Engine Mechanical: Other Infiniti I35 II

Special Service Tools

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

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Intake Manifold

1. Tighten in numerical order shown in the figure.

Scheme 127

1. Tighten all bolts and nuts to 4.9 to 9.8 N.m (0.50 to 0.99 kg.m, 44 to 86 in- lb).
2. Finally tighten all bolts and nuts to 26.5 to 31.4 N.m (2.7 to 3.2 kg-m, 20 to 23 ft-lb). Tighten all bolts and nuts to the final torque, evenly dividing the tightening into at least five steps.

Fuel Tube

1. Tighten in numerical order shown in the figure.

Scheme 128

1. Tighten all bolts to 9.3 to 10.8 N.m (0.95 to 1.1 kg-m, 83 to 95 in-lb).
2. Then tighten all bolts to 20.6 to 26.5 N.m (2.1 to 2.7 kg-m, 16 to 19 ft-lb).

Fuel Damper

Tighten fuel pressure regulator to 2.9 to 3.8 N.m (0.3 to 0.39 kg-m, 26.0 to 33.9 in-lb).

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1. Tighten screws evenly several times to have the fuel damper tightened at the specified torque.
2. Always replace O-ring with new ones.
3. Lubricate O-ring with new engine oil.

Scheme 130

1. Tighten in numerical order shown in the figure. Tighten all bolts to 7.2 to 9.6 N.m (0.74 to 0.97 kg-m, 64 to 84 in-lb). CAUTION: Perform "Throttle Valve Closed Position Learning" when harness connector of electronic throttle control actuator is disconnected. Refer to «THROTTLE POSITION SWITCH, IGNITION TIMING & IDLE SPEED»(ref-135501-S10594987612002022200000) . Perform "Idle Air Volume Learning" when electronic throttle control actuator is replaced. Refer to «THROTTLE POSITION SWITCH, IGNITION TIMING & IDLE SPEED»(ref-135501-S10594987612002022200000) .

Scheme 131

1. Tighten in numerical order shown in the figure. Tighten all bolts to 17.6 to 21.6 N.m (1.8 to 2.2 kg-m, 13 to 15 ft-lb).

Intake Manifold Lower Collector

Tighten bolts and nuts to 17.6 to 21.6 N.m (1.8 to 2.2 kg-m, 13 to 15 ft-lb) in numerical order shown in the figure.

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1. Tighten in numerical order shown in the figure. Tighten all bolts to 17.6 to 21.6 N.m (1.8 to 2.2 kg-m, 13 to 15 ft-lb).

Exhaust Manifold

Tighten nuts to 30 to 32 N.m (3.1 to 3.2 kg-m, 22 to 24 ft-lb) in numerical order shown in the figure.

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1. Warm up engine.
2. Turn ignition switch OFF.
3. Release fuel pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-135816-S32920286352002022500000) .
4. Disconnect ignition coil with power transistor harness connectors, then remove ignition coils.
5. Remove all spark plugs.
6. Remove fuse for fuel injector.
7. Attach a compression tester to No. 1 cylinder.
8. Depress accelerator pedal fully to keep throttle valve wide open.
9. Crank engine and record highest gauge indication.
10. Repeat the measurement on each cylinder as shown above. Always use a fully-charged battery to obtain specified engine speed.
11. If compression in one or more cylinders is low: Pour a small amount of engine oil into cylinders through spark plug holes. Retest compression. If adding oil helps compression, piston rings may be worn or damaged. If so, replace piston rings after checking piston. If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. (Refer to SDS, «VALVE»(ref-231092-S02493311902006050300000) and «VALVE SEAT»(ref-231092-S28582472852006050300000) .) If valve or valve seat is damaged excessively, replace them. If compression stays low in two cylinders that are next to each other: The cylinder head gasket may be leaking, or Both cylinders may have valve component damage. Inspect and repair as necessary.

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POSITION FOR APPLYING LIQUID GASKET

Refer to " LIQUID GASKET APPLICATION PROCEDURE " in "PRECAUTIONS", .

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1. Before installation, wipe off the protruding sealant. CAUTION: After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads. When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil. Apply new engine oil to bolt threads and seat surfaces when installing cylinder head, camshaft sprockets, crankshaft pulley, and camshaft brackets. Before disconnecting fuel hose, release fuel pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-135816-S32920286352002022500000) . When removing the oil pans, oil pump assembly and timing chain from engine, first remove the crankshaft position sensor (POS) from the assembly. Be careful not to damage sensor edges. Do not spill engine coolant on drive belts.

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1. Drain engine oil.
2. Release fuel pressure. Refer to «FUEL SYSTEM PRESSURE RELEASE»(ref-135816-S32920286352002022500000) .
3. Drain coolant by removing cylinder block drain plugs.
4. Remove ornament cover.
5. Remove air duct to intake manifold, collector, PCV hose, vacuum hoses, fuel hoses, wires, harness, connectors and so on.
6. Remove the following. Water hoses EVAP canister purge hose PCV hose PCV valve Water outlet
7. Remove intake manifold upper and lower collectors loosening bolts and nuts in reverse order of tightening. Refer to " «TIGHTENING PROCEDURES»(ref-231092-S21106643642006050300000) ", .
8. Remove RH and LH ignition coils.
9. Remove fuel tube assembly. Refer to «FUEL RAILS & INJECTORS»(ref-135816-S09708319762002022500000) .
10. Remove intake manifold loosening bolts and nuts in reverse order of tightening. Refer to " «TIGHTENING PROCEDURES»(ref-231092-S21106643642006050300000) ", .
11. Remove RH and LH intake valve timing control solenoid valves.
12. Remove RH and LH rocker covers from cylinder head. Loosen bolts in numerical order shown in the figure.
13. Remove engine undercover.
14. Remove front RH wheel and engine side cover.
15. Remove drive belts and idler pulley bracket.
16. Remove power steering oil pump belt and power steering oil pump assembly. Refer to «POWER STEERING OIL PUMP»(ref-152331-S13895812102003021300000) .
17. Remove crankshaft position sensor (POS).
18. Set No. 1 piston at TDC on the compression stroke by rotating crankshaft. Check that intake and exhaust cam nose on No. 1 cylinder are installed as shown. If not, turn the crankshaft one revolution (360°) and align as above.
19. Loosen crankshaft pulley bolt. (At this time remove oil pan rear cover plate and set a suitable tool to ring gear so that crankshaft cannot rotate.) Be careful not to damage the signal plate teeth.
20. Remove crankshaft pulley with a suitable puller.
21. Remove intake valve timing control valve covers. Loosen bolts in reverse order shown in the figure. In the cover, the shaft is engaged with the center hole of the intake camshaft sprocket. Remove it straight out until the engagement comes off.
22. Remove air conditioner compressor and bracket. Refer to «REMOVAL AND INSTALLATION»(ref-180428-S21337147192005072600000) .
23. Remove front exhaust tube and its support.
24. Hang engine at right and left side engine slingers with a suitable hoist. Refer to «ENGINE ASSEMBLY»(ref-231092-S15646056492006050300000) , "Removal and Installation".
25. Remove right side engine mounting, mounting bracket and nuts. Refer to , " «REMOVAL AND INSTALLATION»(ref-231092-S26576899972006050300000) ".
26. Remove center member assembly.
27. Remove upper and lower oil pans. Refer to , " «REMOVAL»(ref-231092-S09925334392006050300000) ".
28. Remove water pump cover.
29. Remove front timing chain case bolts. Loosen bolts in reverse order shown in the figure.
30. Remove front timing chain case. Do not scratch sealing surfaces.
31. Remove timing chain tensioner cover from front timing chain case.
32. Remove front oil seal from front timing chain case. Refer to , " «FRONT OIL SEAL»(ref-231092-S30285315062006050300000) ".
33. Remove internal chain guide.
34. Remove timing chain tensioner and slack side chain guide. Remove chain tensioner as follows. Pull lever down, and release plunger stopper tab. Plunger stopper tab can be pushed up to release (coaxial structure with lever). Insert stopper pin into tensioner body hole to fix lever, and keep the tab released. In figure, Allen wrench [2.5 mm (0.098 in)] is used for stopper pin as an example. Insert plunger into tensioner body by pressing slack guide. Keep slack guide pressed, and fix it by pushing stopper pin through lever hole and body hole. Remove mounting bolts, and remove chain tensioner.
35. Attach a suitable stopper pin to RH and LH camshaft chain tensioners. (For secondary timing chains)
36. Remove intake and exhaust camshaft sprocket bolts. Apply paint to timing chain and camshaft sprockets for alignment during installation. Secure the hexagonal portion of the camshaft using a spanner to loosen mounting bolts.
37. Remove primary and secondary timing chains with camshaft sprockets. Intake camshaft sprocket is two-for-one structure of primary and secondary sprockets. Handle intake camshaft sprocket, taking care of the following. CAUTION: Avoid impact. Do not disassemble (Never loosen bolts A and B).
38. Remove chain tension guide and crankshaft sprocket.
39. Remove rear timing chain case as follows. Loosen mounting bolts in reverse order shown in figure, and remove them. Disconnect liquid gasket applied portion using seal cutter (special service tool: KV101 11100) or an equivalent tool. Then remove rear timing chain case. CAUTION: Do not remove plate metal cover of oil passage. After removing chain case, do not apply any load which affects flatness.
40. Use a scraper to remove all traces of liquid gasket from front timing chain case. Remove old liquid gasket from the bolt hole and thread.
41. Use a scraper to remove all traces of liquid gasket from water pump cover and intake valve timing control solenoid valve covers.

CYLINDER HEAD DISTORTION

Clean surface of cylinder head.

Use a reliable straightedge and feeler gauge to check the flatness of cylinder head surface.

Check along six positions shown in the figure.

Head surface flatness: Limit 0.1 mm (0.004 in)

If beyond the specified limit, resurface or replace it.

The limit for cylinder head resurfacing is determined by the cylinder block resurfacing.

Scheme 170

Resurfacing limit

Amount of cylinder head resurfacing is "A".

Amount of cylinder block resurfacing is "B".

The maximum limit: A + B = 0.2 mm (0.008 in)

After resurfacing cylinder head, check that camshaft rotates freely by hand. If resistance is felt, cylinder head must be replaced.

Nominal cylinder head height

126.3 - 126.5 mm (4.972 - 4.980 in)

CAMSHAFT VISUAL CHECK

Check camshaft for scratches, seizure and wear.

Scheme 171

1. Measure camshaft runout at A and B as shown in the figure. Runout (Total indicator reading): Limit 0.05 mm (0.0020 in)
2. If it exceeds the limit, replace camshaft.

Scheme 172

1. Measure camshaft cam height. Standard cam height: Intake and exhaust 44.865 - 45.055 mm (1.7763 - 1.7738 in) Cam wear limit: 0.2 mm (0.008 in)
2. If wear is beyond the limit, replace camshaft.

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1. Install camshaft bracket and tighten bolts to the specified torque.
2. Measure inner diameter "A" of camshaft bearing. Standard inner diameter: No. 1: 26.000 - 26.021 mm (1.0236 - 1.0244 in) No. 2, 3, 4: 23.500 - 23.521 mm (0.9252 - 0.9260 in)
3. Measure outer diameter of camshaft journal. Standard outer diameter: No. 1: 25.935 - 25.955 mm (1.0211 - 1.0218 in) No. 2, 3, 4: 23.445 - 23.465 mm (0.9230 - 0.9238 in)
4. If clearance exceeds the limit, replace camshaft and/or cylinder head. Camshaft journal clearance: Standard No. 1: 0.045 - 0.086 mm (0.0018 - 0.0034 in) No. 2, 3, 4: 0.035 - 0.076 mm (0.0014 - 0.0030 in) Limit 0.15 mm (0.0059 in)

Scheme 175

1. Install camshaft in cylinder head.
2. Measure camshaft end play. Camshaft end play: Standard 0.115 - 0.188 mm (0.0045 - 0.0074 in) Limit 0.24 mm (0.0094 in)

Scheme 176

1. Install sprocket on camshaft.
2. Measure camshaft sprocket runout. Runout (Total indicator reading): Less than 0.15 mm (0.0059 in)
3. If it exceeds the limit, replace camshaft sprocket.

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1. Measure valve deflection as shown in the figure. (Valve and valve guide mostly wear in this direction.) Valve deflection limit (Dial gauge reading): Intake 0.24 mm (0.0094 in) Exhaust 0.28 mm (0.0110 in)
2. If it exceeds the limit, check valve to valve guide clearance. Measure valve stem diameter and valve guide inner diameter. Check that clearance is within specification. Valve to valve guide clearance limit: Intake 0.08 mm (0.0031 in) Exhaust 0.1 mm (0.004 in) If it exceeds the limit, replace valve or valve guide.

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1. To remove valve guide, heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil.
2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US ton, 2.0 lmp ton) pressure] or hammer and suitable tool.
3. Ream cylinder head valve guide hole. Valve guide hole diameter (for service parts): 10.175 - 10.196 mm (0.4006 - 0.4014 in)
4. Heat cylinder head to 110 to 130°C (230 to 266°F) and press service valve guide onto cylinder head. Projection "L": 12.6 - 12.8 mm (0.496 - 0.504 in)
5. Ream valve guide. Finished size: 6.000 - 6.018 mm (0.2362 - 0.2369 in)

VALVE SEATS

Check valve seats for any evidence of pitting at valve contact surface, and reseat or replace if it has worn out excessively.

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1. Before repairing valve seats, check valve and valve guide for wear. If they have worn, replace them. Then correct valve seat.
2. Use both hands to cut uniformly.

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1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess in cylinder head. Set the machine depth stop to ensure this.
2. Ream cylinder head recess for service valve seat. Oversize [0.5 mm (0.020 in)]: Intake 38.500 - 38.516 mm (1.5157 - 1.5164 in) Exhaust 32.700 - 32.716 mm (1.2874 - 1.2880 in) Be sure to ream in circles concentric to the valve guide center. This will enable valve seat to fit correctly.
3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil.
4. Press fit valve seat until it seats on the bottom.
5. Cut or grind valve seat using suitable tool to the specified dimensions as shown in SDS ( «VALVE SEAT»(ref-231092-S28582472852006050300000) ).
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition. Seat face angle "alpha": 45°15' - 45°45' Contacting width "W": Intake 1.09 - 1.31 mm (0.0429 - 0.0516 in) Exhaust 1.29 - 1.51 mm (0.0508 - 0.0594 in)
8. Use a depth gauge to measure the distance between the mounting surface of the cylinder head spring seat and the valve stem end. If the distance is shorter than specified, repeat step 5 above to adjust it. If it is longer, replace the valve seat with a new one. Valve seat resurface limit "L": Intake 41.07 - 41.67 mm (1.6169 - 1.6405 in) Exhaust 41.00 - 41.60 mm (1.6142 - 1.6378 in)

VALVE DIMENSIONS

Check dimensions of each valve. For dimensions, refer to SDS ( VALVE ).

When valve head has been worn down to 0.5 mm (0.020 in) in margin thickness, replace valve.

Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or less.

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1. Measure dimension "S". Out-of-square "S": Less than 2.0 mm (0.079 in)
2. If it exceeds the limit, replace spring.

Pressure

Check valve spring pressure at specified spring height.

Pressure

Standard

196 N (20.0 kg, 44.1 lb) at height 37.0 mm (1.457 in)

Limit

More than 433 N (44.2 kg, 97.3 lb) at height 27.8 mm (1.094 in)

If it exceeds the limit, replace spring.

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1. Check contact and sliding surfaces for wear or scratches.
2. Check diameter of valve lifter and valve lifter guide bore. Valve lifter outer diameter: 33.977 - 33.987 mm (1.3377 - 1.3381 in) Lifter guide bore diameter: 34.000 - 34.016 mm (1.3386 - 1.3392 in)

Scheme 193

1. Install valve component parts. Always use new valve oil seal. Refer to " «VALVE OIL SEAL»(ref-231092-S16357139212006050300000) ", . Before installing valve oil seal, install valve spring seat. Install valve spring (uneven pitch type) with its narrow pitch side toward cylinder head side (paint mark). After installing valve component parts, tap valve stem tip with plastic hammer to assure a proper fit.

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1. Before installing rear timing chain case, remove old liquid gasket from mating surface using a scraper. Also remove old liquid gasket from mating surface of cylinder block. Remove old liquid gasket from the bolt hole and thread.
2. Before installing cam bracket, remove old liquid gasket from mating surface using a scraper.
3. Before installing the cylinder head gasket, be sure that No. 1 cylinder is at TDC. At this time, the crankshaft key should face toward the right bank.
4. Install cylinder heads with new gaskets. Do not rotate crankshaft and camshaft separately, or valves will strike piston heads. CAUTION: Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between d1 and d2 exceeds the limit, replace them with new ones. Limit (d1 - d2): 0.11 mm (0.0043 in) Lubricate threads and seat surfaces of the bolts with new engine oil.
5. Install cylinder head outside bolts. Tightening procedure: Tighten all bolts to 98 N.m (10 kg-m, 72 ft-lb). Completely loosen all bolts. Tighten all bolts to 34.3 to 44.1 N.m (3.5 to 4.4 kg-m, 26 to 32 ft-lb). Turn all bolts 90 to 95 degrees clockwise. Turn all bolts 90 to 95 degrees clockwise. Tighten in numerical order shown in the figure.
6. Install camshaft chain tensioners on both sides of cylinder head.
7. Install exhaust and intake camshafts and camshaft brackets. Intake camshaft has a drill mark on camshaft sprocket mounting flange. Install it on the intake side. Identification marks are present on camshafts. Position camshaft RH exhaust camshaft dowel pin at about 10 o'clock LH exhaust camshaft dowel pin at about 2 o'clock
8. Before installing camshaft brackets, apply sealant to mating surface of No. 1 camshaft bracket. Refer to " «POSITION FOR APPLYING LIQUID GASKET»(ref-231092-S40266165612006050300000) ", . Use Genuine RTV silicone sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-180422-S02321372872005072600000) . Install camshaft brackets in their original positions. Align stamp mark as shown in the figure. If any part of valve assembly or camshaft is replaced, check valve clearance according to reference data. After completing assembly check valve clearance. Refer to " «CHECKING»(ref-231092-S00772324592006050300000) " and " «ADJUSTING»(ref-231092-S34499472492006050300000) ", and . Reference data valve clearance (Cold): Intake 0.26 - 0.34 mm (0.010 - 0.013 in) Exhaust 0.29 - 0.37 mm (0.011 - 0.015 in) Lubricate threads and seat surfaces of camshaft bracket bolts with new engine oil before installing them. Tighten the camshaft brackets in the following steps.
9. Install intake valve timing control solenoid valves.
10. Install O-rings to cylinder block.
11. Install O-rings to cylinder head.
12. Apply sealant to the hatched portion of rear timing chain case. Refer to " «POSITION FOR APPLYING LIQUID GASKET»(ref-231092-S40266165612006050300000) ", . Apply continuous bead of liquid gasket to mating surface of rear timing chain case. Before installation, wipe off the protruding sealant.
13. Align rear timing chain case with dowel pins, then install on cylinder head and block.
14. Tighten rear chain case bolts. Tighten bolts in numerical order shown in the figure with smaller torque than specified. Tighten bolts to the specified torque repeating step a above.
15. Reinstall all removed parts in reverse order of removal.

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1. Remove ornament cover.
2. Remove air duct with air cleaner case, collectors, hoses, wires, harnesses, connectors and so on.
3. Remove intake manifold collectors.
4. Remove ignition coils and spark plugs.
5. Remove RH and LH rocker covers.
6. Set No. 1 cylinder at TDC on its compression stroke. Align pointer with TDC mark on crankshaft pulley. Check that valve lifters on No. 1 cylinder are loose and valve lifters on No. 4 are tight. If not, turn crankshaft one revolution (360°) and align as above.
7. Check only those valves shown in the figure. Using a feeler gauge, measure clearance between valve lifter and camshaft. Record any valve clearance measurements which are out of specification. They will be used later to determine the required replacement adjusting shim. Valve clearance for checking (Cold): Intake 0.26 - 0.34 mm (0.010 - 0.013 in) Exhaust 0.29 - 0.37 mm (0.011 - 0.015 in)
8. Turn crankshaft 240° and align as above.
9. Set No. 3 cylinder at TDC on its compression stroke.
10. Check only those valves shown in the figure.
11. Turn crankshaft 240° and align as above.
12. Set No. 5 cylinder at TDC on its compression stroke.
13. Check only those valves shown in the figure.
14. If all valve clearances are within specification, install the following parts. If they are out of specification, adjust the valve clearances. Intake manifold collectors RH and LH rocker covers All spark plugs All ignition coils

PISTON RING SIDE CLEARANCE

Side clearance

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)

Max. limit of side clearance

Top ring 0.11 mm (0.0043 in)

2nd ring 0.1 mm (0.004 in)

Scheme 226

If out of specification, replace piston ring. If clearance exceeds maximum limit with new ring, replace piston.

PISTON RING END GAP

End gap

Top ring 0.23 - 0.33 mm (0.0091 - 0.0130 in)

2nd ring 0.33 - 0.48 mm (0.0130- 0.0189 in)

Oil ring 0.20 - 0.80 mm (0.0079 - 0.0315 in)

Max. limit of ring gap

Top ring 0.54 mm (0.0213 in)

2nd ring 0.80 mm (0.0315 in)

Oil ring 0.50 mm (0.0197 in)

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If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, do the following. Rebore cylinder and use oversized piston and piston rings.

Refer to SDS ( PISTON, PISTON RING AND PISTON PIN ).

1. When replacing the piston, check the cylinder block surface for scratches or seizure. If scratches or seizure is found, hone or replace the cylinder block.

CONNECTING ROD BEND AND TORSION

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

If it exceeds the limit, replace connecting rod assembly.

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1. Clean upper surface of cylinder block. Use a reliable straightedge and feeler gauge to check the flatness of cylinder block surface. Check along six positions shown in the figure. Distortion limit: 0.10 mm (0.0039 in)
2. If out of specification, resurface it. The limit for cylinder block resurfacing is determined by cylinder head resurfacing in engine. Resurfacing limit: Amount of cylinder head resurfacing is "A". Amount of cylinder block resurfacing is "B". The maximum limit is as follows: A+B=0.2 mm (0.008 in) Nominal cylinder block height from crankshaft center: 214.95 - 215.05 mm (8.4626 - 8.4665 in) Refer to SDS ( «CYLINDER BLOCK»(ref-231092-S01531308522006050300000) ).
3. If necessary, replace cylinder block.

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1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper. Cylinder bore inner diameter If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary. Out-of-round (X - Y): Limit 0.015 mm (0.0006 in) Taper (A - B - C): Limit 0.015 mm (0.0006 in)
2. Check for scratches and seizure. If seizure is found, hone it. If both cylinder block and piston are replaced with new ones, select piston of the same grade number punched on cylinder block rear position. These numbers are punched in either Arabic or Roman numerals.
3. Measure piston skirt diameter. Piston diameter "A": Refer to SDS ( «PISTON, PISTON RING AND PISTON PIN»(ref-231092-S32887574952006050300000) ). Measuring point "a" (Distance from the top): 41.0 mm (1.61 in)
4. Check that piston-to-bore clearance is within specification. Piston-to-bore clearance "B": 0.010 - 0.030 mm (0.0004 - 0.0012 in)
5. Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. Refer to SDS ( «PISTON, PISTON RING AND PISTON PIN»(ref-231092-S32887574952006050300000) ). If oversize piston is used, use oversize piston ring also.
6. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter "A". Rebored size calculation: D = A + B - C where, D: Bored diameter A: Piston diameter as measured B: Piston-to-bore clearance C: Honing allowance 0.02 mm (0.0008 in)
7. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted in final assembly.
8. Cut cylinder bores. 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.
9. Hone cylinders to obtain specified piston-to-bore clearance.
10. Measure finished cylinder bore for out-of-round and taper. Measurement should be done after cylinder bore cools down.

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1. Check crankshaft main and pin journals for score, wear or cracks.
2. With a micrometer, measure journals for taper and out-of-round. Out-of-round (X - Y): Standard 0.002 mm (0.0001 in) Taper (A - B): Standard 0.002 mm (0.0001 in)
3. Measure crankshaft runout. Runout (Total indicator reading): Limit 0.10 mm (0.0039 in)

BEARING CLEARANCE

1. Use either of the following two methods, however, method "A" gives more reliable results and is preferable.

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1. Set main bearings in their proper positions on cylinder block and main bearing cap.
2. Install main bearing cap and bearing beam to cylinder block. Tighten all bolts in correct order.
3. Measure inner diameters "A" of each main bearing.
4. Measure outer diameters "Dm" of each crankshaft main journal.
5. Calculate main bearing clearance. Main bearing clearance = A - Dm Standard: 0.035 - 0.045 mm (0.0014 - 0.0018 in) Limit: 0.065 mm (0.0026 in) If it exceeds the limit, replace bearing. If clearance cannot be adjusted using any standard bearing grade, grind crankshaft journal and use undersized bearing. When grinding crankshaft journal, confirm that "L" dimension in fillet roll is more than the specified limit. "L": 0.1 mm (0.004 in) Refer to SDS for grinding crankshaft and available service parts.
6. If crankshaft or cylinder block is replaced with a new one, select thickness of main bearings as follows: Grade number of each cylinder block main journal is punched on the respective cylinder block. These numbers are punched in either Arabic or Alphabet. Refer to SDS, «CYLINDER BLOCK»(ref-231092-S01531308522006050300000) . If measured diameter is out of grade punched, decide suitable grade using table in SDS. Grade number of each crankshaft main journal is punched on the respective crankshaft. These numbers are punched in either Arabic or Alphabet. Refer to SDS, «CRANKSHAFT»(ref-231092-S12148699222006050300000) . If measured diameter is out of grade punched, decide suitable grade using table in SDS. Select main bearing with suitable thickness according to the following table. Refer to "SDS", «AVAILABLE MAIN BEARING»(ref-231092-S39561060062006050300000) , for available main bearings. Main bearing selection table

Scheme 245

Scheme 246

Scheme 247

Scheme 248

1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod. Tighten bolts to the specified torque.
3. Measure inner diameter "C" of connecting rod.
4. Measure outer diameter "Dp" of each crankshaft pin journal.
5. Calculate connecting rod bearing clearance. Connecting rod bearing clearance = C - Dp Standard: 0.034 - 0.059 mm (0.0013 - 0.0023 in) Limit: 0.070 mm (0.0028 in)
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearing. Refer to "BEARING CLEARANCE - Main bearing", «BEARING CLEARANCE»(ref-231092-S12198249992006050300000) .
8. If crankshaft is replaced with a new one, select connecting rod bearing according to the following table. Connecting rod bearing grade number (Identification color): These numbers are punched in either Arabic or Roman numerals.

Scheme 249

Scheme 250

1. Measure inner diameter "C" of bushing.
2. Measure outer diameter "Dp" of piston pin.
3. Calculate connecting rod bushing clearance. Connecting rod bushing clearance = C - Dp Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 in) Limit: 0.030 mm (0.0012 in) If it exceeds the limit, replace connecting rod assembly or connecting rod bushing and/or piston set with pin.

DRIVE PLATE RUNOUT

Runout (Total indicator reading)

Drive plate

Less than 0.15 mm (0.0059 in)

Scheme 251

Scheme 252

Scheme 253

Scheme 254

Scheme 255

1. Install new snap ring on one side of piston pin hole.
2. Heat piston to 60 to 70°C (140 to 158°F) and assemble piston, piston pin, connecting rod and new snap ring. Align the direction of piston and connecting rod. Numbers stamped on connecting rod and cap correspond to each cylinder. After assembly, make sure connecting rod swings smoothly.
3. Set piston rings as shown. CAUTION: When piston rings are not replaced, make sure that piston rings are mounted in their original positions. When replacing piston rings, those without punchmarks present can be mounted with either side up. Align piston rings so that end gaps are positioned as shown in the figure.

Scheme 256

1. Install oil jets. Insert oil jet knock pin into the cylinder block knock pin hole, and tighten the mounting bolts.

Scheme 257

Scheme 258

Scheme 259

Scheme 260

Scheme 261

Scheme 262

Scheme 263

Scheme 264

Scheme 265

Scheme 266

Scheme 267

1. Set main bearings in their proper positions on cylinder block and main bearing beam. Confirm that correct main bearings are used. Refer to " «INSPECTION»(ref-231092-S16226576042006050300000) " of this section.
2. Instructions for re-use of main bearing cap bolts. A plastic zone tightening method is used for tightening main bearing cap bolts. Measure d1 and d2 as shown in the figure. d2: Select minimum diameter in the measuring area. If the difference between d1 and d2 exceeds the limit, replace the bolts with new ones. Limit (d1 - d2): 0.11 mm (0.0043 in)
3. After installing crankshaft, main bearing cap, main bearing beam and bearing cap bolts, tighten bearing cap bolts in numerical order as shown. Make sure that the front mark on the main bearing beam faces the front of the engine. Tightening procedure Tighten all bolts to 32 to 38 N.m (3.3 to 3.9 kg-m, 24 to 28 ft-lb). Turn all bolts 90 to 95 degrees clockwise with angle wrench. Prior to tightening bearing cap bolts, place bearing beam in its proper position by shifting crankshaft in the axial direction. After securing bearing cap bolts, make sure crankshaft turns smoothly by hand. Lubricate threads and seat surfaces of the bolts with new engine oil.
4. Measure crankshaft end play. Crankshaft end play: Standard 0.10 - 0.25 mm (0.0039 - 0.0098 in) Limit 0.30 mm (0.0118 in) If beyond the limit, replace bearing with a new one.
5. Install connecting rod bearings in connecting rods and connecting rod caps. Confirm that correct bearings are used.
6. Install pistons with connecting rods. Install them into corresponding cylinders with Tool. Be careful not to scratch cylinder wall with the connecting rod. Arrange so that front mark on piston head faces toward engine front. Install connecting rod caps. Lubricate threads and seat surfaces with new engine oil. Install so that the cylinder number stamped on the connecting rod agrees with that stamped on cap side. Make sure that front mark on the connecting rod cap faces the front of the engine. Re-use connecting rod cap bolts as follows. Make sure that the bolts can be smoothly screwed-in to the end manually. If not, measure the outer diameter "d" shown in the figure. Outer diameter "d" of connecting rod cap bolt: Standard 7.90 - 8.00 mm (0.3110 - 0.3150 in) Limit 7.75 mm (0.3051 in) Tighten connecting rod cap bolts to the specified torque. Connecting rod cap bolt: Tighten nuts to 19 to 21 N.m (1.9 to 2.1 kg-m, 14 to 15 ft-lb). Turn nuts 90 to 95 degrees clockwise with angle wrench.
7. Measure connecting rod side clearance. Connecting rod side clearance: Standard 0.20 - 0.35 mm (0.0079 - 0.0138 in) Limit 0.40 mm (0.0157 in) If beyond the limit, replace connecting rod and/or crankshaft.
8. Install rear oil seal retainer.

Scheme 268

Scheme 269

1. Remove pilot converter using tool or suitable tool.
2. Install pilot converter as shown.

DRIVE PLATE

Install drive plate.

Scheme 270

1. Install the drive plate and reinforce plate in the direction shown in the figure.
2. Secure the crankshaft using a ring gear stopper.
3. Tighten the installation bolts crosswise over several times.