", position "B"). (Clearance) = (Cylinder bore inner diameter) - (Piston skirt diameter).

1. Standard : 0.010 - 0.030 mm (0.0004 - 0.0012 in)
2. Limit : 0.08 mm (0.0031 in)

1. If it exceeds the limit, replace piston and piston pin assembly. Refer to «HOW TO SELECT PISTON»(ref-158963-S00446604132005020300000) .

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, D: Bored diameter A: Piston skirt diameter as measured B: Piston to cylinder bore clearance (standard value) C: Honing allowance 0.02 mm (0.0008 in)
2. Install main bearing caps and main bearing beam, 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 specified piston to cylinder bore clearance.
5. Measure finished cylinder bore for out-of-round and taper. NOTE: Measurement should be done after cylinder bore cools down.

Crankshaft Main Journal Diameter

1. Measure outer diameter of crankshaft main journals with micrometer. Standard : 59.951 - 59.975 mm (2.3603 - 2.3612 in) dia.
2. If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to «MAIN BEARING OIL CLEARANCE»(ref-158963-S42336141922005020300000) .

Scheme 262

1. Measure outer diameter of crankshaft pin journal with micrometer. Standard : 63.940 - 63.964 mm (2.5173 - 2.5183 in) dia.
2. If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer to «CONNECTING ROD BEARING OIL CLEARANCE»(ref-158963-S18679914572005020300000) .

Scheme 263

1. Measure the dimensions at four different points shown in the figure on each main journal and pin journal with micrometer.
2. Out-of-round is indicated by the difference in dimensions between "X" and "Y" at "A" and "B".
3. Taper is indicated by the difference in dimension between "A" and "B" at "X" and "Y". Limit: Out-of-round (Difference between "X" and "Y"): 0.015 mm (0.0006 in) Taper (Difference between "A" and "B"): 0.010 mm (0.0004 in
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 OIL CLEARANCE»(ref-158963-S42336141922005020300000) and/or «CONNECTING ROD BEARING OIL CLEARANCE»(ref-158963-S18679914572005020300000) .

Crankshaft Runout

1. Place V-block on precise flat table, and support the journals on the both end of crankshaft.
2. Place dial indicator straight up on the No. 3 journal.
3. While rotating crankshaft, read the movement of the pointer on dial indicator. (Total indicator reading) Limit : 0.10 mm (0.004 in)
4. If it exceeds the limit, replace crankshaft.

Scheme 264

1. Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified torque. Refer to «ASSEMBLY»(ref-158963-S21089060012005020300000) for the tightening procedure.
2. Measure the inner diameter of connecting rod bearing with inside micrometer. (Bearing oil clearance) = (Connecting rod bearing inner diameter) - (Crankshaft pin journal diameter) Standard : 0.020 - 0.045 mm (0.0008 - 0.0018 in) (actual clearance) Limit : 0.055 mm (0.0022 in)
3. If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to «HOW TO SELECT CONNECTING ROD BEARING»(ref-158963-S30466196562005020300000) .

Scheme 265

1. Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely.
2. Cut 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 cap, and tighten connecting rod bolts to the specified torque. Refer to «ASSEMBLY»(ref-158963-S21089060012005020300000) for the tightening procedure. CAUTION: Do not rotate crankshaft.
4. Remove connecting rod cap and bearing, and using scale on 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»(ref-158963-S15665577732005020300000) .

Scheme 266

1. Install main bearings to cylinder block and main bearing caps, and tighten main bearing cap bolts with main bearing beam to the specified torque. Refer to «ASSEMBLY»(ref-158963-S21089060012005020300000) for the tightening procedure.
2. Measure the inner diameter of main bearing with bore gauge. (Bearing clearance) = (Main bearing inner diameter) - (Crankshaft main journal diameter) Standard No. 1 and 5 journal : 0.001 - 0.011 mm (0.00004 - 0.0004 in) No. 2, 3 and 4 journal : 0.007 - 0.017 mm (0.0003 - 0.0007 in) Limit No. 1 and 5 journal : 0.021 mm (0.0008 in) No. 2, 3 and 4 journal : 0.027 mm (0.0011 in)
3. If clearance exceeds the limit, select proper main bearing according to main bearing inner diameter and crankshaft main journal diameter to obtain specified bearing oil clearance. Refer to «HOW TO SELECT MAIN BEARING»(ref-158963-S38860751572005020300000) .

Scheme 267

1. Remove oil and dust on crankshaft main journal and the surfaces of each bearing completely.
2. Cut plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
3. Install main bearings to cylinder block and main bearing caps, and tighten main bearing bolts with main bearing beam to the specified torque. Refer to «ASSEMBLY»(ref-158963-S21089060012005020300000) for the tightening procedure. CAUTION: Do not rotate crankshaft.
4. Remove main bearing caps and bearings, and using scale on 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»(ref-158963-S01892401932005020300000) .

Scheme 268

1. When main bearing cap is removed after being tightened to the specified torque with main bearings installed, the tip end of bearing must protrude. Refer to «ASSEMBLY»(ref-158963-S21089060012005020300000) for the tightening procedure. Standard : There must be crush height.
2. If the standard is not met, replace main bearings.

Scheme 269

1. When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings installed, the tip end of bearing must protrude. Refer to «ASSEMBLY»(ref-158963-S21089060012005020300000) for the tightening procedure. Standard : There must be crush height.
2. If the standard is not met, replace connecting rod bearings.

Scheme 270

1. Check drive plate and signal plate for deformation or cracks. CAUTION: Do not disassemble drive plate. Do not 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.

STANDARD AND LIMIT

General Specifications Cylinder arrangement V-8 Displacement cm 3 (cu in) 4,494 (274.22) Bore and stroke mm (in) 93 x 82.7 (3.66 x 3.256) Valve arrangement DOHC Firing order 1-8-7-3-6-5-4-2 Number of piston rings Compression 2 Oil 1 Number of main bearings 5 Compression ratio 10.5 Compression pressure kPa (kg/cm 2 , psi)/300 rpm Standard 1,320 (13.5, 191) Minimum 1,130 (11.5, 164) Differential limit between cylinders 98 (1.0, 14) Cylinder number Valve timing Unit: degree a b c d e f 228 240 0 60 0 48

Scheme 271

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Scheme 296