Engine Mechanical: Other Infiniti Q45 III

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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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 192

Power Steering Oil Pump Belt

Install in the reverse order of removal paying attention to the following.

1. Unlock auto tensioner pulley arm to give tension to belt.
2. Rotate crankshaft pulley several turns clockwise several times to equalize belt tension between pulleys.
3. Check that belt tension is within the allowable working range, using indicator notch on the auto tensioner. Refer to «CHECKING DRIVE BELTS»(ref-231095-S32265670572006050300000) .

Alternator, Water Pump and A/C Compressor Belt

Install in the reverse order of removal paying attention to the following.

1. Release auto tensioner, and apply auto tensions to belt.
2. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
3. Confirm tensions of belt at indicator is within the allowable working range. Refer to «CHECKING DRIVE BELTS»(ref-231095-S32265670572006050300000) .

Scheme 193

CHANGING AIR CLEANER FILTER

1. Remove air cleaner cover. Refer to «REMOVAL AND INSTALLATION»(ref-231095-S21134367422006050300000) .
2. Remove two clips and lift up air cleaner filter along with holder.
3. Remove air cleaner filter from holder.

Scheme 194

Surface Distortion

Using straightedge and feeler gauge, inspect surface distortion of intake manifold lower and intake manifold upper.

Scheme 195

1. Limit : 0.1 mm (0.004 in)

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 Hose

Refer to VACUUM DIAGRAMS .

Connecting Quick Connector of Fuel Tube

Install quick connector as follows on engine side only.

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1. Make sure no foreign substances are deposited in and around tube and quick connector, and no damage on them.
2. Thinly apply new engine oil around the fuel tube from tip end to the spool end.
3. Align center to insert quick connector straightly into fuel tube. Insert fuel tube into quick connector until edge side spool is completely inside quick connector, and 2nd spool exposes right below quick connector. CAUTION: Hold A position in illustration when inserting fuel tube into quick connector. Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick connector. Insert until you hear a "click" sound and actually feel the engagement. To avoid mis-identification of engagement with a similar sound, be sure to perform the next step.
4. Pull quick connector by hand holding A position. Make sure it is completely engaged (connected) so that it does not come out from fuel tube. NOTE: Recommended pulling force is 50 N (5.1 kg, 11.2 lb).
5. Install quick connector cap on quick connector joint (on engine side only).
6. Install fuel hose and fuel tube to hose clamps.

Use a reliable straightedge and feeler gauge to check the flatness of each exhaust manifold flange surface.

1. Limit : 0.3mm (0.012in)

Scheme 199

Exhaust Manifold Gasket

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

Scheme 200

1. Install exhaust manifold and three way catalyst in the numerical order shown in the figure.
2. Tighten nuts No. 1 to No. 4 in two steps. Order No. 9 to 12 shows second step.

Check on Fuel Leakage

1. After installing fuel tubes, make sure there is no fuel leakage at connections in the following steps. Apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then check for fuel leaks at connections. Start the engine and rev it up and check for fuel leaks at connections. NOTE: Use mirrors for checking on invisible points. CAUTION: Do not touch the engine immediately after stopped, as engine becomes extremely hot.

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Scheme 202

1. Refer to the followings for removal works related to left-bank. Remove engine cover (with power tool) and air cleaner cover. Refer to «REMOVAL AND INSTALLATION»(ref-231095-S21134367422006050300000) . Remove bracket (installation parts for No. 6 camshaft bracket). Move harness on upper rocker cover and its peripheral aside. Remove ignition coil. Refer to «REMOVAL AND INSTALLATION»(ref-231095-S26003145532006050300000) . Remove PCV valve hose from PCV valve.
2. Refer to the followings for removal works related to right-bank. Remove engine cover (with power tool) and battery cover. Refer to «REMOVAL AND INSTALLATION»(ref-231095-S21134367422006050300000) . Move harness on upper rocker cover and its peripheral aside. Remove ignition coil. Remove PCV valve hose from PCV valve.
3. Loosen bolts in reverse order shown in the figure (with power tool). CAUTION: Do not hold oil filler neck (right bank) not to damage it.

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Scheme 204

1. Apply liquid gasket to joint part of cylinder head and camshaft bracket following the below steps. NOTE: Illustration shows an example of left-bank side (zoomed in shows No. 1 camshaft bracket). Apply only to No. 1 camshaft bracket for right-bank side. Refer to illustration "a" to apply liquid gasket to joint part of No. 1 and No. 6 camshaft bracket and cylinder head. Refer to illustration "b" to apply liquid gasket in 90° to illustration "a". Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-182064-S38599864392005080600000) .
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 order numbers in illustration. 1st step : 1.0 - 3.0 N.m (0.1 - 0.31 kg-m, 9 - 26 in-lb) 2nd step 7.4 - 9.3 N.m (0.75 - 0.95 kg-m, 66 - 82 in-lb)
4. Install in the reverse order of removal after this step.

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1. Remove engine assembly from vehicle. Refer to «REMOVAL AND INSTALLATION»(ref-231095-S06636579622006050300000) .
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-231095-S05769777882006050300000) . Thermostat housing and hose. Refer to «THERMOSTAT AND WATER CONTROL VALVE»(ref-183866-S26807185872005081700000) . Oil pan and oil strainer. Refer to «REMOVAL AND INSTALLATION»(ref-231095-S41795030392006050300000) . Ignition coil (When camshaft sprocket is removed). Refer to «REMOVAL AND INSTALLATION»(ref-231095-S26003145532006050300000) . Rocker cover (When camshaft sprocket is removed). Refer to «REMOVAL AND INSTALLATION»(ref-231095-S35103533352006050300000) .
3. If necessary, remove intake valve timing control position sensor (right and left) and camshaft position sensor (PHASE) from intake valve timing control cover and front cover. CAUTION: Handle components and parts 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.
5. Remove intake valve timing control cover as follows: Loosen and remove fixing bolts in the reverse order of that shown in figure. Use seal cutter or the equivalent 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 intake cam sprocket.
6. Obtain compression TDC of No. 1 cylinder as follows: Turn crankshaft pulley clockwise to align the TDC identification notch (without paint mark) with timing indicator on front cover. At this time, check that the mating mark on camshaft sprocket is in the position as shown in the figure. If the mating mark does not come in the position shown, turn crankshaft pulley once more to bring the mark in the position.
7. Remove crankshaft pulley as follows: Lock crankshaft with a hammer handle or similar tool to loosen fixing bolts. Pull crankshaft pulley with both hands to remove it. CAUTION: Do not remove fixing bolts. Keep loosened fixing bolts in place to protect removed crankshaft pulley from dropping. Do not remove balance weight (inner hexagon bolt) at the front of crankshaft pulley.
8. Remove front cover as follows: Loosen and remove fixing bolts in the reverse order of that shown in figure. Use seal cutter or the equivalent to cut liquid gasket for removal. CAUTION: Exercise care not to damage mating surfaces.
9. If replacement of front oil seal is necessary, lift the seal with a screwdriver for removal. CAUTION: Exercise care not to damage front cover.
10. Remove oil pump drive spacer. Install bolts into two bolt holes [M6 x pitch 1.0 mm (0.04 in)] on front surface. Using a small puller, pull spacer off from crankshaft. NOTE: The center-to-center dimension between the two bolt holes is 33 mm (1.30 in).
11. Remove oil pump.
12. Remove chain tensioner on left bank. NOTE: To remove timing chain and associated 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 a stopper pin [hard wire with approx. 0.5 mm (0.020 in) diameter or a similar tool] to fix plunger. With plunger fixed, remove chain tensioner.
13. Remove chain tensioner guide and slack guide.
14. Remove timing chain and crankshaft sprocket.
15. With hexagonal part of camshaft locked with wrench, loosen bolts securing camshaft sprocket to remove camshaft sprocket. CAUTION: To avoid interference between valves and pistons, do not turn crankshaft or camshaft with timing chain is disconnected.
16. Using the same procedure as for left bank, remove timing chain and associated parts on right side.

Outer Diameter of Camshaft Journal

Measure outer diameter of camshaft journal.

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1. Standard outer diameter: 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

1. Tighten camshaft bracket bolt with specified torque.
2. Using inside micrometer, measure inner diameter of camshaft bracket. Standard: 26.000-26.021 mm (1.0236 - 1.0244 in)

Calculation of Camshaft Journal Clearance

(Journal clearance) = (inner diameter of camshaft bracket) - (outer diameter of camshaft journal)

1. Standard
2. No. 1 : 0.045 - 0.083 mm (0.0018 - 0.0033 in)
3. No. 2, 3, 4, 5 : 0.030 - 0.068 mm (0.0012 - 0.0027 in)

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1. When out of the specified range above, replace either or both camshaft and cylinder head. NOTE: Inner diameter of camshaft bracket is manufactured together with cylinder head. Replace the whole cylinder head assembly.

Scheme 217

1. Install dial gauge 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. When out of the specified range, replace with new camshaft and measure again.
3. When out of the specified range again, replace with new cylinder head.

Scheme 218

1. Install camshaft in cylinder head.
2. Install camshaft sprocket to camshaft.
3. Measure camshaft sprocket runout. Runout : Less than 0.15 mm (0.0059 in)
4. If it exceeds the specifications, replace camshaft sprocket.

Valve Lifter and Adjusting Shim

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

Scheme 219

Outer Diameter of Valve Lifter

Measure outer diameter of valve lifter.

1. Standard: 33.965-33.975 mm (1.3372-1.3376 in)

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Valve Lifter Hole Diameter

Using inside micrometer, measure diameter of valve lifter hole of cylinder head.

1. Standard: 34.000 - 34.016 mm (1.3386 -1.3392 in)

Calculation of Valve Lifter Clearance

(Valve lifter clearance) = (hole diameter of valve lifter) - (outer diameter of valve lifter)

1. Standard: 0.025 - 0.051 mm (0.0010 - 0.0020 in)

Scheme 221

1. When out of specified range, referring to each specification of outer and inner diameter, replace either or both valve lifter and cylinder head.

VALVE GUIDE CLEARANCE

Perform this inspection before removing valve guide.

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1. Make sure that the valve stem diameter is within the specification.
2. Push the valve out by approx. 15 mm (0.59 in) toward the combustion chamber side to measure the valve's run-out volume (in the direction of dial gauge) with dial gauge.
3. The half of the run-out volume accounts for the 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)

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.

1. Limit : 2.0 mm (0.079 in)

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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.

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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 225

Outline

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

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1. Release fuel pressure. Refer to «FUEL PRESSURE RELEASE»(ref-151802-S17369107142003010800000) .
2. Remove engine cover and engine undercover with power tool.
3. Drain engine coolant from radiator drain plug.
4. Remove the following parts: Engine hood Front tower bar Battery Air duct (inlet) Air duct and air cleaner case assembly Drive belts. Refer to «REMOVAL AND INSTALLATION»(ref-231095-S00603610242006050300000) . Power valve vacuum tank Cooling fan and tubes Radiator assembly and hoses (Refer to «RADIATOR»(ref-183866-S03334760602005081700000) .) Water suction pipe Engine room LH
5. Disconnect engine room harness from the engine side and set it aside for easier work.
6. Disconnect heater hoses, and install plugs to avoid leakage of engine coolant.
7. Disconnect wire bonding exhaust manifold cover to vehicle.
8. Disconnect vacuum hose between vehicle and engine and set it aside.
9. Remove reservoir tank for cooling fan.
10. 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 «COMPRESSOR»(ref-182027-S03631927382005080600000) . Engine room RH
11. Disconnect fuel hose at the engine side connection. For disconnection/connection of quick connector, Refer to «REMOVAL AND INSTALLATION»(ref-231095-S27218587162006050300000) .
12. Disconnect engine room harness from the engine side and set it aside for easier work.
13. Disconnect wire bonding exhaust manifold cover to vehicle.
14. Disconnect vacuum hose between vehicle and engine and set it aside.
15. Disconnect reservoir tank for power steering from engine and move it aside for easier work.
16. Move away relay case. Vehicle underbody
17. Disconnect power steering oil pump from engine. Move it from its location and secure with a rope for easier work. Refer to «POWER STEERING OIL PUMP»(ref-182021-S16870429142005080600000) .
18. Remove pipe of cooler for automatic transmission.
19. Remove exhaust front tube.
20. Disconnect steering lower joint, and release steering shaft. Refer to «POWER STEERING GEAR AND LINKAGE»(ref-182021-S01679076992005080600000) .
21. Disconnect propeller shaft. Refer to «REAR PROPELLER SHAFT»(ref-182015-S06678624682005080600000) . After disconnection, plug the opening on transmission side. Removal
22. Remove transmission assembly. Refer to «TRANSMISSION ASSEMBLY»(ref-182060-S21427462442005080600000) .
23. 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)
24. Lift with hoist and secure the engine in position.
25. Remove engine mounting nuts on bottom surface.
26. Carefully lift up engine assembly, avoiding interference with vehicle body, move it away and upward.
27. With engine assembly lifted up, remove rear end of exhaust manifold to avoid contact with vehicle.
28. Remove engine assembly from vehicle. CAUTION: Before and during this lifting, always check if any harnesses are left connected. Avoid damage to oil/grease smearing or spills onto engine mount insulator.

HOW TO SELECT PISTON

Piston Selective Fitting When New Cylinder Block is Used

Check the cylinder bore grade on the rear upper side between cylinder block banks, and select the piston of the same grade.

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When Cylinder Block is Reused

1. Measure the cylinder block bore inner diameter.
2. Determine the bore grade by comparing the measurement with the values under the "Cylinder bore inner diameter" of the piston selection table. Select the piston of the same grade.

Scheme 230

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 service parts, no grades can be selected (Only 0 grade is available).

HOW TO SELECT CONNECTING ROD BEARING

When New Connecting Rod and Crankshaft are Used

Compare the pin diameter grade of 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.

Scheme 231

When Crankshaft and Connecting Rod are Reused

1. Measure the pin outer diameter of the crankshaft.
2. Compare the measurement with the values of the selection table of connecting rod bearing.

Scheme 232

Note. (At shipment from the plant) For an engine, all the connecting rod assemblies are in the same weight class. For service parts, no weight grades can be selected.

Scheme 233

Undersize Bearings Usage Guide

1. When the specified oil clearance is not obtained with standard size connecting rod bearings, use undersize (US) bearings.
2. When using undersize bearings, measure the bearing inner diameters with bearings installed, and grind the crankshaft pin so that the oil clearance satisfies the standard.

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HOW TO SELECT MAIN BEARING

When New Cylinder Block and Crankshaft are Used

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1. Apply main bearing housing grade on upper rear side between cylinder block banks to row in main bearing selection table.
2. Apply journal diameter grade on crankshaft front to column in main bearing selection table.
3. Find sign at crossing of row and column in main bearing selection table. 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 bearing grade table. 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 journal.
2. Apply measurement in above step 1 to main bearing selection table.
3. Follow step 3 and later in "When new cylinder block and crankshaft are used".

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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.

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1. Using a dial gauge, measure the clearance between the thrust bearings and the crankshaft arm when the 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 repair limit, replace the thrust bearings, and measure again. If it still exceeds the repair limit, replace the crankshaft also.

Scheme 245

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 repair limit, replace the connecting rod bearings, and measure again. If it still exceeds the repair limit, replace the crankshaft also.

Inner Diameter of Piston Pin

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

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

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Outer Diameter of Piston Pin

Measure outer diameter of piston pin with a micrometer.

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

Scheme 247

Piston and Piston Pin Clearance

(Piston pin clearance) = (Piston pin bore diameter) - (Outer diameter of piston pin)

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

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1. If clearance is exceeds specification, replace either or both of piston/piston pin assembly and connecting rod assembly with reference to specification of each parts.
2. Refer to piston selection table to replace piston/piston pin assembly. Refer to «HOW TO SELECT PISTON»(ref-231095-S37784464572006050300000) .
3. Refer to connecting rod bearing selection table to replace connecting rod. Refer to «HOW TO SELECT CONNECTING ROD BEARING»(ref-231095-S31383437672006050300000) . NOTE: The connecting rod small end grade and piston pin hole (piston pin) grade are provided only for the parts installed at the plant. For service parts, no grades can be selected. (Only 0 grade is available.)
4. Refer to «CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)»(ref-231095-S09188932582006050300000) for the values for each grade at the plant.

Scheme 250

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 0.10 mm (0.0039 in)
2. If out of specification, replace piston and/or piston ring assembly.

Scheme 251

1. Check if inner diameter of cylinder bore is within specification. Refer to «PISTON TO CYLINDER BORE CLEARANCE»(ref-231095-S03235000342006050300000) .
2. Insert piston ring until middle of cylinder with piston, and measure gap. 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 specification, 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 252

Scheme 253

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.

CONNECTING ROD BEARING (BIG END)

Install the connecting rod cap without the connecting rod bearing installed. After tightening the connecting rod nut to the specified torque, measure the connecting rod large end inner diameter using an inside micrometer.

1. Standard : 55.000 - 55.013 mm (2.1654 - 2.1659 in)

Scheme 254

Inner Diameter of Connecting Rod (Small End)

Measure inner diameter of bushing.

Scheme 255

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

Measure outer diameter of piston pin.

Scheme 256

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

Connecting Rod Bushing Oil Clearance (Small End)

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

1. Standard : 0.005 - 0.017 mm (0.0002 - 0.007 in)

Scheme 257

1. If the measured value exceeds the standard, replace the connecting rod assembly and/or piston and piston pin assembly.
2. If replacing the piston and piston pin assembly, refer to the Table for Selective Fitting for Piston to select the piston corresponding to the applicable bore grade of the cylinder block to be used. Refer to «HOW TO SELECT PISTON»(ref-231095-S37784464572006050300000) .

Factory installed parts grading

Service parts apply only to grade 0.

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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 distortion limit, replace the cylinder block.

Scheme 261

1. Install the main bearing caps with the main bearings removed, and tighten the mounting bolts to the specified torque.
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.

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Scheme 263

1. Using a bore gauge, measure cylinder bore 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): Less than 0.015 mm (0.0006 in) Taper limit (Difference between A and C): Less than 0.010 mm (0.0004 in)
2. If the measured value exceeds the repair limit, or if there are scratches and/or seizure on the cylinder inner wall, hone or bore the inner wall.
3. An oversize piston is provided. When using an oversize piston, hone the cylinder so that the clearance between the piston and cylinder satisfies the standard. Oversize (OS) : 0.2 mm (0.008 in)
4. If oversize piston is used, use it for all cylinders with oversize piston rings.

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Scheme 265

1. Measure piston skirt diameter. 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

1. Calculate by outer diameter of piston skirt and inner diameter of cylinder (direction X, position B). (Clearance) = (Inner diameter of cylinder) - (Outer diameter of piston skirt) 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.

Reboring Cylinder Bore

1. 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 (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.
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-bore clearance.
5. Measure finished cylinder bore for out-of-round and taper. NOTE: Measurement should be done after cylinder bore cools down.

OUTER DIAMETER OF CRANKSHAFT JOURNAL

Measure outer diameter of crankshaft journals

1. Standard : 63.940 - 63.964 mm (2.5173 - 2.5183 in)

OUTER DIAMETER OF CRANKSHAFT PIN

Measure outer diameter of crankshaft pin.

Scheme 266

1. Standard : 51.956 - 51.974 mm (2.0455-2.0462 in)

Scheme 267

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 dimension 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 (X-Y) : 0.015 mm (0.0006 in) Taper (A-B) : 0.010 mm (0.0004 in)

Scheme 268

1. Place a V-block on a precise flat table to support the journals on the both end of the crankshaft.
2. Place a dial gauge straight up on the No. 3 journal.
3. While rotating the crankshaft, read the movement of the pointer on the dial gauge.
4. Half of the movement shows the runout. Limit: 0.05 mm (0.002 in)

Scheme 269

1. Install the connecting rod bearings to the connecting rod and the cap, and tighten the connecting rod nut to the specified torque. Using a inside micrometer measure the inner diameter of connecting rod bearing. (Oil clearance) = (Inner diameter of connecting rod bearing) - (Outer diameter of crankshaft pin) Standard : 0.020 - 0.045 mm (0.0008 - 0.0018 in) Limit : 0.055 mm (0.0022 in)
2. If clearance cannot be adjusted within the standard, grind crankshaft pin and use undersized bearing. Refer to «HOW TO SELECT CONNECTING ROD BEARING»(ref-231095-S31383437672006050300000) .

Scheme 270

1. Remove oil and dust on the crankshaft pin 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 the connecting rod bearings to the connecting rod and the connecting rod bearing cap, and tighten the connecting rod nut to the specified torque. CAUTION: Never rotate the crankshaft.
4. Remove the connecting rod cap and bearings, and using the scale on the plastigage bag, measure the plastigage width. NOTE: The procedure when the measured value exceeds the repair limit is same as that described in "Method of Measurement".

Method of Measurement

1. Install the main bearings to the 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-231095-S33433804852006050300000) . (Oil clearance) = (Inner diameter of main bearing) - (Outer diameter of crankshaft journal) Standard: No. 1 and 5 journals : 0.001 - 0.011 mm (0.0004 - 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 the measured value exceeds the repair limit, select main bearings referring to the main bearing inner diameter and crankshaft journal outer diameter, so that the oil clearance satisfies the standard. Refer to «HOW TO SELECT MAIN BEARING»(ref-231095-S00287616602006050300000) .

Scheme 271

1. Remove oil and dust on the crankshaft journal and the surfaces of each bearing completely.
2. Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes
3. Install the main bearings to the cylinder block and main bearing cap, and tighten the main bearing bolts to the specified torque. CAUTION: Never rotate the crankshaft.
4. Remove the bearing cap and bearings, and using the scale on the plastigage bag, measure the plastigage width. NOTE: The procedure when the measured value exceeds the repair limit is same as that described in "Method of Measurement".

Scheme 272

1. When the bearing cap is removed after being tightened to the specified torque with main bearings installed, the tip end of bearing must protrude. Standard : There must be crush height
2. If the standard is not met, replace main bearings.