Engine Mechanical: Other Infiniti QX80 I

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 " and " SEAT BELTS " articles of this Service Information.

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

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.

Scheme 208

Precaution for Handling High Pressure Fuel System

1. High pressure fuel system components are between high pressure fuel pump and fuel injector.
2. Always release fuel pressure and never start the engine when performing removal and installation.
3. When removing or installing parts without releasing fuel pressure, fuel may be splashed and, if fuel contacts skin or eyes, it may cause inflammation.

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 Tool

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 (J26336-A), but part (2) is not so. KV10107902 (J-38959) Valve oil seal puller Removing 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 KV10111100 (J-37228) Seal cutter Removing steel oil pan and front cover KV10112100 (BT8653-A) Angle wrench Tightening bolts for bearing cap, cylinder head, etc. KV10117100 (J-44626) Heated oxygen sensor wrench Loosening or tightening air fuel ratio sensor 1 22 mm (0.87 in) KV10120100 (J-47245) Ring gear stopper Removing and installing crankshaft pulley - (J-45488) Quick connector release Removing fuel tube quick connectors in engine room (Available in SEC. 164 of PARTS CATALOG: Part No. 16441 6N210) KV10119300 (-) Adapter and torque wrench assembly Tightening rocker cover mounting bolts. (specified torque) KV10119600 (-) Injector remover Removing fuel injector KV101197S0 (-) Injector seal drift set KV10119730 (-) Seal installer KV10119710 (-) Drift KV10119720 (-) Seal guide Installing fuel injector seal ring EG15050500 (J-45402) Compression gauge adapter Checking compression pressure

Scheme 209

Scheme 210

Scheme 211

Scheme 212

Scheme 213

Scheme 214

Scheme 215

Commercial Service Tool

(Kent-Moore No.) Tool name Description (-) Tube presser Pressing the tube of liquid gasket (-) Power tool Loosening nuts and bolts (-) Spark plug wrench Removing and installing spark plug 14 mm (0.55 in) (-) Manual lift table caddy Removing and installing engine (-) Pilot bushing puller Removing pilot converter (-) 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) 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) 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 heated oxygen sensor (Use with anti-seize lubricant shown below.) J-43897-18 (18 mm dia.) for zirconia heated oxygen sensor and air fuel ratio sensor J-43897-12 (12 mm dia.) for titania heated oxygen sensor and air fuel ratio sensor (-) 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) (-) Compression gauge with flexible type adapter Checking compression pressure

Scheme 216

Scheme 217

Scheme 218

Scheme 219

Scheme 220

Scheme 221

Checking

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

Exploded View

Refer to " COMPONENTS " for symbols in the figure.

Refer to " COMPONENTS " for symbols in the figure.

Intake Manifold

Tighten in numerical order as shown in the figure below.

Scheme 222

Scheme 223

1. Tighten in numerical order as shown in the figure below. NOTE: The figure shows the electric throttle control actuator viewed from the air duct side.
2. Perform the " «THROTTLE VALVE CLOSED POSITION LEARNING»(ref-618040-S03875051792014052700000) " when harness connector of electric throttle control actuator is disconnected. Refer to " «DESCRIPTION»(ref-618040-S18319660282014052700000) ".
3. Perform the " «IDLE AIR VOLUME LEARNING»(ref-618040-S33550653232014052700000) " and " «THROTTLE VALVE CLOSED POSITION LEARNING»(ref-618040-S03875051792014052700000) " when electric throttle control actuator is replaced. Refer to the following table: ENGINE Reference Idle Air Volume Learning Throttle Valve Closed Position Learning VK56VD FOR USA AND CANADA " «DESCRIPTION»(ref-618040-S28697262052014052700000) " " «DESCRIPTION»(ref-618040-S18319660282014052700000) "

Scheme 224

Refer to " COMPONENTS " for symbols in the figure.

Scheme 225

1. Remove engine cover and bracket (rear). Refer to " «EXPLODED VIEW»(ref-618039-S29844956622014052700000) ".
2. Disconnect PCV hose from rocker cover.
3. Remove air cleaner case (upper) and air duct. Refer to " «EXPLODED VIEW»(ref-618039-S35096297512014052700000) ".
4. Move the following parts to the position without the hindrance for work. Oil level gauge guide. Refer to " «EXPLODED VIEW»(ref-618039-S05361728722014052700000) ". Power steering fluid reservoir tank bracket. Refer to " «EXPLODED VIEW»(ref-618044-S02480985432014052700000) ". EVAP canister purge control solenoid valve. " «EXPLODED VIEW»(ref-618039-S29160082932014052700000) ". Fuel feed hose. Refer to " «EXPLODED VIEW»(ref-618039-S02440423432014052700000) ".
5. Remove VVEL actuator motor assembly. Refer to " «EXPLODED VIEW»(ref-618039-S00533758542014052700000) ".
6. Remove ignition coil. Refer to " «EXPLODED VIEW»(ref-618039-S41509091952014052700000) ". CAUTION: Never impact it.
7. Remove rocker cover. Loosen bolts in reverse order shown in the figure below.
8. Remove rocker cover gasket from rocker cover.
9. Use scraper to remove all traces of liquid gasket from cylinder head & VVEL ladder assembly. CAUTION: Never scratch or damage the mating surface when cleaning off old liquid gasket.
10. Remove PCV valve from rocker cover, if necessary.
11. Remove oil filler cap from rocker cover, if necessary.

Scheme 226

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 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 227

Refer to " COMPONENTS " for symbols in the figure.

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 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 228

Refer to " COMPONENTS " for symbols in the figure.

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 229

Refer to " COMPONENTS " for symbols in the figure.

Scheme 230

VVEL control shaft position sensor mounting bolt

Torque Value: 7.0 N.m (0.71 kg-m, 62 in-lb)

Note. VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinder head assembly.

Scheme 231

1. Remove VVEL actuator motor assembly. Refer to " «EXPLODED VIEW»(ref-618039-S00533758542014052700000) ".
2. Remove rocker covers (bank 1 and bank 2). Refer to " «EXPLODED VIEW»(ref-618039-S11896676402014052700000) ".
3. Remove VVEL actuator housing assembly. Refer to " «EXPLODED VIEW»(ref-618039-S00533758542014052700000) ".
4. Remove front cover, camshaft sprockets, and timing chains. Refer to " «EXPLODED VIEW»(ref-618039-S01507607752014052700000) ".
5. Remove VVEL ladder assembly. Loosen mounting bolts (gold color) in the reverse order as shown in the figure below. CAUTION: Never loosen adjusting bolts and mounting bolts (black color). When removing VVEL ladder assembly, hold the drive shaft from below so as not to drop it.
6. Remove exhaust camshaft.
7. Remove valve lifter, if necessary. Identify installation positions, and store them without mixing them up.

Exhaust Camshaft Journal Oil Clearance

EXHAUST CAMSHAFT JOURNAL DIAMETER

Scheme 232

1. Measure the outer diameter of exhaust camshaft journal with a micrometer (A). Standard: Refer to " «CAMSHAFT»(ref-618039-S16540701132014052700000) ".

VVEL LADDER ASSEMBLY (EXH SIDE) INNER DIAMETER

Scheme 233

1. Tighten VVEL ladder assembly bolts to the specified torque. Refer to " «ASSEMBLY»(ref-618039-S24101000942014052700000) " for the tightening procedure.
2. Measure inner diameter (A) of VVEL ladder assembly (exhaust side) with a bore gauge. Standard: Refer to " «CAMSHAFT»(ref-618039-S16540701132014052700000) ".

EXHAUST CAMSHAFT JOURNAL OIL CLEARANCE

1. (Oil clearance) = [VVEL ladder assembly (exhaust side) inner diameter] - [Exhaust camshaft journal diameter]. Standard and limit: Refer to " «CAMSHAFT»(ref-618039-S16540701132014052700000) ".
2. If the calculated value exceeds the limit, replace either or both exhaust camshaft and VVEL ladder assembly & cylinder head assembly. NOTE: VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinder head assembly.

Scheme 234

Scheme 235

1. Install a dial indicator in thrust direction on front end of camshaft. Measure the end play of a dial indicator when exhaust camshaft is moved forward/backward (in direction of axis). Standard and limit: Refer to " «CAMSHAFT»(ref-618039-S16540701132014052700000) ".
2. Measure the following parts if out of the limit. Dimension "A" for exhaust camshaft No. 1 journal Standard: 30.500 - 30.548 mm (1.2008 - 1.2027 in) Dimension "B" for cylinder head No. 1 journal bearing Standard: 30.360 - 30.385 mm (1.1953 - 1.1963 in)
3. Refer to the standards above, and then replace exhaust camshaft and/or VVEL ladder assembly & cylinder head assembly. NOTE: Cylinder head assembly cannot be replaced as a single part, because it is machined together with VVEL ladder assembly.

Scheme 236

1. Put V-block on precise flat table, and support No. 2 and 5 journals of exhaust camshaft. CAUTION: Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations.
2. Measure the exhaust camshaft sprocket runout with a dial indicator. (Total indicator reading) Limit: Refer to " «CAMSHAFT»(ref-618039-S16540701132014052700000) ".
3. If it exceeds the limit, replace exhaust camshaft sprocket.

Scheme 237

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-618039-S16540701132014052700000) ".

Valve Lifter Clearance (EXH)

VALVE LIFTER OUTER DIAMETER

Scheme 238

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-618039-S16540701132014052700000) ".

VALVE LIFTER HOLE DIAMETER

Scheme 239

1. Measure the inner diameter of valve lifter hole of cylinder head with an inside micrometer. Standard: Refer to " «CAMSHAFT»(ref-618039-S16540701132014052700000) ".

VALVE LIFTER CLEARANCE

1. (Valve lifter clearance) = (Valve lifter hole diameter) - (Valve lifter outer diameter) Standard: Refer to " «CAMSHAFT»(ref-618039-S16540701132014052700000) ".
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 & cylinder head assembly. NOTE: Cylinder head assembly cannot be replaced as a single part, because it is machined together with VVEL ladder assembly.

Scheme 240

Scheme 241

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-618039-S16540701132014052700000) ".
2. Measure the following parts if out of the limit. Dimension "A" for drive shaft No. 1 journal Standard: 30.500 - 30.548 mm (1.2008 - 1.2027 in) Dimension "B" for cylinder head No. 1 journal bearing Standard: 30.360 - 30.385 mm (1.1953 - 1.1963 in)
3. If it exceeds the limit, replace VVEL ladder assembly & 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 5 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 four locations.
2. Measure the camshaft sprocket (INT) runout with a dial indicator. (Total indicator reading) Limit: Refer to " «CAMSHAFT»(ref-618039-S16540701132014052700000) ".
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 & cylinder head assembly. Refer to " «CAMSHAFT»(ref-618039-S16540701132014052700000) ".

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

Scheme 242

Valve Lifter Clearance (INT)

VALVE LIFTER OUTER DIAMETER

Scheme 243

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-618039-S16540701132014052700000) ".

VALVE LIFTER HOLE DIAMETER

Scheme 244

1. Measure the inner diameter of valve lifter hole of cylinder head with an inside micrometer. Standard: Refer to " «CAMSHAFT»(ref-618039-S16540701132014052700000) ".

VALVE LIFTER CLEARANCE

1. (Valve lifter clearance) = (Valve lifter hole diameter) - (Valve lifter outer diameter) Standard: Refer to " «CAMSHAFT»(ref-618039-S16540701132014052700000) ".
2. If the calculated value is out of the standard, replace VVEL ladder assembly & cylinder head assembly. NOTE: Since the valve lifter (INT) cannot be replaced by the piece, VVEL ladder assembly & 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 245

1. Using a scraper, wipe out 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-618039-S13712633802014052700000) ". If it exceeds the limit, replace VVEL ladder assembly & 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-618039-S13712633802014052700000) ".
2. If dimensions are out of the standard. Replace valve (EXH) and check valve seat contact. Refer to " «VALVE SEAT CONTACT»(ref-618039-S40952847762014052700000) ". (Exhaust side) Replace VVEL ladder assembly & cylinder head assembly. Refer to " «EXPLODED VIEW»(ref-618039-S11126209662014052700000) ". (Intake side) NOTE: Since the valve (INT) cannot be replaced by the piece, VVEL ladder assembly & cylinder head assembly replacement are required.

Valve Guide Clearance

Valve Stem Diameter

1. Measure the diameter of valve stem with micrometer (A). Standard: Refer to " «CYLINDER HEAD»(ref-618039-S13712633802014052700000) ".

Valve Guide Inner Diameter

1. Measure the inner diameter of valve guide with bore gauge. Standard: Refer to " «CYLINDER HEAD»(ref-618039-S13712633802014052700000) ".

Valve Guide Clearance

Scheme 246

1. (Valve guide clearance) = (Valve guide inner diameter) - (Valve stem diameter) Standard: Refer to " «CYLINDER HEAD»(ref-618039-S13712633802014052700000) ".
2. If the calculated value exceeds the limit. Replace valve (EXH) and/or valve guide (EXH). Refer to " «EXPLODED VIEW»(ref-618039-S11126209662014052700000) ". (Exhaust side) Replace VVEL ladder assembly & cylinder head assembly. Refer to " «EXPLODED VIEW»(ref-618039-S11126209662014052700000) ". (Intake side) NOTE: Since the valve (INT) and valve guide (INT) cannot be replaced by the piece, VVEL ladder assembly & cylinder head assembly replacement are required.

Scheme 247

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 re-check, replace valve seat (EXH). Refer to " «EXPLODED VIEW»(ref-618039-S11126209662014052700000) ". (Exhaust side) If not, replace VVEL ladder assembly & cylinder head assembly. Refer to " «EXPLODED VIEW»(ref-618039-S11126209662014052700000) ". (Intake side) NOTE: Since the valve seat (INT) cannot be replaced by the piece, VVEL ladder assembly & cylinder head assembly replacement are required.

Scheme 248

1. Set a try square (A) along the side of valve spring (with valve spring seat) and rotate spring. Measure the maximum clearance between the top of spring and try square. Limit: Refer to " «CYLINDER HEAD»(ref-618039-S13712633802014052700000) ".
2. If it exceeds the limit. Replace valve spring (with valve spring seat) (EXH). Refer to " «EXPLODED VIEW»(ref-618039-S11126209662014052700000) ". (Exhaust side) Replace VVEL ladder assembly & cylinder head assembly. Refer to " «EXPLODED VIEW»(ref-618039-S11126209662014052700000) ". (Intake side) NOTE: Since the valve spring (with valve spring seat) (INT) cannot be replaced by the piece, VVEL ladder assembly & cylinder head assembly replacement are required.

Scheme 249

1. Check the valve spring (with valve spring seat) pressure at specified spring height. Standard : Refer to " «CYLINDER HEAD»(ref-618039-S13712633802014052700000) ".
2. If the installation load or load with valve open is out of the standard. Replace valve spring (with valve spring seat) (EXH). Refer to " «EXPLODED VIEW»(ref-618039-S11126209662014052700000) ". (Exhaust side) Replace VVEL ladder assembly & cylinder head assembly. Refer to " «EXPLODED VIEW»(ref-618039-S11126209662014052700000) ". (Intake side) NOTE: Since the valve spring (with valve spring seat) (INT) cannot be replaced by the piece, VVEL ladder assembly & cylinder head assembly replacement are required.

Outline

At first, remove the transmission and transfer assembly, steering gear and front final drive facing downward. Then remove the engine.

Preparation

1. Remove engine cover. Refer to " «EXPLODED VIEW»(ref-618039-S29844956622014052700000) ".
2. Release fuel pressure. Refer to " «WORK PROCEDURE»(ref-618040-S18622321542014052700000) ".
3. Remove battery and tray. Refer to " «EXPLODED VIEW»(ref-618030-S16537336902014052700000) ".
4. Remove the following components and related parts: Hood assembly. Refer to " «EXPLODED VIEW»(ref-618038-S04051608622014052700000) ". Front under cover. Refer to " «EXPLODED VIEW»(ref-618043-S16569758662014052700000) ". Front road wheel and tires. Refer to " «EXPLODED VIEW»(ref-618045-S01795190782014052700000) ".
5. Drain engine oil. Refer to " «DRAINING»(ref-618049-S34982655492014052700000) ".
6. Drain engine coolant. Refer to " «DRAINING»(ref-618041-S20176606032014052700000) ". CAUTION: Perform this step when engine is cold. Never spill engine coolant on drive belts.
7. Drain power steering fluid. Refer to " «EXPLODED VIEW»(ref-618044-S02480985432014052700000) ".

Engine Room Front

1. Remove drive belt. Refer to " «EXPLODED VIEW»(ref-618039-S14726112972014052700000) ".
2. Remove fan shroud. Refer to " «EXPLODED VIEW»(ref-618041-S30452018462014052700000) ".
3. Remove cooling fan and fan coupling. Refer to " «EXPLODED VIEW»(ref-618041-S11074657482014052700000) ".
4. Remove radiator hoses (upper and lower).
5. Remove radiator.

Vehicle Underbody

1. Remove exhaust front tube. Refer to " «EXPLODED VIEW»(ref-618047-S02963109012014052700000) ".
2. Remove protector A and B. Refer to " «FRONT TUBE ASSEMBLY: EXPLODED VIEW»(ref-618050-S21978750222014052700000) ".
3. Remove front suspension rear cross member. Refer to " «2WD: EXPLODED VIEW»(ref-618051-S37351552972014052700000) " (2WD models) or " «4WD: EXPLODED VIEW»(ref-618051-S21180294812014052700000) " (AWD models).
4. Remove oil cooler. Refer to " «EXPLODED VIEW»(ref-618049-S30521811762014052700000) ".
5. Remove A/T assembly. Refer to " «2WD: EXPLODED VIEW»(ref-618051-S37351552972014052700000) " (2WD models) or " «4WD: EXPLODED VIEW»(ref-618051-S21180294812014052700000) " (AWD models).
6. Remove steering gear assembly. Refer to " «EXPLODED VIEW»(ref-618044-S00003107612014052700000) ".
7. Remove front final drive assembly. Refer to " «EXPLODED VIEW»(ref-618052-S05295321182014052700000) ".
8. Remove exhaust manifold. Refer to " «EXPLODED VIEW»(ref-618039-S09315994722014052700000) ".
9. Remove alternator. Refer to " «EXPLODED VIEW»(ref-618046-S40509153662014052700000) ".

Engine Room LH

1. Remove air cleaner and air duct. Refer to " «EXPLODED VIEW»(ref-618039-S35096297512014052700000) ".
2. Remove A/C compressor. Refer to " «EXPLODED VIEW»(ref-618032-S06719390942014052700000) ".
3. Disconnect fuel feed hose and EVAP hose. Refer to " «EXPLODED VIEW»(ref-618039-S02440423432014052700000) ". CAUTION: Fit plugs onto disconnected hoses to prevent fuel leakage.

Engine Room RH

1. Remove power steering oil pump and reservoir tank. Refer to " «EXPLODED VIEW»(ref-618044-S33979584762014052700000) ".
2. Disconnect heater hose at heater core side, and fit a plug onto hose end to prevent engine coolant leakage.
3. Disconnect ground cable.
4. Disconnect all clips and connectors of the engine harness from vehicle side.

Scheme 250

Scheme 251

1. Install alternator bracket. Refer to " «EXPLODED VIEW»(ref-618046-S40509153662014052700000) ". Temporarily tighten mounting bolts.
2. Remove intake manifold. Refer to " «EXPLODED VIEW»(ref-618039-S29160082932014052700000) ".
3. Remove starter motor. Refer to " «EXPLODED VIEW»(ref-618054-S38059858302014052700000) ".
4. Install engine slingers. Slinger bolts: Torque Value: 45.0 N.m (4.6 kg-m, 33 ft-lb)
5. Lift using a hoist and secure the engine in position.
6. Remove engine mounting bracket (LH, RH) and engine mounting insulator (LH, RH). Refer to " «EXPLODED VIEW»(ref-618039-S42857537872014052700000) ".
7. Remove the engine from the vehicle, avoid interference with the vehicle body. CAUTION: Before and during 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.

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 252

Scheme 253

1. Remove the engine assembly from the vehicle. Refer to " «EXPLODED VIEW»(ref-618039-S42857537872014052700000) ".
2. Remove crankshaft pulley. Refer to " «FRONT OIL SEAL: REMOVAL AND INSTALLATION»(ref-618039-S00058778182014052700000) ". NOTE: The drive plate is fixed with a ring gear stopper [SST: KV10120100 (J-47245)]. Loosen the crankshaft pulley mounting bolts before installing the engine stand.
3. Remove the parts that may restrict installation of engine to a widely used engine stand. Drive plate: Refer to " «EXPLODED VIEW»(ref-618039-S36601575142014052700000) ".
4. Lift the engine with hoist to install it onto the widely used engine stand. CAUTION: Use an engine stand that has a load capacity [240 kg (529 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. Refer to " «EXPLODED VIEW»(ref-618039-S29160082932014052700000) ". Remove fuel injector and fuel tube assembly. Refer to " «EXPLODED VIEW»(ref-618039-S34574599772014052700000) ". Remove ignition coil. Refer to " «EXPLODED VIEW»(ref-618039-S41509091952014052700000) ". Remove rocker cover. Refer to " «EXPLODED VIEW»(ref-618039-S11896676402014052700000) ". Remove exhaust manifold. Refer to " «EXPLODED VIEW»(ref-618039-S09315994722014052700000) ". Other removable brackets. NOTE: The figure shows an example of widely used engine stand (A) that can hold mating surface of transmission with drive plate 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-618049-S34982655492014052700000) ".
6. Drain engine coolant by removing water drain plug (3) from both sides of the cylinder block as shown in the figure below. Refer to " «COMPONENTS»(ref-618029-S35771567592014052700000) " for symbol marks in the figure. Water drain plug torque Torque Value: 19.6 N.m (2.0 kg/m, 14 ft-lb)

Piston Pin Hole Diameter

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

Standard: Refer to " CYLINDER BLOCK ".

Scheme 254

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-618039-S18775635642014052700000) ". NOTE: Piston is available together with piston pin as assembly.

Scheme 255

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-618039-S23374632392014052700000) ".
2. If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, replace piston also.

Scheme 256

1. Check that the cylinder bore inner diameter is within the specification.
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-618039-S23374632392014052700000) ".
3. If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, re-bore cylinder and use oversize piston and piston rings.

Scheme 257

1. Check with a connecting rod aligner. Bend limit: Refer to «CYLINDER BLOCK»(ref-618039-S23374632392014052700000) . Torsion limit "Cylinder Block" .
2. If it exceeds the limit, replace connecting rod assembly.

Scheme 258

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-618039-S35957098892014052700000) " for the tightening procedure.
2. Measure the inner diameter of connecting rod big end with an inside micrometer. Standard: Refer to " «CYLINDER BLOCK»(ref-618039-S23374632392014052700000) ".
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 259

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 ".

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-618039-S18775635642014052700000) ".
3. If replacing connecting rod assembly, refer to " «CONNECTING ROD BEARING»(ref-618039-S27864517562014052700000) " to select the connecting rod bearing.

Scheme 260

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-618039-S23374632392014052700000) ".
3. If it exceeds the limit, replace cylinder block.

Scheme 261

1. Install main bearing cap (2) without installing main bearings, and tighten main bearing cap bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-618039-S35957098892014052700000) " for the tightening procedure.
2. Measure the inner diameter of main bearing housing with a bore gauge. Standard: Refer to " «CYLINDER BLOCK»(ref-618039-S23374632392014052700000) ".
3. If out of the standard, replace cylinder block (1) and main bearing cap as assembly. NOTE: Cylinder block cannot be replaced as a single part, because it is machined together with main bearing cap.

Scheme 262

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: 120 mm (4.72 in) Wear limit: Out-of-round (Difference between "A" and "B"): Refer to " «CYLINDER BLOCK»(ref-618039-S23374632392014052700000) ". Taper limit (Difference between "C" and "E")
2. If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, hone or re-bore the inner wall.
3. Oversize piston is provided. When using oversize piston, re-bore 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 263

Piston-to-Cylinder Bore Clearance

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

Scheme 264

(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-618039-S23374632392014052700000) ".

Re-boring Cylinder Bore

1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter. Re-bored size calculation: D = A + B - C where, D: Bored diameter A: Piston skirt diameter as measured B: Piston to cylinder bore clearance (standard value) C: Honing allowance 0.02 mm (0.0008 in)
2. Install main bearing cap, 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-618039-S23374632392014052700000) ".
2. If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to " «MAIN BEARING»(ref-618039-S32044400962014052700000) ".

Scheme 265

1. Measure the outer diameter of crankshaft pin journal with a micrometer (A). Standard: Refer to " «CYLINDER BLOCK»(ref-618039-S23374632392014052700000) ".
2. If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer to " «CONNECTING ROD BEARING»(ref-618039-S27864517562014052700000) ".

Scheme 266

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. Out-of-round (Difference between "c" and "d"): Refer to " «CYLINDER BLOCK»(ref-618039-S23374632392014052700000) ". Taper (Difference between "a" and "b")
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-618039-S32044400962014052700000) " and/or " «CONNECTING ROD BEARING»(ref-618039-S27864517562014052700000) ".

Scheme 267

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-618039-S23374632392014052700000) ".
4. If it exceeds the limit, replace crankshaft.

Scheme 268

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-618039-S35957098892014052700000) " 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-618039-S13331002342014052700000) ".
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-618039-S18775635642014052700000) ".

Scheme 269

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-618039-S35957098892014052700000) " 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 270

1. Install main bearings (3) to cylinder block (1) and main bearing cap (2), and tighten main bearing cap bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-618039-S35957098892014052700000) " 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-618039-S01405827272014052700000) ".
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-618039-S18775635642014052700000) ".

Scheme 271

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 main bearing cap, and tighten main bearing cap bolts with main bearing cap to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-618039-S35957098892014052700000) " for the tightening procedure. CAUTION: Never rotate crankshaft.
4. Remove main 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 272

1. When main bearing cap 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-618039-S35957098892014052700000) " for the tightening procedure. A: Crush height Standard: There must be crush height.
2. If the standard is not met, replace main bearings.

Scheme 273

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-618039-S35957098892014052700000) " for the tightening procedure. Standard: There must be crush height.
2. If the standard is not met, replace connecting rod bearings.

Scheme 274

1. Measure the outer diameters (A), (B) at two positions as shown in the figure below.
2. If reduction appears in (A) range, regard it (B). Limit [(B) - (A)]: 0.15 mm (0.0059 in)
3. If it exceeds the limit (large difference in dimensions), replace main bearing cap bolts with new one.

Scheme 275

1. Measure the outer diameters (A), (B) at two positions as shown in the figure below.
2. If reduction appears in (A) range, regard it (B). Limit [(B) - (A)]: 0.10 mm (0.0039 in)
3. If it exceeds the limit (large difference in dimensions), replace main bearing cap sub bolts with new one.

Scheme 276

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)]: 0.08 mm (0.0032 in)
4. If it exceeds the limit (large difference in dimensions), replace the bolt with new one.

OIL JET

1. Check nozzle for deformation and damage.
2. Blow compressed air from nozzle, and check for clogs.
3. Using a clean plastic stick, press check valve in oil jet relief valve. Check that valve moves smoothly with proper reaction force.
4. If it is not satisfied, clean or replace oil jet.

WHEN NEW CYLINDER BLOCK IS USED

Check the cylinder bore grade on the bottom face of the cylinder block, and select the piston of the same grade.

Note. Piston is available with piston pin as a set for the service part.

Scheme 277

Scheme 278

1. Measure the cylinder bore inner diameter. Refer to " «CYLINDER BLOCK»(ref-618039-S23374632392014052700000) ".
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.

Scheme 279

Scheme 280

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-618039-S28368704222014052700000) ".
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 journal diameter column of "CONNECTING ROD BEARING SELECTION TABLE".
4. Follow from step 3 in "WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED".

Scheme 281

CONNECTING ROD BEARING GRADE TABLE

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

Scheme 282

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. CAUTION: In grinding crankshaft pin to use undersize bearings, keep the fillet R (A) [1.5 - 1.7 mm (0.059 - 0.067 in)]. Bearing undersize table: Refer to " «CONNECTING ROD BEARING»(ref-618039-S13331002342014052700000) ".

Scheme 283

Scheme 284

1. Apply the main bearing housing grade on the bottom face of the cylinder block to the row in "MAIN BEARING SELECTION TABLE".
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". CAUTION: Initial clearance for No. 1, 5 journal and No. 2, 3, 4 journal is different. Use two different selection table for each part. No. 1, 5 journal and No. 2, 3, 4 journal have the same signs but different measures. Never confuse.
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-618039-S28368704222014052700000) ".
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 from step 3 in "When New Cylinder Block and Crankshaft are Used".

Scheme 285

Scheme 286

MAIN BEARING GRADE TABLE (ALL JOURNALS)

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

Scheme 287

1. When the specified main bearing oil clearance is not obtained with standard size main bearings, use underside (US) bearing.
2. When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and grind main journal so that the main bearing oil clearance satisfies the standard. CAUTION: In grinding crankshaft main journal to use undersize bearings, keep the fillet R (A) [1.5 - 1.7 mm (0.059 - 0.067 in)]. Bearing undersize table: Refer to " «MAIN BEARING»(ref-618039-S01405827272014052700000) ".

DRIVE BELT

SPARK PLUG

EXHAUST MANIFOLD

EXHAUST CAMSHAFT

Unit: mm (in) Items Standard Limit Exhaust camshaft journal oil clearance 0.030 - 0.071 (0.0012 - 0.0028) 0.150 (0.0059) VVEL ladder assembly bracket inner diameter (EXH side) 26.000 - 26.021 (1.0236 - 1.0244) - Exhaust camshaft journal diameter 25.935 - 25.955 (1.0211 - 1.0218) - Exhaust camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) 0.24 (0.0094) Exhaust camshaft cam height "A" 45.475 - 45.665 (1.7904 - 1.7978) 45.275 (1.7825) Exhaust camshaft runout [TIR (1) ] Less than 0.02 (0.0008) 0.05 (0.002) Exhaust camshaft sprocket runout [TIR (1) ] - 0.2 (0.0079) (1) Total indicator reading

INTAKE CAMSHAFT

VALVE LIFTER

VALVE CLEARANCE

AVAILABLE VALVE LIFTER

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

Scheme 288

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" 126.3 (4.97)

Unit: mm (in) Valve head diameter "D" Intake 36.6 - 36.9 (1.441 - 1.453) Exhaust 31.2 - 31.5 (1.228 - 1.240) Valve length "L" Intake 99.19 - 99.69 (3.9051 - 3.9248) Exhaust 93.74 - 94.24 (3.6905 - 3.7102) Valve stem diameter "d" Intake 5.965 - 5.980 (0.2348 - 0.2354) Exhaust 5.955 - 5.970 (0.2344 - 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)

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 - 0.063 (0.0012 - 0.0025) 0.09 (0.004) Projection length "L" Intake 12.6 - 12.8 (0.496 - 0.504) Exhaust 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 32.200 - 32.216 (1.2677 - 1.2683) 32.700 - 32.716 (1.2874 - 1.2880) (4) Valve seat outer diameter "d" Intake 38.097 - 38.113 (1.4999 - 1.5005) - Exhaust 32.280 - 32.296 (1.2709 - 1.2715) 32.780 - 32.796 (1.2906 - 1.2912) (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 28.7 (1.130) Diameter "d2" (2) Intake 35.9 - 36.4 (1.413 - 1.433) Exhaust 30.3 - 30.8 (1.193 - 1.213) Angle "α1" 59 - 61° Angle "α2" 88°75' - 90°25' Angle "α3" 119 - 121° 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

AVAILABLE PISTON

Unit: mm (in) Items Standard Oversize (Service) [0.2 (0.008)] Piston skirt diameter "A" Grade No. 1 97.980 - 97.990 (3.8575 - 3.8579) - Grade No. 2 97.990 - 98.000 (3.8579 - 3.8583) - Grade No. 3 98.000 - 98.010 (3.8583 - 3.8587) - Service - 98.190 - 98.200 (3.8657 - 3.8661) Items Standard Limit "H" dimension 40.0 (1.5748) - Piston pin hole diameter 21.993 - 21.999 (0.8659 - 0.8661) - Piston to cylinder bore clearance 0.010 - 0.030 (0.0004 - 0.0012) 0.08 (0.0031)

PISTON RING

PISTON PIN

CONNECTING ROD

CRANKSHAFT

Unit: mm (in) Main journal diameter. "Dm" grade (No. 1 and 5 journal) Standard Grade No. G 63.964 - 63.963 (2.5183 - 2.5182) Grade No. H 63.963 - 63.962 (2.5182 - 2.5182) Grade No. J 63.962 - 63.961 (2.5182 - 2.5181) Grade No. K 63.961 - 63.960 (2.5181 - 2.5181) Grade No. L 63.960 - 63.959 (2.5181 - 2.5181) Grade No. M 63.959 - 63.958 (2.5181 - 2.5180) Grade No. N 63.958 - 63.957 (2.5180 - 2.5180) Grade No. P 63.957 - 63.956 (2.5180 - 2.5179) Grade No. R 63.956 - 63.955 (2.5179 - 2.5179) Grade No. S 63.955 - 63.954 (2.5179 - 2.5179) Grade No. T 63.954 - 63.953 (2.5179 - 2.5178) Grade No. U 63.953 - 63.952 (2.5178 - 2.5178) Grade No. V 63.952 - 63.951 (2.5178 - 2.5178) Grade No. W 63.951 - 63.950 (2.5178 - 2.5177) Grade No. X 63.950 - 63.949 (2.5177 - 2.5177) Grade No. Y 63.949 - 63.948 (2.5177 - 2.5176) Grade No. 1 63.948 - 63.947 (2.5176 - 2.5176) Grade No. 2 63.947 - 63.946 (2.5176 - 2.5176) Grade No. 3 63.946 - 63.945 (2.5176 - 2.5175) Grade No. 4 63.945 - 63.944 (2.5175 - 2.5175) Grade No. 5 63.944 - 63.943 (2.5175 - 2.5174) Grade No. 6 63.943 - 63.942 (2.5174 - 2.5174) Grade No. 7 63.942 - 63.941 (2.5174 - 2.5174) Grade No. 9 63.941 - 63.940 (2.5174 - 2.5173) Main journal diameter. "Dm" grade (No. 2, 3 and 4 journal) Standard Grade No. A 63.963 - 63.964 (2.5182 - 2.5183) Grade No. B 63.962 - 63.963 (2.5182 - 2.5182) Grade No. C 63.961 - 63.962 (2.5181 - 2.5182) Grade No. D 63.960 - 63.961 (2.5181 - 2.5181) Grade No. E 63.959 - 63.960 (2.5181 - 2.5181) Grade No. F 63.958 - 63.959 (2.5180 - 2.5181) Grade No. G 63.957 - 63.958 (2.5180 - 2.5180) Grade No. H 63.956 - 63.957 (2.5179 - 2.5180) Grade No. J 63.955 - 63.956 (2.5179 - 2.5179) Grade No. K 63.954 - 63.955 (2.5179 - 2.5179) Grade No. L 63.953 - 63.954 (2.5178 - 2.5179) Grade No. M 63.952 - 63.953 (2.5178 - 2.5178) Grade No. N 63.951 - 63.952 (2.5178 - 2.5178) Grade No. P 63.950 - 63.951 (2.5177 - 2.5178) Grade No. R 63.949 - 63.950 (2.5177 - 2.5177) Grade No. S 63.948 - 63.949 (2.5176 - 2.5177) Grade No. T 63.947 - 63.948 (2.5176 - 2.5176) Grade No. U 63.946 - 63.947 (2.5176 - 2.5176) Grade No. V 63.945 - 63.946 (2.5175 - 2.5176) Grade No. W 63.944 - 63.945 (2.5175 - 2.5175) Grade No. X 63.943 - 63.944 (2.5174 - 2.5175) Grade No. Y 63.942 - 63.943 (2.5174 - 2.5174) Grade No. 1 63.941 - 63.942 (2.5174 - 2.5174) Grade No. 2 63.940 - 63.941 (2.5173 - 2.5174) Pin journal diameter. "Dp" grade Standard Grade No. 0 53.968 - 53.974 (2.1247 - 2.1250) Grade No. 1 53.962 - 53.968 (2.1245 - 2.1247) Grade No. 2 53.956 - 53.962 (2.1243 - 2.1245) Center distance "r" 45.96 - 46.04 (1.8095 - 1.8126) Taper Limit 0.0025 (0.0001) Out-of-round 0.0025 (0.0001) Crankshaft runout [TIR (1) ] Standard Less than 0.05 (0.002) Limit 0.10 (0.0039) Crankshaft end play Standard 0.10 - 0.26 (0.0039 - 0.0102) Limit 0.30 (0.012) (1) Total indicator reading

Scheme 289

MAIN BEARING

UNDERSIZE

MAIN BEARING OIL CLEARANCE

CONNECTING ROD BEARING

CONNECTING ROD BEARING OIL CLEARANCE