Engine Mechanical: Other Infiniti M45 II

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. Refer to «FUEL PRESSURE RELEASE»(ref-173766-S34645699222005032200000) .
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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Connecting Water Hose

Install water hose so that its overlap width for connection is between 27 mm (1.06 in) and 32 mm (1.26 in) (target: 27 mm, 1.06 in).

Connecting Vacuum Tube

Refer to VACUUM HOSE DRAWING .

Surface Distortion

1. Use a reliable straightedge and feeler gauge to check the flatness of exhaust manifold fitting surface. Limit: 0.3 mm (0.012 in)
2. If it exceeds the limit, replace exhaust manifold and three way catalyst.

Scheme 211

Exhaust Manifold Gasket

Install exhaust manifold gasket with its directional protrusion set upward. Refer to illustration of components on former page. Refer to REMOVAL AND INSTALLATION .

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.

Scheme 212

Camshaft Runout

1. Put V block on precise flat bed, 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 four locations.
2. Set dial indicator vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure camshaft runout on dial indicator. (Total indicator reading) Limit: 0.02 mm (0.0008 in.)

Scheme 213

1. If it exceeds the limit, replace camshaft.

Scheme 214

1. Measure camshaft cam height with micrometer. Standard cam height Intake: 44.865 - 45.055 mm (1.7663 - 1.7738 in.) Exhaust: 43.925 - 44.115 mm (1.7293 - 1.7368 in.) Cam wear limit: 0.2 mm (0.008 in.)
2. If it exceeds the limit, replace camshaft.

Camshaft Journal Oil Clearance

Outer Diameter of Camshaft Journal

Scheme 215

1. Measure outer diameter of camshaft journal with micrometer. Standard: No. 1: 25.938 - 25.955 mm (1.0212 - 1.0218 in.) No. 2, 3, 4, 5: 25.953 - 25.970 mm (1.0218 - 1.0224 in.)

Inner Diameter of Camshaft Bracket

Scheme 216

1. Tighten camshaft bracket bolt with specified torque. Refer to «INSTALLATION»(ref-159010-S29135513342005032300000) for the tightening procedure.
2. Using inside micrometer, measure inner diameter "A" of camshaft bracket. Standard: 26.000 - 26.021 mm (1.0236 - 1.0244 in.) Calculation of Camshaft Journal Oil Clearance
3. (Journal oil clearance) = (inner diameter of camshaft bracket) - (outer diameter of camshaft journal) Standard: No. 1: 0.045 - 0.083 mm (0.0018 - 0.0033 in.) No. 2, 3, 4, 5: 0.030 - 0.068 mm (0.0012 - 0.0027 in.)
4. If out of the standard, replace either or both camshaft and cylinder head. NOTE: It is impossible to replace only camshaft bracket as camshaft bracket is manufactured with cylinder head. Replace the whole cylinder head assembly.

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Scheme 218

1. Install dial indicator in thrust direction on front end of camshaft. Measure end play 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 standard. 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 219

1. Install camshaft in cylinder head. Refer to «INSTALLATION»(ref-159010-S29135513342005032300000) for the tightening procedure.
2. Install camshaft sprocket to camshaft.
3. Measure camshaft sprocket runout. (Total indicator reading) Limit: 0.15 mm (0.0059 in.)
4. 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 220

1. If anything above is found, replace valve lifter or adjusting shim.
2. When replacing adjusting shim, refer to «ADJUSTMENT»(ref-159010-S31388605312005032300000) .

Valve Lifter Clearance

Outer Diameter of Valve Lifter

Scheme 221

Scheme 222

1. Measure outer diameter of valve lifter with micrometer. Standard: 33.965 - 33.975 mm (1.3372 - 1.3376 in.) Valve Lifter Hole Diameter
2. Using inside micrometer, measure diameter of valve lifter hole of cylinder head. Standard: 34.000 - 34.016 mm (1.3386 - 1.3392 in.) Calculation of Valve Lifter Clearance
3. (Valve lifter clearance) = (hole diameter of valve lifter) - (outer diameter of valve lifter) Standard: 0.025 - 0.051 mm (0.0010 - 0.0020 in.)
4. If out of the standard, referring to each specification of outer and inner diameter, replace either or both valve lifter and cylinder head.

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Scheme 230

1. Install valve lifters and adjusting shims if removed. Install removed parts in the same locations as before.
2. Install camshafts. Refer to the table below for identification of right and left bank, and intake and exhaust. Install so that dowel pin at the front of camshaft face is in the direction 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.
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 camshaft bracket (No. 1) as in the illustration. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-180766-S18255399172005072900000) . 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 camshaft bracket (No. 6) on left bank intake as in illustration. 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 fixing 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 fixing bolts.
6. Check and adjust valve clearances. Refer to «VALVE CLEARANCE»(ref-159010-S04924722882005032300000) .
7. Install in the reverse order of removal.

Cylinder Head Distortion

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

1. Wipe off oil and remove water scale (like deposit), gasket, sealer, carbon, etc. with scraper. CAUTION: Use utmost care not to allow gasket debris to enter passages for oil or water.
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 231

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Scheme 233

1. Install cylinder head gasket.
2. Follow the steps below to tighten fixing bolts in the numerical order shown in figure to install cylinder head. CAUTION: If cylinder head bolts are re-used, check their outer diameters before installation. Refer to «OUTER DIAMETER OF CYLINDER HEAD BOLTS»(ref-159010-S36987754452005032300000) . In step c , loosen bolts in reverse order of that indicated in figure. Apply engine oil to threads and seating surface of bolts. Tighten all bolts. :98.1 N.m (10 kg-m, 72 ft-lb) Completely loosen all bolts. : 0 N.m (0 kg-m, 0 ft-lb) Tighten all bolts. : 44.1 N.m (4.5 Kg-m, 33 ft-lb) Turn all bolts 60 degrees clockwise. (Angle tightening) Turn all bolts 60 degrees clockwise again. (Angle tightening) CAUTION: Check and confirm the tightening angle by using the angle wrench (SST) and the cylinder head bolt wrench (commercial service tool). Avoid judgment by visual inspection without the SST.
3. Install in the reverse order of removal.

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Scheme 236

1. Remove spark plug with the spark plug wrench (commercial service tool).
2. Remove adjusting shim and valve lifter. Confirm installation point and keep parts in an organized way to avoid mixing them up.
3. Remove valve collet. Compress valve spring with the 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 (with valve spring seat). CAUTION: Do not remove valve spring seat from valve spring.
5. Push valve stem to combustion chamber side, and remove valve. Confirm installation point and keep parts in an organized way to avoid mixing then up.
6. Remove valve oil seal with the valve oil seal puller (SST).
7. If valve guide must be replaced, refer to «VALVE GUIDE CLEARANCE»(ref-159010-S03208059642005032300000) .
8. If valve seat must be replaced, refer to «VALVE SEAT REPLACEMENT»(ref-159010-S31217821482005032300000) .
9. Remove spark plug tube, as necessary. Using a pair of pliers, pull spark plug tube out of cylinder head. CAUTION: Take care not to damage cylinder head. Once removed, a spark plug tube will be deformed and cannot be reused. Do not remove it unless absolutely necessary.

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Scheme 240

1. When valve guide is removed, install it. Refer to «VALVE GUIDE CLEARANCE»(ref-159010-S03208059642005032300000) .
2. When valve seat is removed, install it. Refer to «VALVE SEAT REPLACEMENT»(ref-159010-S31217821482005032300000) .
3. Install valve oil seal. Install with the valve oil seal drift (SST) to match dimension in illustration.
4. Install valve. Install larger diameter to intake side.
5. Install valve spring (with valve spring seat). Install smaller pitch (valve spring seat side) to cylinder head side.
6. Install valve spring retainer.
7. Install valve collet. Compress valve spring with the 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.
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) from edge of spark plug tube press-fit side. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-180766-S18255399172005072900000) . Using a 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 the spark plug wrench (commercial service tool).

Scheme 241

1. Check dimensions of each valve. For dimensions, refer to «VALVE DIMENSIONS»(ref-159010-S41468255872005032300000) .
2. If dimensions are out of the standard, replace valve.

Valve Stem Diameter

Measure diameter of valve stem with micrometer.

Scheme 242

1. Standard
2. Intake: 5.972 - 5.980 mm (0.2351 - 0.2354 in)
3. 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
2. 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).

Valve guide clearance

1. Standard
2. Intake: 0.020 - 0.046 mm (0.0008 - 0.0018 in)
3. Exhaust: 0.030 - 0.056 mm (0.0012 - 0.0022 in)

1. Limit
2. Intake: 0.08 mm (0.003 in)
3. Exhaust: 0.10 mm (0.004 in)

1. If it exceeds the limit, replace valve and/or valve guide.

Valve Seat Contact

1. After confirming that the dimensions of valve guides and valves are within specifications, perform this procedure.
2. Apply Prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve contact on the surface.
3. Check if the contact area band is continuous all around the circumference.
4. If not, grind to adjust valve fitting and check again. If the contacting surface still has NG conditions even after the re-check, replace valve seat.

Scheme 243

Valve Spring Squareness

Set try square along the side of valve spring and rotate the spring. Measure the maximum clearance between the top face of spring and try square.

Scheme 244

Limit: 2.0 mm (0.079 in)

1. If it exceeds the limit, replace valve spring.

Valve Spring Dimensions And Valve Spring Pressure Load

Check valve spring pressure at specified spring height.

Scheme 245

1. Standard
2. Free height 46.35 - 46.85 mm (1.8247 - 1.8444 in)
3. Installation height 33.8 mm (1.331 in)
4. Installation load 165- 189 N (16.8 - 19.3 kg, 37- 42 lb.)
5. Height during valve open 24.4 mm (0.961 in.)
6. Load with valve open 290- 330 N (29.6- 33.7 kg, 65 - 74 lb.)

1. If the dimensions exceed the standard, replace the valve spring.

Scheme 246

Outline

After removal of transmission, lift up engine assembly to remove it from vehicle.

Preparation

1. Release fuel pressure. Refer to «FUEL PRESSURE RELEASE»(ref-173766-S34645699222005032200000) .
2. Remove engine cover. Refer to «ENGINE ROOM COVER»(ref-159010-S24478988662005032300000) .
3. Remove engine undercover with power tool.
4. Drain coolant from radiator drain plug. Refer to «DRAINING ENGINE COOLANT»(ref-172473-S40658208392005022800000) .
5. Remove the following parts: Hood assembly; Refer to «HOOD»(ref-180678-S13249416602005072800000) . Tower bar; Refer to «FRONT»(ref-166061) . Battery: Refer to «REMOVAL AND INSTALLATION»(ref-180749-S21518267602005072900000) . Air duct and air cleaner case assembly; Refer to «AIR CLEANER AND AIR DUCT»(ref-159010-S06177113492005032300000) . Drive belts; Refer to «DRIVE BELTS»(ref-159010-S14430122632005032300000) . Accelerator wire; Refer to «ACCELERATOR CONTROL SYSTEM»(ref-173668) . Cooling fan and tubes; Refer to «COOLING FAN»(ref-172473-S08022088772005022800000) . Radiator assembly and hoses. Refer to «REMOVAL AND INSTALLATION»(ref-172473-S22886197052005022800000) . Water suction pipe; Refer to «THERMOSTAT AND WATER CONTROL VALVE»(ref-172473-S35656811072005022800000) .

Engine Room Left

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 coolant.
3. Disconnect wire bonding exhaust manifold cover to vehicle.
4. Disconnect vacuum hose between vehicle and engine and set it aside.
5. Remove reservoir tank for cooling fan. Refer to «COOLING FAN»(ref-172473-S08022088772005022800000) .
6. Remove A/C compressor from brackets, and install A/C compressor temporarily with ropes or equivalent to avoid applying any pressures on piping or disturbing installation or removal of any vehicle parts. Refer to «REMOVAL AND INSTALLATION OF COMPRESSOR»(ref-171295-S41189065182005020200000) .

Engine Room Right

1. Disconnect fuel hose at the engine side connection. For disconnection/connection of quick connector, refer to «FUEL INJECTOR AND FUEL TUBE»(ref-159010-S06407600942005032300000) .
2. Disconnect engine room harness from the engine side and set it aside for easier work.
3. Disconnect wire bonding exhaust manifold cover to vehicle.
4. Disconnect vacuum hose between vehicle and engine and set it aside.
5. Disconnect reservoir tank for power steering from engine and move it aside for easier work. Refer to «HYDRAULIC LINE»(ref-172964-S41394182292005030800000) .

Vehicle Underbody

1. 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»(ref-172964-S17613950202005030800000) .
2. Remove pipe of cooler for automatic transmission. Refer to «TRANSMISSION ASSEMBLY»(ref-170821-S42413579512005011800000) .
3. Remove exhaust front tube with power tool. Refer to «REMOVAL AND INSTALLATION»(ref-180674-S28308161512005072800000) .
4. Disconnect steering lower joint, and release steering shaft. Refer to «REMOVAL AND INSTALLATION»(ref-172964-S20635872332005030800000) .
5. Remove front cross bar. Refer to «FRONT»(ref-166061) .
6. Disconnect propeller shaft. Refer to «REMOVAL AND INSTALLATION»(ref-173819-S27128930682005032300000) . After disconnection, plug the opening on transmission side.

Scheme 247

Scheme 248

1. Remove transmission assembly. Refer to «TRANSMISSION ASSEMBLY»(ref-170821-S42413579512005011800000) .
2. Install engine slingers into front of left bank cylinder head and rear of right bank cylinder head. Slinger bolts: 30.4 - 36.3 N.m (3.1 - 3.7 Kg-m, 23 - 26 ft-lb)
3. Lift with hoist and secure engine in position.
4. Remove engine mounting nuts on bottom surface.
5. Carefully lift up engine assembly, avoiding interference with vehicle body, move it away and upward.
6. With engine assembly lifted up, remove rear end of exhaust manifold to avoid contact with vehicle. Refer to «EXHAUST MANIFOLD AND THREE WAY CATALYST»(ref-159010-S33734709812005032300000) .
7. Remove engine assembly from vehicle. CAUTION: Before and during this lifting, always check if any harnesses are left connected. Avoid damage from oil/grease smearing or spilling onto engine mounting insulator.

When Cylinder Block is Reused

1. Measure the cylinder block bore inner diameter. Refer to «INNER DIAMETER OF CYLINDER BORE»(ref-159010-S40443872172005032300000) .
2. Determine the bore grade by comparing the measurement with the values under the "Cylinder bore inner diameter" of the piston selection table. Select piston of the same grade.

Scheme 249

Note. The piston is available together with piston pin as an assembly. The piston pin (piston pin bore) grade is provided only for the parts installed at the plant. For the service parts, no 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

1. Compare the pin diameter grade ("0", "1" or "2") on the crankshaft front surface with the values of the selection table of connecting rod bearing.

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

Scheme 250

When Crankshaft And Connecting Rod Are Reused

1. Measure the connecting rod big end diameter. Refer to «CONNECTING ROD BIG END DIAMETER»(ref-159010-S31386124942005032300000) .
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-159010-S23859957762005032300000) .
4. Determine the grade of crankshaft pin journal diameter grade by corresponding to the measured dimension in "Crankshaft pin journal diameter" column of "Selection Table of Connecting Rod Bearing".
5. Select connecting rod bearing of the same grade.

Scheme 251

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 bearings, measure the connecting rod bearing inner diameter with bearings installed, and grind crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard.

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Scheme 255

1. Apply main bearing housing grade on upper rear side between cylinder block banks to row in «MAIN BEARINGS SELECTION TABLE»(ref-159010-S21145989822005032300000) .
2. Apply journal diameter grade on crankshaft front to column in «MAIN BEARINGS SELECTION TABLE»(ref-159010-S21145989822005032300000) .
3. Find sign at crossing of row and column in «Main Bearings Selection Table»(ref-159010-S21145989822005032300000) . CAUTION: Initial clearance for No. 1, 5 journal and No. 2, 3, 4 journal is different. Use two different selection lists 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 BEARINGS SELECTION TABLE»(ref-159010-S21145989822005032300000) . NOTE: Grade list 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 inner diameter of cylinder block main bearing housing and outer diameter of crankshaft main journal. Refer to «INNER DIAMETER OF MAIN BEARING HOUSING»(ref-159010-S14750734042005032300000) , «CRANKSHAFT MAIN JOURNAL DIAMETER»(ref-159010-S01820763592005032300000) .
2. Apply measurement in above step 1 to «MAIN BEARINGS SELECTION TABLE»(ref-159010-S21145989822005032300000) .
3. Follow step 3 and later in «WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE USED»(ref-159010-S13353688412005032300000) .

Scheme 256

Scheme 257

Scheme 258

Use Undersize Bearing Usage Guide

1. Use undersize (US) bearing when oil clearance with standard size main bearing is not within specification.
2. When using undersize (US) bearing, measure inner diameter of bearing installed and grind journal until oil clearance falls within specification. Bearing Undersize Table

Scheme 259

Scheme 260

Scheme 261

1. Using a dial indicator, measure the clearance between the thrust bearings and the crankshaft arm when crankshaft is moved fully forward or backward. 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 the thrust bearings, and measure again. If it still exceeds the limit, replace crankshaft also.

Scheme 262

1. Measure the 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.

Inner Diameter of Piston Pin

Measure the inner diameter of piston pin bore with an inside micrometer.

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

Scheme 263

Outer Diameter of Piston Pin

Measure outer diameter of piston pin with a micrometer.

Standard: 21.989 - 22.001 mm (0.8657 - 0.8662 in.)

Scheme 264

Piston and Piston Pin Clearance

(Piston and piston pin clearance) = (Inner diameter of piston pin) - (Outer diameter of piston pin)

Standard: 0.002 - 0.006 mm (0.0001 - 0.0002 in.)

1. If the clearance exceeds the standard, replace piston/piston pin assembly.
2. Refer to piston selection table to replace piston/piston pin assembly. Refer to «HOW TO SELECT PISTON»(ref-159010-S15487966882005032300000) . NOTE: Piston is available together with piston pin as assembly. Piston pin hole (piston pin) grade is provided only for the parts installed at the plant. For service parts, no grades can be selected. (Only 0 grade is available.)

Scheme 265

1. Measure the 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 0.10 mm (0.0039 in.)
2. If out of the limit, replace piston and/or piston ring assembly.

Scheme 266

1. Check if the inner diameter of cylinder bore is within specification. Refer to «PISTON TO CYLINDER BORE CLEARANCE»(ref-159010-S07857807602005032300000) .
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 0.52 mm (0.0205 in.) Oil ring 0.96 mm (0.0378 in.)
3. If out of the limit, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylinder and use oversized piston and piston ring.

Scheme 267

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 268

1. Install connecting rod cap without connecting rod bearing installed. After tightening the connecting rod nut to the specified torque. Refer to «ASSEMBLY»(ref-159010-S26970920052005032300000) for the tightening procedure.
2. Measure the connecting rod big end diameter using an inside micrometer. Standard: 55.000 - 55.013 mm (2.1654 - 2.1659 in.)
3. If it exceeds the standard, replace connecting rod.

Inner Diameter of Connecting Rod Bushing

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

Scheme 269

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

Measure the outer diameter of piston pin with micrometer.

Scheme 270

Standard: 21.989 - 22.001 mm (0.8657 - 0.8662 in.)

Connecting Rod Bushing Oil Clearance

(Connecting rod bushing oil clearance) = (Inner diameter of connecting rod bushing) - (Outer diameter of piston pin)

Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 in.)

Scheme 271

1. If the measured value exceeds the standard, replace connecting rod assembly and/or piston/piston pin assembly.
2. If replacing piston and piston pin assembly, refer to «PISTON TO CYLINDER BORE CLEARANCE»(ref-159010-S38865601422005032300000) .
3. If replacing connecting rod assembly, refer to «OIL CLEARANCE OF CONNECTING ROD BEARING»(ref-159010-S13193587502005032300000) to select the connecting rod bearing.

Factory Installed Parts Grading

Service parts apply only to grade "0".

Scheme 272

Scheme 273

Scheme 274

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 the engine oil or engine coolant passages.
2. Measure the distortion on the block upper face at some different points in 6 directions. Limit: 0.1 mm (0.004 in.)
3. If out of the limit, replace cylinder block.

Scheme 275

1. Install main bearing caps with main bearings removed, and tighten the mounting bolts to the specified torque. Refer to «ASSEMBLY»(ref-159010-S26970920052005032300000) for the tightening procedure.
2. Using a bore gauge, measure the inner diameter of the main bearing housing. Standard: 68.944 - 68.968 mm (2.7143 - 2.7153 in.)
3. If out of the standard, replace the cylinder block and main bearing caps as an assembly. NOTE: These components cannot be replaced as a single unit, because they were processed together.

Scheme 276

Scheme 277

1. Using a bore gauge, measure the cylinder bore diameter for wear, out-of-round and taper at 6 different points on each cylinder. (X and Y directions at A, B and C) NOTE: When determining cylinder bore grade, measure cylinder bore at B position. Standard inner diameter: 93.000 - 93.030 mm (3.6614 - 3.6626 in.) Wear limit: 0.20 mm (0.0079 in) Out-of-round (Difference between X and Y): 0.015 mm (0.0006 in.) Taper limit (Difference between A and C): 0.010 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 bore the inner wall.
3. Oversize piston is provided. When using oversize piston, hone cylinder so that the clearance between piston and cylinder satisfies the standard. Oversize (OS): 0.2 mm (0.008 in.)

Scheme 278

1. Measure the piston outer diameter 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)

Scheme 279

Piston to Cylinder Bore Clearance

1. Calculate by outer diameter of piston and inner diameter of cylinder bore (direction X, position B). (Clearance) = (Inner diameter of cylinder bore) - (Outer diameter of piston) Standard: 0.010 - 0.030 mm (0.0004 - 0.0012 in.) Limit: 0.08 mm (0.0031 in.)
2. If it exceeds the limit, replace piston/piston pin assembly. Refer to «HOW TO SELECT PISTON»(ref-159010-S15487966882005032300000) .

Reboring Cylinder Bore

1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston outer diameter. Rebored Size Calculation: D = A+B - C Where, D: Bored diameter A: Piston outer 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 tighten to the specified torque. Otherwise, cylinder bores may be distorted in final assembly. Refer to «ASSEMBLY»(ref-159010-S26970920052005032300000) .
3. Cut the cylinder bores. NOTE: When any cylinder needs boring, all other cylinders must also be bored. Do not cut too much out of the 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 the finished cylinder bore for out-of-round and taper. NOTE: Measurement should be done after the cylinder bore cools down.

Crankshaft Main Journal Diameter

1. Measure the outer diameter of crankshaft main journals with micrometer. Standard: 63.940 - 63.964 mm (2.5173 - 2.5183 in.)
2. If out of standard, measure the main bearing oil clearance. Then use the undersize bearing. Refer to «OIL CLEARANCE OF MAIN BEARING»(ref-159010-S25964697932005032300000) .

Scheme 280

1. Measure the outer diameter of crankshaft pin journal. Standard: 51.956 - 51.974 mm (2.0455 - 2.0462 in.)
2. If out of standard, measure the connecting rod bearing oil clearance. Then use the undersized bearing. Refer to «OIL CLEARANCE OF CONNECTING ROD BEARING»(ref-159010-S13193587502005032300000) .

Scheme 281

1. Using a micrometer, measure the dimensions at 4 different points shown in the figure on each journal and pin.
2. Out-of-roundness is indicated by the difference in the dimension between X and Y at A and B.
3. Taper is indicated by the difference in the 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 journal or pin. Then select main bearing or connecting rod bearing. Refer to «OIL CLEARANCE OF MAIN BEARING»(ref-159010-S25964697932005032300000) and/or «OIL CLEARANCE OF CONNECTING ROD BEARING»(ref-159010-S13193587502005032300000) .

Scheme 282

1. Place a V-block on a precise flat table to 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 the dial indicator. (Total indicator reading) Limit: 0.10 mm (0.039 in)
4. If it exceeds the limit, replace crankshaft.

Scheme 283

1. Install connecting rod bearings to connecting rod and cap, and tighten the connecting rod nut to the specified torque. Refer to «ASSEMBLY»(ref-159010-S26970920052005032300000) for the tightening procedure.
2. Using a inside micrometer measure the inner diameter of connecting rod bearing. (Oil clearance) = (Inner diameter of connecting rod bearing) - (Crankshaft pin journal diameter) Standard: 0.020 - 0.045 mm (0.0008 - 0.0018 in.) 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-159010-S14894019222005032300000) .

Scheme 284

1. Remove oil and dust on the 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 bearing cap, and tighten the connecting rod nut to the specified torque. Refer to «ASSEMBLY»(ref-159010-S26970920052005032300000) for the tightening procedure. CAUTION: Never rotate crankshaft.
4. Remove connecting rod cap and bearings, and using the scale on the plastigage bag, measure the plastigage width. NOTE: When the measured value exceeds the limit, the procedure is same as that described in "Method of Measurement."

Scheme 285

1. Install main bearings to cylinder block and main bearing cap. Measure the main bearing inner diameter with the bearing cap bolt tightened to the specified torque. Refer to «ASSEMBLY»(ref-159010-S26970920052005032300000) for the tightening procedure. (Oil clearance) = (Inner diameter of main bearing) - (Outer diameter of crankshaft main journal) Standard: No. 1 and 5 journals: 0.001 - 0.011 mm (0.00004 - 0.0004 in.) No. 2, 3, and 4 journals: 0.007 - 0.017 mm (0.0003 - 0.0007 in.) Limit: No. 1 and 5 journals: 0.021 mm (0.0008 in.) No. 2, 3, and 4 journals: 0.027 mm (0.0011 in.)
2. 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-159010-S09174528462005032300000) .

Scheme 286

1. Remove oil and dust on the crankshaft main 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 bearings to cylinder block and main bearing cap, and tighten the main bearing bolts to the specified torque. Refer to «ASSEMBLY»(ref-159010-S26970920052005032300000) for the tightening procedure. CAUTION: Never rotate crankshaft.
4. Remove bearing cap and bearings, and using the scale on the plastigage bag, measure the plastigage width. NOTE: When the measured value exceeds the limit, the procedure is same as that described in "Method of Measurement".

Scheme 287

1. When the 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-159010-S26970920052005032300000) for the tightening procedure. Standard: There must be crush height.
2. If out of the standard, replace main bearings.

Scheme 288

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-159010-S26970920052005032300000) for the tightening procedure. Standard: There must be crush height.
2. If out of the standard, replace connecting rod bearings.