Engine Mechanical (Convertible): Other Infiniti Q60 I

Precaution for Procedure without Cowl Top Cover

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

Scheme 214

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

The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the " SRS AIRBAG (CONVERTIBLE) " and " SEAT BELTS (CONVERTIBLE) " articles of this Service Information.

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

Service Procedure Precautions for Models with a Pop-up Roll Bar

Precaution for Battery Service

Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interference between the window edge and the vehicle when the door is opened/closed. During normal operation, the window slightly raises and lowers automatically to prevent any window to vehicle interference. The automatic window function will not work with the battery disconnected.

Precautions Necessary for Steering Wheel Rotation After Battery Disconnection

For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and cannot be turned.

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

DISCONNECTING FUEL PIPING

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

Special Service Tools

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

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

Scheme 215

Scheme 216

Scheme 217

Scheme 218

Scheme 219

Commercial Service Tools

(Kent-Moore No.) Tool name Description (-) Tube presser Pressing the tube of liquid gasket (-) Power tool Loosening nuts and bolts (-) TORX socket Removing and installing flywheel Size: T55 (-) Manual lift table caddy Removing and installing engine (J-24239-01) Cylinder head bolt wrench Loosening and tightening cylinder head bolt, and used with the angle wrench [SST: KV10112100 (BT8653-A)] 13 (0.51) dia. 12 (0.47) 10 (0.39) Unit: mm (in) (-) Compression gauge Adapter Checking compression pressure (-) Spark plug wrench Removing and installing spark plug 14 mm (0.55 in) (-) Valve seat cutter set Finishing valve seat (EXH) dimensions (-) Piston ring expander Removing and installing piston ring (-) Valve guide drift Removing and installing valve guide (EXH) Exhaust: 9.5 mm (0.374 in) dia. 5.5 mm (0.217 in) dia. (-) Valve guide reamer Reaming valve guide (EXH) inner hole Reaming hole for oversize valve guide (EXH) Exhaust: c: 6.0 mm (0.236 in) dia. d: 10.2 mm (0.402 in) dia. (J-43897-18) (J-43897-12) Oxygen sensor thread cleaner Reconditioning the exhaust system threads before installing a new air fuel ratio sensor and heated oxygen sensor (Use with anti-seize lubricant shown below.) J-43897-18 [18 mm (0.71 in) dia.] for zirconia heated oxygen sensor and air fuel ratio sensor J-43897-12 [12 mm (0.47 in) dia.] for titania heated oxygen sensor Mating surface shave cylinder Flutes (-) Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907) Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads (-) Feeler gauge Inspection valve clearance (Use a curved-tip gauge)

Scheme 220

Scheme 221

Scheme 222

Scheme 223

Scheme 224

Scheme 225

Scheme 226

Scheme 227

Scheme 228

Scheme 229

Checking

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

WATER HOSE

1. Insert hose by 27 to 32 mm (1.06 to 1.26 in) from connector end.
2. Clamp hose at location of 3 to 7 mm (0.12 to 0.28 in) from hose end.

ELECTRIC THROTTLE CONTROL ACTUATOR (BANK 1 AND BANK 2)

1. Tighten in numerical order as shown in the figure below. NOTE: The figure shows the electric throttle control actuator (bank 1) viewed from the air duct side. Viewed from the air duct side, the order of tightening mounting bolts of electric throttle control actuator (bank 2) is the same as that of the electric throttle control actuator (bank 1).
2. Perform the " «THROTTLE VALVE CLOSED POSITION LEARNING»(ref-659742-S42030708352014100100000) " when harness connector of electric throttle control actuator is disconnected. Refer to " «THROTTLE VALVE CLOSED POSITION LEARNING: DESCRIPTION»(ref-659742-S02344247532014100100000) ".
3. Perform the " «IDLE AIR VOLUME LEARNING»(ref-659742-S34502147892014100100000) " and "Throttle Valve Closed Position Learning" when electric throttle control actuator is replaced. Refer to " «IDLE AIR VOLUME LEARNING: DESCRIPTION»(ref-659742-S32544183542014100100000) " and " «THROTTLE VALVE CLOSED POSITION LEARNING: DESCRIPTION»(ref-659742-S02344247532014100100000) ".

Scheme 230

Refer to " COMPONENTS " for symbols in the figure.

Scheme 231

1. Release fuel pressure. Refer to " «INSPECTION»(ref-659741-S33796297922014100100000) ".
2. Remove intake manifold collector. Refer to " «EXPLODED VIEW»(ref-659738-S30429584682014100100000) ".
3. Remove fuel tube and fuel injector assembly. Refer to " «EXPLODED VIEW»(ref-659738-S24568157532014100100000) ".
4. Loosen mounting bolts in reverse of the order shown in the figure below to remove intake manifold with power tool. CAUTION: Cover engine openings to avoid entry of foreign materials. Put a mark on the intake manifold and the cylinder head with paint before removal because they need to be installed in the specified direction.
5. Remove gaskets.

AIR FUEL RATIO SENSOR 1

Scheme 232

1. Check the surface distortion of the exhaust manifold mating surface with a straightedge (A) and a feeler gauge (B). Limit: Refer to " «EXHAUST MANIFOLD»(ref-659738-S10453816732014100100000) ".
2. If it exceeds the limit, replace exhaust manifold.

Scheme 233

Refer to FUEL INJECTOR AND FUEL TUBE

Refer to " COMPONENTS " for symbols in the figure.

Check for Fuel Leakage

1. Turn ignition switch "ON" (with the engine stopped). With fuel pressure applied to fuel piping, check that there is no fuel leakage at connection points. NOTE: Use mirrors for checking at points out of clear sight.
2. Start the engine. With engine speed increased, check that again that there is no fuel leakage at connection points. CAUTION: Never touch the engine immediately after it is stopped because the engine is extremely hot.

Scheme 234

Refer to " COMPONENTS " for symbols in the figure.

Timing Chain

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

Scheme 235

Outline

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

Preparation

1. Release fuel pressure. Refer to " «INSPECTION»(ref-659741-S33796297922014100100000) ".
2. Disconnect both battery cables. Refer to " «EXPLODED VIEW»(ref-659730-S37691368612014100100000) ".
3. Drain engine coolant from radiator. Refer to " «DRAINING»(ref-659739-S13884844802014100100000) ". CAUTION: Perform this step when engine is cold. Never spill engine coolant on drive belt.
4. Remove the following parts: Radiator reservoir tank: Refer to " «EXPLODED VIEW»(ref-659739-S33175327982014100100000) ". Engine cover: Refer to " «EXPLODED VIEW»(ref-659738-S25330451632014100100000) ". Front road wheel and tires (power tool) Engine undercover (power tool) Cowl top cover: Refer to " «EXPLODED VIEW»(ref-659749-S36722016382014100100000) " Air duct and air cleaner case assembly (RH and LH): Refer to " «EXPLODED VIEW»(ref-659738-S28866194412014100100000) ". Cooling fan assembly: Refer to " «EXPLODED VIEW»(ref-659739-S33175327982014100100000) ".
5. Discharge refrigerant from A/C circuit. Refer to " «COLLECTION AND CHARGE»(ref-659732-S12577230332014100100000) ".
6. Remove radiator hoses (upper and lower). Refer to " «EXPLODED VIEW»(ref-659739-S33175327982014100100000) ".

Engine Room LH

1. Disconnect heater hose at vehicle side, and fit a plug onto hose end to prevent engine coolant leakage.
2. Disconnect A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope. Refer to " «EXPLODED VIEW»(ref-659732-S14710533522014100100000) ".
3. Disconnect brake booster vacuum hose.
4. Disconnect ground cable.

Engine Room RH

1. Disconnect battery positive cable at vehicle side and temporarily fasten it on engine.
2. Disconnect all clips and connectors of the engine room harness from engine back side.
3. Disconnect fuel feed hose (with damper) and EVAP hose. Refer to " «EXPLODED VIEW»(ref-659738-S24568157532014100100000) ". CAUTION: Fit plugs onto disconnected hoses to prevent fuel leakage.
4. Remove reservoir tank of power steering oil pump and piping from vehicle, and temporarily secure them on engine. Refer to " «EXPLODED VIEW»(ref-659744-S06422952502014100100000) ". CAUTION: When temporarily securing, keep the reservoir tank upright to avoid fluid leakage.

Vehicle Inside

Follow the procedure below to disconnect engine room harness connectors at passenger room side, and temporarily secure them on engine.

1. Remove passenger-side kicking plate and dash side finisher. Refer to " «EXPLODED VIEW»(ref-659750-S05945862332014100100000) ".
2. Disconnect engine room harness connectors at unit sides TCM, ECM and other locations.
3. Disengage intermediate fixing point. Pull out engine room harnesses to engine room side, and temporarily secure them on engine. CAUTION: When pulling out harnesses, take care not to damage harnesses and connectors. After temporarily securing, cover connectors with vinyl or similar material to protect against adhesion of foreign materials.

Vehicle Underbody

1. Remove A/T fluid cooler hoses (A/T models) and power steering oil pump oil cooler hoses.
2. Disconnect heated oxygen sensor 2 harness. Refer to " «EXPLODED VIEW»(ref-659743-S06482998112014100100000) ".
3. Remove three way catalyst and exhaust front tube. Refer to " «EXPLODED VIEW»(ref-659743-S06482998112014100100000) ".
4. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Refer to " «EXPLODED VIEW»(ref-659744-S39256188692014100100000) ".
5. Remove rear propeller shaft. Refer to " «EXPLODED VIEW»(ref-659751-S09306457762014100100000) " (M/T models) or " «EXPLODED VIEW»(ref-659752-S35687489482014100100000) " (A/T models).
6. Disengage control rod and remove clutch tube. Refer to " «EXPLODED VIEW»(ref-659747-S05833154622014100100000) " (M/T models).
7. Disengage A/T control rod at A/T shift selector side. Then, temporarily secure it on the transmission assembly, so that it does not sag. Refer to " «EXPLODED VIEW»(ref-659748-S01890809392014100100000) " (A/T models).
8. Remove rear plate cover from oil pan (upper). Then remove bolts fixing drive plate to torque converter. Refer to " «EXPLODED VIEW»(ref-659738-S07308347352014100100000) " (A/T models).
9. Remove transmission joint bolts that pierce at oil pan (upper) lower rear side. Refer to " «EXPLODED VIEW»(ref-659738-S11918651892014100100000) ".
10. Remove front stabilizer connecting rod from transverse link. Refer to " «EXPLODED VIEW»(ref-659753-S34694901982014100100000) ".
11. Remove lower ends of left and right steering knuckle from transverse link. Refer to " «EXPLODED VIEW»(ref-659754-S26384282872014100100000) ".
12. Separate steering outer sockets from steering knuckle. Refer to " «EXPLODED VIEW»(ref-659744-S30640004692014100100000) ".
13. Remove transverse links mounting bolts at suspension member side. Refer to " «EXPLODED VIEW»(ref-659753-S26576699792014100100000) ".

Scheme 236

1. Use a manual lift table caddy (commercial service tool) or equivalently rigid tool such as a transmission jack. Securely support bottom of suspension member and the transmission assembly. CAUTION: Use a piece of wood or a similar item as the supporting surface to secure a completely stable condition.
2. Remove rear engine mounting member bolts.
3. Remove front suspension member mounting bolts and nuts. Refer to " «EXPLODED VIEW»(ref-659753-S30247161102014100100000) ".
4. Carefully lower jack, or raise lift, to remove the engine, the transmission assembly and front suspension member. When performing work, observe the following caution items: CAUTION: Confirm there is no interference with the vehicle. Check that all connection points have been disconnected. Keep in mind that the center of gravity of the vehicle changes. If necessary, use jack(s) to support the vehicle at rear jacking point(s) to prevent it from falling off the lift.

Scheme 237

1. Install engine slingers into front of cylinder head (bank 1) and rear of cylinder head (bank 2). Slinger bolts: Torque: 28.0 N.m (2.9 kg-m, 21 ft-lb)
2. Remove power steering oil pump from engine side. Refer to " «EXCEPT FOR SPORT MODELS: EXPLODED VIEW»(ref-659744-S40560944842014100100000) " or " «SPORT MODELS: EXPLODED VIEW»(ref-659744-S22373191662014100100000) ".
3. Remove engine mounting insulators (RH and LH) under side nuts with power tool.
4. Lift with hoist and separate the engine and the transmission assembly from front suspension member. CAUTION: Before and during this lifting, always check that any harnesses are left connected. Never damage engine mounting insulator and avoid oil/grease smearing or spills onto engine mounting insulator.
5. Remove alternator. Refer to " «EXPLODED VIEW»(ref-659746-S30938230882014100100000) ".
6. Remove starter motor. Refer to " «EXPLODED VIEW»(ref-659755-S36673969812014100100000) ".
7. Remove crankshaft position sensor. Refer to " «EXPLODED VIEW»(ref-659738-S25365276782014100100000) ". CAUTION: Handle crankshaft position sensor carefully and avoid impacts. Never disassemble. Never place crankshaft position sensor in a location where it is exposed to magnetism.
8. Separate the engine from the transmission assembly. Refer to " «EXPLODED VIEW»(ref-659747-S05833154622014100100000) " (M/T models) or " «EXPLODED VIEW»(ref-659748-S17943944442014100100000) " (A/T models).
9. Remove each engine mounting insulator and each engine mounting bracket from the engine with power tool.

Setting

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

Scheme 238

Scheme 239

Scheme 240

1. Remove the engine assembly from the vehicle. Refer to " «EXPLODED VIEW»(ref-659738-S37192500652014100100000) ".
2. Remove the parts that may restrict installation of engine to a widely use engine stand. NOTE: The procedure is described assuming that you use a widely use engine stand holding the surface, to which transmission is installed. Remove clutch cover and clutch disc. Refer to " «EXPLODED VIEW»(ref-659756-S41885641102014100100000) " (M/T models). Remove drive plate (A/T models) or flywheel (M/T models) with power tool. Fix crankshaft with a ring gear stopper [SST: KV10118600 (J-48641)], and remove mounting bolts. Loosen mounting bolts in diagonal order. Check for deformation or damage of drive plate (A/T models) or flywheel (M/T models). CAUTION: Never disassemble drive plate (A/T models) or flywheel (M/T models). Never place drive plate (A/T models) or flywheel (M/T models) with signal plate facing down. When handling signal plate, take care not to damage or scratch it. Handle signal plate in a manner that prevents it from becoming magnetized.
3. Remove pilot converter (A/T models) using the pilot bushing puller [SST: ST16610001 (J-23907)] (A) if necessary.
4. Lift the engine with hoist to install it onto the widely use engine stand. CAUTION: Use an engine stand that has a load capacity [220 kg (485 lb) or more] large enough for supporting the engine weight. If the load capacity of the stand is not adequate, remove the following parts beforehand to reduce the potential risk of overturning the stand. Remove intake manifold collector. Refer to " «EXPLODED VIEW»(ref-659738-S30429584682014100100000) ". Remove fuel injector and fuel tube assembly. Refer to " «EXPLODED VIEW»(ref-659738-S24568157532014100100000) ". Remove intake manifold. Refer to " «EXPLODED VIEW»(ref-659738-S33614148182014100100000) ". Remove ignition coil. Refer to " «EXPLODED VIEW»(ref-659738-S26174732752014100100000) ". Remove rocker cover. Refer to " «EXPLODED VIEW»(ref-659738-S26174732752014100100000) ". Remove exhaust manifold. Refer to " «EXPLODED VIEW»(ref-659738-S33975661602014100100000) ". Other removable brackets. NOTE: The figure shows an example of widely use engine stand (A) that can hold mating surface of transmission with drive plate (A/T models) or flywheel (M/T models) removed. CAUTION: Before removing the hanging chains, check the engine stand is stable and there is no risk of overturning.
5. Drain engine oil. Refer to " «DRAINING»(ref-659745-S21496124642014100100000) ".
6. Drain engine coolant by removing water drain plug (1) from both sides of the cylinder block as shown in the figure below.

Camshaft (EXH) Journal Oil Clearance

CAMSHAFT (EXH) JOURNAL DIAMETER

Scheme 241

1. Measure the outer diameter of camshaft (EXH) journal with a micrometer (A). Standard: Refer to " «CAMSHAFT»(ref-659738-S00628572622014100100000) ".

VVEL LADDER ASSEMBLY (EXHAUST SIDE) INNER DIAMETER

Scheme 242

1. Tighten VVEL ladder assembly bolts to the specified torque. Refer to " «INSTALLATION»(ref-659738-S15675864522014100100000) " for the tightening procedure.
2. Measure inner diameter (A) of VVEL ladder assembly (Exhaust side) with a bore gauge. Standard: Refer to " «CAMSHAFT»(ref-659738-S00628572622014100100000) ".

CAMSHAFT (EXH) JOURNAL OIL CLEARANCE

1. (Oil clearance) = [VVEL ladder assembly (Exhaust side) inner diameter] - [Camshaft (EXH) journal diameter]. Standard and limit: Refer to " «CAMSHAFT»(ref-659738-S00628572622014100100000) ".
2. If the calculated value exceeds the limit, replace either or both camshaft (EXH) and VVEL ladder assembly and cylinder head assembly. NOTE: VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinder head assembly.

Scheme 243

Scheme 244

1. Install a dial indicator in thrust direction on front end of camshaft. Measure the end play of a dial indicator when camshaft (EXH) is moved forward/backward (in direction of axis). Standard and limit: Refer to " «CAMSHAFT»(ref-659738-S00628572622014100100000) ".
2. Measure the following parts if out of the limit. Dimension "A" for camshaft (EXH) No. 1 journal Standard: 27.500 - 27.548 mm (1.0827 - 1.0846 in) Dimension "B" for cylinder head No. 1 journal bearing Standard: 27.360 - 27.385 mm (1.0772 - 1.0781 in)
3. Refer to the standards above, and then replace camshaft (EXH) and/or VVEL ladder assembly and cylinder head assembly. NOTE: Cylinder head assembly cannot be replaced as a single part, because it is machined together with VVEL ladder assembly.

Scheme 245

1. Put V-block on precise flat table, and support No. 2 and 4 journals of camshaft (EXH). CAUTION: Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other three locations.
2. Measure the camshaft sprocket (EXH) runout with a dial indicator. (Total indicator reading) Limit: Refer to " «CAMSHAFT»(ref-659738-S00628572622014100100000) ".
3. If it exceeds the limit, replace camshaft sprocket (EXH).

Scheme 246

1. Check if surface of valve lifter has any wear or crack.
2. If wear or crack is found, replace valve lifter (EXH). Refer to " «CAMSHAFT»(ref-659738-S00628572622014100100000) ".

Valve Lifter Clearance (EXH)

VALVE LIFTER OUTER DIAMETER

Scheme 247

1. Measure the outer diameter at 1/2 height of valve lifter with a micrometer (A) since valve lifter is in barrel shape. Standard: Refer to " «CAMSHAFT»(ref-659738-S00628572622014100100000) ".

VALVE LIFTER HOLE DIAMETER

Scheme 248

1. Measure the inner diameter of valve lifter hole of cylinder head with an inside micrometer. Standard: Refer to " «CAMSHAFT»(ref-659738-S00628572622014100100000) ".

VALVE LIFTER CLEARANCE

1. (Valve lifter clearance) = (Valve lifter hole diameter) - (Valve lifter outer diameter) Standard: Refer to " «CAMSHAFT»(ref-659738-S00628572622014100100000) ".
2. If the calculated value is out of the standard, referring to each standard of valve lifter outer diameter and valve lifter hole diameter, replace either or both valve lifter and VVEL ladder assembly and cylinder head assembly. NOTE: Cylinder head assembly cannot be replaced as a single part, because it is machined together with VVEL ladder assembly.

Scheme 249

1. Install a dial indicator in thrust direction on front end of drive shaft. Measure the end play of a dial indicator when drive shaft is moved forward/backward (in direction of axis). Standard and limit: Refer to " «CAMSHAFT»(ref-659738-S00628572622014100100000) ".
2. Measure the following parts if out of the limit. Dimension "A" for drive shaft No. 1 journal Standard: 27.500 - 27.548 mm (1.0827 - 1.0846 in) Dimension "B" for cylinder head No. 1 journal bearing Standard: 27.360 - 27.385 mm (1.0772 - 1.0781 in)
3. If it exceeds the limit, replace VVEL ladder assembly and cylinder head assembly. NOTE: Cylinder head assembly cannot be replaced as a single part, because it is machined together with VVEL ladder assembly.

Camshaft Sprocket (INT) Runout

1. Put V-block on precise flat table, and support No. 2 and 4 journals of drive shaft. CAUTION: Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other three locations.
2. Measure the camshaft sprocket (INT) runout with a dial indicator. (Total indicator reading) Limit: Refer to " «CAMSHAFT»(ref-659738-S00628572622014100100000) ".
3. If it exceeds the limit, replace camshaft sprocket (INT).

Valve Lifter (INT)

1. Check if surface of valve lifter has any wear or crack.
2. If wear or crack is found, replace VVEL ladder assembly and cylinder head assembly. Refer to " «CAMSHAFT»(ref-659738-S00628572622014100100000) ".

Note. Since the valve lifter (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head assembly replacement are required.

Valve Lifter Clearance (INT)

VALVE LIFTER OUTER DIAMETER

1. Measure the outer diameter at 1/2 height of valve lifter (INT) with a micrometer (A) since valve lifter is in barrel shape. Standard: Refer to " «CAMSHAFT»(ref-659738-S00628572622014100100000) ".

VALVE LIFTER HOLE DIAMETER

1. Measure the inner diameter of valve lifter hole of cylinder head with an inside micrometer. Standard: Refer to " «CAMSHAFT»(ref-659738-S00628572622014100100000) ".

VALVE LIFTER CLEARANCE

1. (Valve lifter clearance) = (Valve lifter hole diameter) - (Valve lifter outer diameter) Standard: Refer to " «CAMSHAFT»(ref-659738-S00628572622014100100000) ".
2. If the calculated value is out of the standard, replace VVEL ladder assembly and cylinder head assembly. NOTE: Since the valve lifter (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head assembly replacement are required.

Cylinder Head Distortion

Note. When performing this inspection, cylinder block distortion should be also checked. Refer to " INSPECTION ".

Scheme 250

1. Using a scraper, wipe off oil, scale, gasket, sealant and carbon deposits from surface of cylinder head. CAUTION: Never allow gasket fragments to enter engine oil or engine coolant passages.
2. At each of several locations on bottom surface of cylinder head, measure the distortion in six directions (A), (B), (C), (D), (E), and (F). Limit: Refer to " «CYLINDER HEAD»(ref-659738-S08062276532014100100000) ". If it exceeds the limit, replace VVEL ladder assembly and cylinder head assembly. NOTE: Cylinder head assembly cannot be replaced as a single part, because it is machined together with VVEL ladder assembly.

Valve Dimensions

1. Check the dimensions of each valve. For the dimensions, refer to " «CYLINDER HEAD»(ref-659738-S08062276532014100100000) ".
2. If dimensions are out of the standard. Replace valve (EXH) and check valve seat contact. Refer to " «VALVE SEAT CONTACT»(ref-659738-S34373940612014100100000) ". (Exhaust side) Replace VVEL ladder assembly and cylinder head assembly. Refer to " «EXPLODED VIEW»(ref-659738-S38934256652014100100000) ". (Intake side) NOTE: Since the valve (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head assembly replacement are required.

Valve Guide Clearance

Valve Stem Diameter

Scheme 251

1. Measure the diameter of valve stem with micrometer (A). Standard: Refer to " «CYLINDER HEAD»(ref-659738-S08062276532014100100000) ". Valve Guide Inner Diameter
2. Measure the inner diameter of valve guide with bore gauge. Standard: Refer to " «CYLINDER HEAD»(ref-659738-S08062276532014100100000) ". Valve Guide Clearance
3. (Valve guide clearance) = (Valve guide inner diameter) - (Valve stem diameter) Standard: Refer to " «CYLINDER HEAD»(ref-659738-S08062276532014100100000) ".
4. If the calculated value exceeds the limit. Replace valve (EXH) and/or valve guide (EXH). Refer to " «EXPLODED VIEW»(ref-659738-S21457411992014100100000) ". (Exhaust side) Replace VVEL ladder assembly and cylinder head assembly. Refer to " «EXPLODED VIEW»(ref-659738-S38934256652014100100000) ". (Intake side) NOTE: Since the valve (INT) and valve guide (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head assembly replacement are required.

Scheme 252

1. After confirming that the dimensions of valve guides and valves are within the 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. If not, grind to adjust valve fitting and check again. If the contacting surface still has "NG" conditions even after the recheck, replace valve seat (EXH). Refer to " «EXPLODED VIEW»(ref-659738-S21457411992014100100000) ". (Exhaust side) If not, replace VVEL ladder assembly and cylinder head assembly. Refer to " «EXPLODED VIEW»(ref-659738-S38934256652014100100000) ". (Intake side) NOTE: Since the valve seat (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head assembly replacement are required.

Scheme 253

1. Set a try square (A) along the side of valve spring and rotate spring. Measure the maximum clearance between the top of spring and try square. B: Contact Limit: Refer to " «CYLINDER HEAD»(ref-659738-S08062276532014100100000) ".
2. If it exceeds the limit. Replace valve spring (EXH). Refer to " «EXPLODED VIEW»(ref-659738-S21457411992014100100000) ". (Exhaust side) Replace VVEL ladder assembly and cylinder head assembly. Refer to " «EXPLODED VIEW»(ref-659738-S38934256652014100100000) ". (Intake side) NOTE: Since the valve spring (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head assembly replacement are required.

Scheme 254

1. Check the valve spring pressure at specified spring height. Standard : Refer to " «CYLINDER HEAD»(ref-659738-S08062276532014100100000) ".
2. If the installation load or load with valve open is out of the standard. Replace valve spring (EXH). Refer to " «EXPLODED VIEW»(ref-659738-S21457411992014100100000) ". (Exhaust side) Replace VVEL ladder assembly and cylinder head assembly. Refer to " «EXPLODED VIEW»(ref-659738-S38934256652014100100000) ". (Intake side) NOTE: Since the valve spring (INT) cannot be replaced by the piece, VVEL ladder assembly and cylinder head assembly replacement are required.

Piston Pin Hole Diameter

Measure the inner diameter of piston pin hole with an inside micrometer (A).

Standard: Refer to " CYLINDER BLOCK ".

Scheme 255

Piston to Piston Pin Oil Clearance

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

Standard: Refer to " CYLINDER BLOCK ".

1. If the calculated value is out of the standard, replace piston and piston pin assembly.
2. When replacing piston and piston pin assembly, refer to " «DESCRIPTION»(ref-659738-S20782983062014100100000) ". NOTE: Piston is available together with piston pin as assembly. Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no piston pin grades can be selected. (Only "0" grade is available.)

Scheme 256

1. Measure the side clearance of piston ring (1) and piston ring groove with a feeler gauge (C). Standard and limit: Refer to " «CYLINDER BLOCK»(ref-659738-S27817040702014100100000) ".
2. If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, replace piston also.

Scheme 257

1. Check that the cylinder bore inner diameter is within the specification. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-659738-S33734177172014100100000) ".
2. Lubricate with new engine oil to piston (1) and piston ring (2), and then insert piston ring until middle of cylinder with piston, and measure the piston ring end gap with a feeler gauge (B). Standard and limit: Refer to " «CYLINDER BLOCK»(ref-659738-S27817040702014100100000) ".
3. If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, rebore cylinder and use oversize piston and piston rings.

Scheme 258

1. Check with a connecting rod aligner. Bend limit : Refer to " «CYLINDER BLOCK»(ref-659738-S27817040702014100100000) ".
2. If it exceeds the limit, replace connecting rod assembly.

Scheme 259

1. Install connecting rod bearing cap without installing connecting rod bearing, and tighten connecting rod bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-659738-S33734177172014100100000) " for the tightening procedure.
2. Measure the inner diameter of connecting rod big end with an inside micrometer. Standard: Refer to " «CYLINDER BLOCK»(ref-659738-S27817040702014100100000) ".
3. If out of the standard, replace connecting rod assembly.

Connecting Rod Bushing Inner Diameter

Measure the inner diameter of connecting rod bushing with an inside micrometer (A).

Standard: Refer to " CYLINDER BLOCK ".

Scheme 260

Connecting Rod Bushing Oil Clearance

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

Standard and limit: Refer to " CYLINDER BLOCK ".

Scheme 261

1. If the calculated value exceeds the limit, replace connecting rod assembly and/or piston and piston pin assembly.
2. If replacing piston and piston pin assembly, refer to " «DESCRIPTION»(ref-659738-S20782983062014100100000) ".
3. If replacing connecting rod assembly, refer to " «CONNECTING ROD BEARING»(ref-659738-S38047017372014100100000) " to select the connecting rod bearing.

Factory installed parts grading

Scheme 262

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

Scheme 263

1. Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or other contamination. CAUTION: Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.
2. Measure the distortion on the cylinder block upper face at some different points in six directions (C), (D), (E), (F), (G), and (H) with a straightedge (A) and a feeler gauge (B). Limit: Refer to " «CYLINDER BLOCK»(ref-659738-S27817040702014100100000) ".
3. If it exceeds the limit, replace cylinder block.

Scheme 264

1. Install lower cylinder block (2) without installing main bearings, and tighten lower cylinder block bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-659738-S33734177172014100100000) " for the tightening procedure.
2. Measure the inner diameter of main bearing housing with a bore gauge. Standard: Refer to " «CYLINDER BLOCK»(ref-659738-S27817040702014100100000) ".
3. If out of the standard, replace cylinder block (1) and lower cylinder block as assembly. NOTE: Cylinder block cannot be replaced as a single part, because it is machined together with lower cylinder block.

Scheme 265

Scheme 266

1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper at six different points on each cylinder. [(A) and (B) directions at (C), (D) and (E)] is in longitudinal direction of engine. f: 10 mm (0.39 in) g: 60 mm (2.36 in) h: 125 mm (4.92 in) Standard and limit: Refer to " «CYLINDER BLOCK»(ref-659738-S27817040702014100100000) ".
2. If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, hone or rebore the inner wall.
3. Oversize piston is provided. When using oversize piston, rebore cylinder so that the clearance of the piston-to-cylinder bore satisfies the standard. CAUTION: When using oversize piston, use oversize pistons for all cylinders with oversize piston rings. Oversize (O/S): 0.2 mm (0.008 in)

Piston Skirt Diameter

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

Measure point

Refer to " CYLINDER BLOCK ".

Standard

Scheme 267

Piston-to-Cylinder Bore Clearance

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

A: Direction A

C: Position C

E: Position E

f: 10 mm (0.39 in)

g: 60 mm (2.36 in)

h: 125 mm (4.92 in)

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

Standard and limit: Refer to " CYLINDER BLOCK ".

1. If the calculated value exceeds the limit, replace piston and piston pin assembly. Refer to " «CYLINDER BLOCK»(ref-659738-S27817040702014100100000) ".

Reboring Cylinder Bore

1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter. Rebored size calculation: D = A + B - C where, Piston skirt diameter as measured Piston to cylinder bore clearance (standard value) Honing allowance 0.02 mm (0.0008 in) Bored diameter
2. Install lower cylinder block, and tighten to the specified torque. Otherwise, cylinder bores may be distorted in final assembly.
3. Cut cylinder bores. NOTE: When any cylinder needs boring, all other cylinders must also be bored. Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a time.
4. Hone cylinders to obtain the specified piston to cylinder bore clearance.
5. Measure finished cylinder bore for the out-of-round and taper. NOTE: Perform measurement after cylinder bore cools down.

CRANKSHAFT MAIN JOURNAL DIAMETER

1. Measure the outer diameter of crankshaft main journals with a micrometer. Standard: Refer to " «CYLINDER BLOCK»(ref-659738-S27817040702014100100000) ".
2. If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to " «MAIN BEARING»(ref-659738-S28068284852014100100000) ".

Scheme 268

1. Measure the outer diameter of crankshaft pin journal with a micrometer (A). Standard: Refer to " «CYLINDER BLOCK»(ref-659738-S27817040702014100100000) ".
2. If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer to " «CONNECTING ROD BEARING»(ref-659738-S38047017372014100100000) ".

Scheme 269

1. Measure the dimensions at four different points as shown in the figure below on each main journal and pin journal with a micrometer.
2. Out-of-round is indicated by the difference in the dimensions between (d) and (c) at (a) and (b).
3. Taper is indicated by the difference in the dimensions between. Limit: Refer to " «CYLINDER BLOCK»(ref-659738-S27817040702014100100000) ".
4. If the measured value exceeds the limit, correct or replace crankshaft.
5. If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select the main bearing and/or connecting rod bearing. Refer to " «MAIN BEARING»(ref-659738-S28068284852014100100000) " and/or " «CONNECTING ROD BEARING»(ref-659738-S38047017372014100100000) ".

Scheme 270

1. Place V-block on precise flat table, and support the journals on both ends of crankshaft.
2. Place a dial indicator straight up on the No. 3 journal.
3. While rotating crankshaft, read the movement of the pointer on a dial indicator. (Total indicator reading) Standard and limit: Refer to " «CYLINDER BLOCK»(ref-659738-S27817040702014100100000) ".
4. If it exceeds the limit, replace crankshaft.

Scheme 271

1. Install connecting rod bearings (1) to connecting rod (2) and connecting rod cap, and tighten connecting rod bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-659738-S33734177172014100100000) " for the tightening procedure.
2. Measure the inner diameter of connecting rod bearing with an inside micrometer. (Oil clearance) = (Connecting rod bearing inner diameter) - (Crankshaft pin journal diameter) Standard and limit: Refer to " «CONNECTING ROD BEARING»(ref-659738-S42625225752014100100000) ".
3. If the calculated value exceeds the limit, select proper connecting rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer to " «DESCRIPTION»(ref-659738-S20782983062014100100000) ".

Scheme 272

1. Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely.
2. Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
3. Install connecting rod bearings to connecting rod and connecting rod bearing cap, and tighten connecting rod bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-659738-S33734177172014100100000) " for the tightening procedure. CAUTION: Never rotate crankshaft.
4. Remove connecting rod bearing cap and bearings, and using the scale on the plastigage bag, measure the plastigage width. NOTE: The procedure when the measured value exceeds the limit is the same as that described in the "Method by Calculation".

Scheme 273

1. Install main bearings (3) to cylinder block (1) and lower cylinder block (2), and tighten lower cylinder block bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-659738-S33734177172014100100000) " for the tightening procedure.
2. Measure the inner diameter of main bearing with a bore gauge. (Oil clearance) = (Main bearing inner diameter) - (Crankshaft main journal diameter) Standard and limit: Refer to " «MAIN BEARING»(ref-659738-S31211818962014100100000) ".
3. If the calculated value exceeds the limit, select proper main bearing according to main bearing inner diameter and crankshaft main journal diameter to obtain the specified bearing oil clearance. Refer to " «DESCRIPTION»(ref-659738-S20782983062014100100000) ".

Method of Using Plastigage

1. Remove engine oil and dust on crankshaft journal and the surfaces of each bearing completely.
2. Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
3. Install main bearing to cylinder block and lower cylinder block, and tighten lower cylinder block bolts with lower cylinder block to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-659738-S33734177172014100100000) " for the tightening procedure. CAUTION: Never rotate crankshaft.
4. Remove lower cylinder block and bearings, and using the scale on the plastigage bag, measure the plastigage width. NOTE: The procedure when the measured value exceeds the limit is the same as that described in the "Method by Calculation".

Scheme 274

1. When lower cylinder block is removed after being tightened to the specified torque with main bearings (1) installed, the tip end of bearing must protrude. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-659738-S33734177172014100100000) " for the tightening procedure. Standard: There must be crush height.
2. If the standard is not met, replace main bearings.

Scheme 275

1. When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings (1) installed, the tip end of bearing must protrude. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-659738-S33734177172014100100000) " for the tightening procedure. Standard: There must be crush height.
2. If the standard is not met, replace connecting rod bearings.

Scheme 276

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

Scheme 277

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

Scheme 278

1. Measure the deflection of flywheel contact surface to clutch with a dial indicator (A).
2. Measure the deflection at 210 mm (8.27 in) dia. Standard: 0.45 mm (0.0177 in) or less.
3. If measured value is out of the standard, replace flywheel.

MOVEMENT AMOUNT OF FLYWHEEL (M/T models)

Movement Amount in Radial (Rotation) Direction

Check the movement amount of radial (rotation) direction with the following procedure

Scheme 279

Scheme 280

1. Install a bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel center line. Tighten bolt at a force of 9.8 N.m (1.00 kg-m, 87 in-lb) to keep it from loosening.
2. Put a matching mark on circumferences of the two flywheel masses without applying any load (measurement standard points).
3. Apply a force of 9.8 N.m (1.00 kg-m, 87 in-lb) in each direction, and mark the movement amount on the mass on the transaxle side.
4. Measure the dimensions of movement amounts (C) and (D) on circumference of the flywheel on the transaxle side. Standard: Less than 29.9 mm (1.177 in) If measured value is out of the standard, replace flywheel.

DRIVE PLATE (A/T models)

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

OIL JET

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

Scheme 281

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

WHEN NEW CYLINDER BLOCK IS USED

Check the cylinder bore grade ("1", "2" or "3") on rear side of cylinder block, and select piston of the same grade.

Scheme 282

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

Scheme 283

1. Measure the cylinder bore inner diameter. Refer to " «INSPECTION»(ref-659738-S32565099392014100100000) ".
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner diameter of the "PISTON SELECTION TABLE".
3. Select piston of the same grade.

PISTON SELECTION TABLE

Note. Piston is available together with piston pin as assembly. Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no piston pin grades can be selected. (Only "0" grade is available.) No second grade mark is available on piston.

Scheme 284

Scheme 285

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

WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED

1. Measure connecting rod big end diameter and crankshaft pin journal diameter. Refer to " «INSPECTION»(ref-659738-S32565099392014100100000) ".
2. Correspond the measured dimension in "connecting rod big end diameter" row of "CONNECTING ROD BEARING SELECTION TABLE".
3. Correspond the measured dimension in "crankshaft pin diameter" column of "CONNECTING ROD BEARINGS ELECTION TABLE".
4. Follow step 3 and later in "WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED".

Scheme 286

CONNECTING ROD BEARING GRADE TABLE

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

UNDERSIZE BEARING 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 (US) bearing, measure the connecting rod bearing inner diameter with bearing installed, and grind crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard.

Scheme 287

Bearing undersize table: Refer to " CONNECTING ROD BEARING ".

Scheme 288

Scheme 289

1. "MAIN BEARING SELECTION TABLE" rows correspond to bearing housing grade on rear side of cylinder block.
2. "MAIN BEARING SELECTION TABLE" columns correspond to journal diameter grade on front side of crankshaft.
3. Select main bearing grade at the point where selected row and column meet in "MAIN BEARING SELECTION TABLE".
4. Apply sign at crossing in above step 3 to "MAIN BEARING GRADE TABLE". NOTE: "MAIN BEARING GRADE TABLE" applies to all journals. Service parts are available as a set of both upper and lower.

WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED

1. Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter. Refer to " «INSPECTION»(ref-659738-S32565099392014100100000) ".
2. Correspond the measured dimension in "Cylinder block main bearing housing inner diameter" row of "MAIN BEARING SELECTION TABLE".
3. Correspond the measured dimension in "Crankshaft main journal diameter" column of "MAIN BEARING SELECTION TABLE".
4. Follow step 3 and later in "When New Cylinder Block and Crankshaft are Used".

Scheme 290

MAIN BEARING GRADE TABLE (ALL JOURNALS)

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

1. When the specified main bearing oil clearance is not obtained with standard size main bearings, use undersize (US) bearing.
2. When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and grind main journal so that the main bearing oil clearance satisfies the standard. CAUTION: In grinding crankshaft main journal to use undersize bearings, keep the fillet R (A) [1.5 - 1.7 mm (0.059 - 0.067 in)]. Bearing undersize table: Refer to " «MAIN BEARING»(ref-659738-S31211818962014100100000) ".

DRIVE BELT

SPARK PLUG

INTAKE MANIFOLD

EXHAUST MANIFOLD

CAMSHAFT (EXH)

Unit: mm (in) Items Standard Limit Camshaft (EXH) journal oil clearance No. 1 0.045 - 0.086 (0.0018 - 0.0034) 0.150 (0.0059) No. 2, 3, 4 0.035 - 0.076 (0.0014 - 0.0030) VVEL ladder assembly bracket inner diameter (EXH) No. 1 26.000 - 26.021 (1.0236 - 1.0244) - No. 2, 3, 4 23.500 - 23.521 (0.9252 - 0.9260) - Camshaft (EXH) journal diameter No. 1 25.935 - 25.955 (1.0211 - 1.0218) - No. 2, 3, 4 23.445 - 23.465 (0.9230 - 0.9238) - Camshaft (EXH) end play 0.115 - 0.188 (0.0045 - 0.0074) 0.24 (0.0094) Camshaft (EXH) cam height "A" Bank 1 45.015 - 45.205 (1.7722 - 1.7797) 0.2 (0.008) (1) Bank 2 46.735 - 46.925 (1.8400 - 1.8474) Camshaft (EXH) runout [TIR (2) ] Less than 0.02 (0.0008) 0.05 (0.0020) Camshaft sprocket (EXH) runout [TIR (2) ] - 0.15 (0.0059) (1) Cam wear limit (2) Total indicator reading

CAMSHAFT (INT)

VALVE LIFTER

VALVE CLEARANCE

AVAILABLE VALVE LIFTER

Unit: mm (in) Identification (stamped) mark Thickness 788 7.88 (0.3102) 790 7.90 (0.3110) 792 7.92 (0.3118) 794 7.94 (0.3126) 796 7.96 (0.3134) 798 7.98 (0.3142) 800 8.00 (0.3150) 802 8.02 (0.3157) 804 8.04 (0.3165) 806 8.06 (0.3173) 808 8.08 (0.3181) 810 8.10 (0.3189) 812 8.12 (0.3197) 814 8.14 (0.3205) 816 8.16 (0.3213) 818 8.18 (0.3220) 820 8.20 (0.3228) 822 8.22 (0.3236) 824 8.24 (0.3244) 826 8.26 (0.3252) 828 8.28 (0.3260) 830 8.30 (0.3268) 832 8.32 (0.3276) 834 8.34 (0.3283) 836 8.36 (0.3291) 838 8.38 (0.3299) 840 8.40 (0.3307)

CYLINDER HEAD

Unit: mm (in) Items Standard Limit Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004) Normal cylinder head height "H" 126.4 (4.98)

Unit: mm (in) Valve head diameter "D" Intake 36.6 - 36.9 (1.441 - 1.453) Exhaust 30.2 - 30.5 (1.189 - 1.201) Valve length "L" Intake 100.11 (3.94) Exhaust 94.67 (3.7272) Valve stem diameter "d" Intake 5.965 - 5.980 (0.2348 - 0.2354) Exhaust 5.962 - 5.970 (0.2347 - 0.2350) Valve seat angle "α" Intake 45°15' - 45°45' Exhaust Valve margin "T" Intake 1.1 (0.043) Exhaust 1.3 (0.051) Valve margin "T" limit 0.5 (0.020) Valve stem end surface grinding limit 0.2 (0.008)

Scheme 291

VALVE GUIDE

Unit: mm (in) Items Standard Oversize (Service) [0.2 (0.008)] (1) Valve guide Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029) (1) Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369) Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014) (1) Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023) Items Standard Limit Valve guide clearance Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.003) Exhaust 0.030 - 0.056 (0.0012 - 0.0022) 0.09 (0.004) Projection length "L" 12.6 - 12.8 (0.496 - 0.504) (1) Parts settings are for exhaust side only

VALVE SEAT

Unit: mm (in) Items Standard Oversize (Service) [0.5 (0.02)] (4) Cylinder head seat recess diameter "D" Intake 38.000 - 38.016 (1.4961 - 1.4967) - Exhaust 31.600 - 31.616 (1.2441 - 1.2447) 32.100 - 32.116 (1.2638 - 1.2644) (4) Valve seat outer diameter "d" Intake 38.097 - 38.113 (1.4999 - 1.5005) - Exhaust 31.680 - 31.696 (1.2472 - 1.2479) 32.180 - 32.196 (1.2669 - 1.2676) (4) Valve seat interference fit Intake 0.081 - 0.113 (0.0032 - 0.0044) Exhaust 0.064 - 0.096 (0.0025 - 0.0038) Diameter "d1" (1) Intake 34.6 (1.362) Exhaust 27.7 (1.091) Diameter "d2" (2) Intake 35.9 - 36.4 (1.413 - 1.433) Exhaust 29.3 - 29.8 (1.154 - 1.173) Angle "α1" Intake 60° Exhaust 60° Angle "α2" Intake 88°45' - 90°15' Exhaust 88°45' - 90°15' Angle "α3" Intake 120° Exhaust 120° Contacting width "W" (3) Intake 1.0 - 1.4 (0.039 - 0.055) Exhaust 1.2 - 1.6 (0.047 - 0.063) Height "h" Intake 5.9 - 6.0 (0.232 - 0.236) - Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.95 - 5.05 (0.1949 - 0.1988) (4) Depth "H" 6.0 (0.236) (1) Diameter made by intersection point of conic angles "α1" and "α2" (2) Diameter made by intersection point of conic angles "α2" and "α3" (3) Machining data (4) Parts settings are for exhaust side only

VALVE SPRING

CYLINDER BLOCK

Unit: mm (in) Surface flatness Standard Less than 0.03 (0.0012) Limit 0.1 (0.004) Main bearing housing inner diameter Standard 69.993 - 70.017 (2.7556 - 2.7566) Cylinder bore Inner diameter Standard Grade No. 1 95.500 - 95.510 (3.7598 - 3.7602) Grade No. 2 95.510 - 95.520 (3.7602 - 3.7606) Grade No. 3 95.520 - 95.530 (3.7606 - 3.7610) Wear limit 0.2 (0.008) Out-of-round Limit 0.015 (0.0006) Taper 0.010 (0.0004) Main bearing housing inner diameter grade (Without bearing) Grade No. A 69.993 - 69.994 (2.7556 - 2.7557) Grade No. B 69.994 - 69.995 (2.7557 - 2.7557) Grade No. C 69.995 - 69.996 (2.7557 - 2.7557) Grade No. D 69.996 - 69.997 (2.7557 - 2.7558) Grade No. E 69.997 - 69.998 (2.7558 - 2.7558) Grade No. F 69.998 - 69.999 (2.7558 - 2.7559) Grade No. G 69.999 - 70.000 (2.7559 - 2.7559) Grade No. H 70.000 - 70.001 (2.7559 - 2.7559) Grade No. J 70.001 - 70.002 (2.7559 - 2.7560) Grade No. K 70.002 - 70.003 (2.7560 - 2.7560) Grade No. L 70.003 - 70.004 (2.7560 - 2.7561) Grade No. M 70.004 - 70.005 (2.7561 - 2.7561) Grade No. N 70.005 - 70.006 (2.7561 - 2.7561) Grade No. P 70.006 - 70.007 (2.7561 - 2.7562) Grade No. R 70.007 - 70.008 (2.7562 - 2.7562) Grade No. S 70.008 - 70.009 (2.7562 - 2.7563) Grade No. T 70.009 - 70.010 (2.7563 - 2.7563) Grade No. U 70.010 - 70.011 (2.7563 - 2.7563) Grade No. V 70.011 - 70.012 (2.7563 - 2.7564) Grade No. W 70.012 - 70.013 (2.7564 - 2.7564) Grade No. X 70.013 - 70.014 (2.7564 - 2.7565) Grade No. Y 70.014 - 70.015 (2.7565 - 2.7565) Grade No. 4 70.015 - 70.016 (2.7565 - 2.7565) Grade No. 7 70.016 - 70.017 (2.7565 - 2.7566) Difference in inner diameter between cylinders Standard Less than 0.03 (0.0012)

Scheme 292

AVAILABLE PISTON

Unit: mm (in) Items Standard Oversize (Service) [0.2 (0.008)] Piston skirt diameter "A" Grade No. 1 95.480 - 95.490 (3.7590 - 3.7594) - Grade No. 2 95.490 - 95.500 (3.7594 - 3.7598) - Grade No. 3 95.500 - 95.510 (3.7598 - 3.7602) - Service - 95.680 - 95.710 (3.7669 - 3.7681) Items Standard Limit "a" dimension 38.8 (1.528) - Piston pin hole diameter Grade No. 0 21.993 - 21.999 (0.8659 - 0.8661) - Grade No. 1 21.999 - 22.005 (0.8661 - 0.8663) - Piston to cylinder bore clearance 0.010 - 0.030 (0.0004 - 0.0012) 0.08 (0.0031)

Scheme 293

PISTON RING

PISTON PIN

CONNECTING ROD

CRANKSHAFT

Unit: mm (in) Main journal diameter. "Dm" grade Standard Grade No. A 64.975 - 64.974 (2.5581 - 2.5580) Grade No. B 64.974 - 64.973 (2.5580 - 2.5580) Grade No. C 64.973 - 64.972 (2.5580 - 2.5579) Grade No. D 64.972 - 64.971 (2.5579 - 2.5579) Grade No. E 64.971 - 64.970 (2.5579 - 2.5579) Grade No. F 64.970 - 64.969 (2.5579 - 2.5578) Grade No. G 64.969 - 64.968 (2.5578 - 2.5578) Grade No. H 64.968 - 64.967 (2.5578 - 2.5578) Grade No. J 64.967 - 64.966 (2.5578 - 2.5577) Grade No. K 64.966 - 64.965 (2.5577 - 2.5577) Grade No. L 64.965 - 64.964 (2.5577 - 2.5576) Grade No. M 64.964 - 64.963 (2.5576 - 2.5576) Grade No. N 64.963 - 64.962 (2.5576 - 2.5576) Grade No. P 64.962 - 64.961 (2.5576 - 2.5575) Grade No. R 64.961 - 64.960 (2.5575 - 2.5575) Grade No. S 64.960 - 64.959 (2.5575 - 2.5574) Grade No. T 64.959 - 64.958 (2.5574 - 2.5574) Grade No. U 64.958 - 64.957 (2.5574 - 2.5574) Grade No. V 64.957 - 64.956 (2.5574 - 2.5573) Grade No. W 64.956 - 64.955 (2.5573 - 2.5573) Grade No. X 64.955 - 64.954 (2.5573 - 2.5572) Grade No. Y 64.954 - 64.953 (2.5572 - 2.5572) Grade No. 4 64.953 - 64.952 (2.5572 - 2.5572) Grade No. 7 64.952 - 64.951 (2.5572 - 2.5571) Pin journal diameter. "Dp" grade Standard Grade No. A 53.974 - 53.973 (2.1250 - 2.1249) Grade No. B 53.973 - 53.972 (2.1249 - 2.1249) Grade No. C 53.972 - 53.971 (2.1249 - 2.1248) Grade No. D 53.971 - 53.970 (2.1248 - 2.1248) Grade No. E 53.970 - 53.969 (2.1248 - 2.1248) Grade No. F 53.969 - 53.968 (2.1248 - 2.1247) Grade No. G 53.968 - 53.967 (2.1247 - 2.1247) Grade No. H 53.967 - 53.966 (2.1247 - 2.1246) Grade No. J 53.966 - 53.965 (2.1246 - 2.1246) Grade No. K 53.965 - 53.964 (2.1246 - 2.1246) Grade No. L 53.964 - 53.963 (2.1246 - 2.1245) Grade No. M 53.963 - 53.962 (2.1245 - 2.1245) Grade No. N 53.962 - 53.961 (2.1245 - 2.1244) Grade No. P 53.961 - 53.960 (2.1244 - 2.1244) Grade No. R 53.960 - 53.959 (2.1244 - 2.1244) Grade No. S 53.959 - 53.958 (2.1244 - 2.1243) Grade No. T 53.958 - 53.957 (2.1243 - 2.1243) Grade No. U 53.957 - 53.956 (2.1243 - 2.1242) Center distance "r" 42.96 - 43.04 (1.6913 - 1.6945) Taper (Difference between "A" and "B") Limit 0.0025 (0.0001) Out-of-round (Difference between "X" and "Y") 0.0025 (0.0001) Crankshaft runout [TIR (1) ] Standard Less than 0.05 (0.0020) Limit 0.10 (0.0039) Crankshaft end play Standard 0.10 - 0.25 (0.0039 - 0.0098) Limit 0.30 (0.0118) (1) Total indicator reading

MAIN BEARING

Unit: mm (in) Grade number Thickness Width Identification color Remarks 0 2.500 - 2.503 (0.0984 - 0.0985) 19.9 - 20.1 (0.783 - 0.791) Black Grade is the same for upper and lower bearings. 1 2.503 - 2.506 (0.0985 - 0.0987) Brown 2 2.506 - 2.509 (0.0987 - 0.0988) Green 3 2.509 - 2.512 (0.0988 - 0.0989) Yellow 4 2.512 - 2.515 (0.0989 - 0.0990) Blue 5 2.515 - 2.518 (0.0990 - 0.0991) Pink 6 2.518 - 2.521 (0.0991 - 0.0993) Purple 7 2.521 - 2.524 (0.0993 - 0.0994) White 01 UPR 2.503 - 2.506 (0.0985 - 0.0987) Brown Grade and color are different for upper and lower bearings. LWR 2.500 - 2.503 (0.0984 - 0.0985) Black 12 UPR 2.506 - 2.509 (0.0987 - 0.0988) Green LWR 2.503 - 2.506 (0.0985 - 0.0987) Brown 23 UPR 2.509 - 2.512 (0.0988 - 0.0989) Yellow LWR 2.506 - 2.509 (0.0987 - 0.0988) Green 34 UPR 2.512 - 2.515 (0.0989 - 0.0990) Blue LWR 2.509 - 2.512 (0.0988 - 0.0989) Yellow 45 UPR 2.515 - 2.518 (0.0990 - 0.0991) Pink LWR 2.512 - 2.515 (0.0989 - 0.0990) Blue 56 UPR 2.518 - 2.521 (0.0991 - 0.0993) Purple LWR 2.515 - 2.518 (0.0990 - 0.0991) Pink 67 UPR 2.521 - 2.524 (0.0993 - 0.0994) White LWR 2.518 - 2.521 (0.0991 - 0.0993) Purple

UNDERSIZE

MAIN BEARING OIL CLEARANCE

CONNECTING ROD BEARING

CONNECTING ROD BEARING OIL CLEARANCE