Engine Mechanical: Other Nissan 350Z I

Precautions 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 for Disconnecting Fuel Piping

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

Special Service Tools

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

Scheme 301

Scheme 302

Scheme 303

Scheme 304

Scheme 305

Scheme 306

Scheme 307

Checking Drive Belts

1. Inspect belts for cracks, fraying, wear and oil. If necessary, replace.
2. Inspect drive belt deflection at a point on the belt midway between pulleys. Inspection should be done only when engine is cold, or over 30 minutes after engine is stopped. Measure belt tension with tension gauge (BT3373-F or equivalent) at points marked (Scheme 308) When measuring deflection, apply 98 N (10 kg, 22 lb) at the > marked point. Adjust if belt deflection exceeds the limit or if belt tension is not within specifications.

Scheme 308

Belt deflection and tension

Scheme 309

Scheme 310

ALTERNATOR AND POWER STEERING OIL PUMP BELT

1. Remove undercover with power tool.
2. Loosen idler pulley lock nut (A) and adjust tension by turning adjusting bolt (B). For specified belt tension, refer to " «Checking Drive Belts»(ref-170482-S19433449592005011000000) ".
3. Tighten nut (A). : 31.4 - 38.2 N.m (3.2 - 3.9 kg-m, 24 - 28 ft-lb)

Scheme 311

A/C COMPRESSOR BELT

1. Remove undercover with power tool.
2. Loosen idler pulley lock nut (C) and adjust tension by turning adjusting bolt (D). For specified belt tension, refer to " «Checking Drive Belts»(ref-170482-S19433449592005011000000) ". Tighten nut (C). : 30.4 - 39.2 N.m (3.1 - 4.0 kg-m, 23 - 28 ft-lb)

Camshaft Runout

1. Put V-block on precise flat table, and support No. 2 and 4 journal of camshaft. CAUTION: Do not support journal No. 1 (on the side of camshaft sprocket) because it has a different diameter from the other three locations.
2. Set dial indicator vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the camshaft runout on dial indicator. (Total indicator reading) Standard: Less than 0.02 mm (0.0020 in) Limit: 0.05 mm (0.0020 in)
4. If it exceeds the limit, replace camshaft.

Scheme 312

Camshaft Cam Height

1. Measure the camshaft cam height with micrometer. Standard cam height (intake and exhaust) : 44.865 - 45.055 mm (1.7663 - 1.7738 in) Cam wear limit : 0.2 mm (0.008 in)
2. If wear is beyond the limit, replace camshaft.

Scheme 313

CAMSHAFT JOURNAL DIAMETER

1. Measure the outer diameter of camshaft journal with micrometer. Standard: No. 1: 25.935 - 25.955 mm (1.0211 - 1.0218 in) No. 2, 3, 4: 23.445 - 23.465 mm (0.9230 - 0.9238 in)

Scheme 314

CAMSHAFT BRACKET INNER DIAMETER

1. Tighten camshaft bracket bolt with the specified torque, Refer to " «INSTALLATION»(ref-170482-S30713980612005011000000) " for the tightening procedure.
2. Measure the inner diameter "A" of camshaft bracket with bore gauge. Standard: No. 1: 26.000 - 26.021 mm (1.0236 - 1.0244 in) No. 2, 3, 4: 23.500 - 23.521 mm (0.9252 - 0.9260 in)

Scheme 315

CAMSHAFT JOURNAL OIL CLEARANCE

1. (Oil clearance) = (Camshaft bracket inner diameter) - (Camshaft journal diameter) Standard: No. 1: 0.045 - 0.086 mm (0.0018 - 0.0034 in) NO. 2, 3, 4: 0.035 - 0.076 mm (0.0014 - 0.0030 in) Limit: 0.15 mm (0.0059 in)
2. If it exceeds the limit, replace either or both camshaft and cylinder head.

Note. Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head. Replace whole cylinder head assembly.

Scheme 316

1. Install dial indicator in thrust direction on front end of camshaft. Measure the end play of dial indicator when camshaft is moved forward/backward (in direction to axis) Standard: 0.115 - 0.188 mm (0.0045 - 0.0074 in) Limit: 0.24 mm (0.0094 in)
2. Measure the following parts if out of the limit Dimension "A" for camshaft 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 and/or cylinder head.

Scheme 317

Camshaft Sprocket Runout

1. Put-V-block on precise flat table, and support No. 2 and 4 journal of camshaft. CAUTION: Do not support journal No. 1 (on the side of camshaft sprocket) because it has a different diameter from the other three locations.
2. Measure the camshaft sprocket runout with dial indicator. (Total indicator reading) Limit: 0.15 mm (0.0059 in) If it exceeds the limit, replace camshaft sprocket.

Scheme 318

Valve Lifter

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

1. If anything above is found, replace valve lifter, Refer to «"Available Valve Lifter"»(ref-170482-S26587613102005011000000) .

Scheme 319

VALVE LIFTER OUTER DIAMETER

1. Measure the outer diameter at 1/2 height of valve lifter with micrometer since valve lifter is in barrel shape. Standard (Intake and exhaust) : 33.977 - 33.987 mm (1.3377 - 1.3381 in)

Scheme 320

VALVE LIFTER HOLE DIAMETER

1. Measure the inner diameter of valve lifter hole of cylinder head with inside micrometer. Standard (Intake and exhaust) : 34.000 - 34.016 mm (1.3386 - 1.3392 in)

Scheme 321

VALVE LIFTER CLEARANCE

1. (Valve lifter clearance) = (Valve lifter hole diameter) - (Valve lifter outer diameter) Standard (Intake and exhaust) : 0.013 - 0.039 mm (0.0005 - 0.0015 in)
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 cylinder head.

Scheme 322

Scheme 323

Scheme 324

Scheme 325

Scheme 326

Scheme 327

Scheme 328

Scheme 329

Scheme 330

Scheme 331

1. Install timing chain tensioners (secondary) on both sides of cylinder head. Install timing chain tensioner with its stopper pin attached. Install timing chain tensioner with sliding part facing downward on right-side cylinder head, and with sliding part facing upward on left-side cylinder head. Install new O-ring (Scheme 322)
2. Install valve lifter. Install it in the original position.
3. Install camshafts. Install camshaft with dowel pin attached to its front end face on the exhaust side. Follow your identification marks made during removal, or follow the identification marks that are present on new camshafts for proper placement and direction. Install camshaft so that dowel pin hole and dowel pin on front end face are positioned (Scheme 326), (No. 1 cylinder TDC on its compression stroke). NOTE: Large and small pin holes are located on front end face of camshaft (INT), at intervals of 180 degrees. Face small dia. side pin hole upward (in cylinder head upper face direction). Though camshaft does not stop at the portion (Scheme 326), for the placement of cam nose, it is generally accepted camshaft is placed for the same direction of (Scheme 326).
4. Install camshaft brackets. Remove foreign material completely from camshaft bracket backside and from cylinder head installation face. Install camshaft bracket in original position and direction (Scheme 327) Install camshaft brackets (No. 2 to 4) aligning the stamp marks (Scheme 328) NOTE: There are no identification marks indicating left and right for camshaft bracket (No. 1). Apply liquid gasket to mating surface of camshaft bracket (No. 1) as shown on right and left banks. Use Genuine RTV Silicon Sealant or equivalent. Refer to "RECOMMENDED FLUIDS AND LUBRICANTS ".
5. Tighten camshaft bracket bolts in the following steps, in numerical order (Scheme 330) Tighten No. 7 to 10 in order as shown.: 1.96 N.m (0.2 kg-m, 17 in-lb) Tighten No. 1 to 6 in order as shown.: 1.96 N.m (0.2 kg-m, 17 in-lb) Tighten No. 1 to 10 in numerical order as shown.: 5.88 N.m (0.6 kg-m, 52 in-lb) Tighten No. 1 to 6 in numerical order as shown.: 9.02 - 11.8 N.m (0.92 - 1.20 kg-m, 80 - 104 in-lb) Tighten No. 7 to 10 in numerical order as shown.: 8.3 - 10.3 N.m (0.85 - 1.0 kg-m, 74 - 91 in-lb) CAUTION: After tightening mounting bolts of camshaft brackets (No. 1), be sure to wipe off excessive liquid gasket from the parts list below. Mating surface of rocker cover Mating surface of rear timing chain case
6. Measure difference in levels between front end faces of camshaft bracket (No. 1) and cylinder head. Standard: -0.14 to 0.14 mm (-0.0055 to 0.0055 in) Measure two positions (both intake and exhaust side) for a single bank. If measured value is out of the standard, re-install camshaft bracket (No. 1).
7. Check and adjust the valve clearance, Refer to " «Valve Clearance»(ref-170482-S41294586052005011000000) ".
8. Install in the reverse order of removal after this step.

Cylinder Head Distortion

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

1. Using scraper, wipe off oil, scale, gasket, sealant and carbon deposits from surface of cylinder head. CAUTION: Do not 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. Limit: 0.1 mm (0.004 in) If it exceeds the limit, replace cylinder head.

Scheme 332

Scheme 333

Scheme 334

Scheme 335

Scheme 336

1. Install new cylinder head gaskets.
2. Turn crankshaft until No. 1 piston is set at TDC. Crankshaft key should line up with the right bank cylinder center line (Scheme 333)
3. Install cylinder head follow the steps below to tighten cylinder head bolts in numerical order (Scheme 334) Apply new engine oil to threads and seat surfaces of cylinder head bolts. Tighten all cylinder head bolts.: 98.1 N.m (10 kg-m, 72 ft-lb) Completely loosen all cylinder head bolts.: 0 N.m (0 kg-m, 0 ft-lb) CAUTION: In step "b", loosen bolts in reverse order of that indicated in (Scheme 334). Tighten all cylinder head bolts.: 34.3 - 44.1 N.m (3.5 - 4.4 kg-m, 26 - 32 ft-lb) Turn all bolts 90 to 95 degrees clockwise [target: 90 degrees (angle tightening)]. CAUTION: Check the tightening angle by using angle wrench [SST]. Avoid judgment by visual inspection without tool. Check tightening angle indicated on angle wrench [SST] indicator plate. Turn all bolts 90 to 95 degrees clockwise again [target: 90 degrees (angle tightening)].
4. After installing cylinder head, measure distance between front end faces of cylinder block and cylinder head (left and right banks). Standard: 14.1 - 14.9 mm (0.555 - 0.587 in) If the measured value is out of the standard, re-install cylinder head.
5. Install in the reverse order of removal after this step.

VALVE DIMENSIONS

1. Check dimensions of each valve. For dimensions, refer to " «Valve Dimensions»(ref-170482-S16427040822005011000000) ".
2. If dimensions are out of the standard, replace valve.

Scheme 337

Valve Stem Diameter

Measure diameter of valve stem with micrometer.

1. Standard
2. Intake: 5.965 - 5.980 mm (0.2348 - 0.2354 in)
3. Exhaust: 5.955 - 5.970 mm (0.2344 - 0.2350 in)

Scheme 338

Valve Guide Inner Diameter

Measure inner diameter of valve guide with inside micrometer.

1. Standard
2. Intake and Exhaust: 6.000 - 6.018 mm (0.2362 - 0.2369 in)

Valve Guide Clearance

(Valve Guide Clearance) = (Valve guide inner diameter) - (Valve stem diameter).

1. Valve guide clearance
2. Standard
3. Intake: 0.020 - 0.053 mm (0.0008 - 0.0021 in)
4. Exhaust: 0.030 - 0.063 mm (0.0012 - 0.0025 in)
5. Limit
6. Intake: 0.08 mm (0.003 in)
7. Exhaust: 0.09 mm (0.004 in)

1. If it exceeds the limit, replace valve and/or valve guide. When valve guide must be replaced, refer to " «VALVE GUIDE REPLACEMENT»(ref-170482-S11537901782005011000000) ".

VALVE SPRING SQUARENESS

1. Set try square along the side of valve spring and rotate spring. Measure the maximum clearance between the top face of spring and try square. Limit: 2.1 mm (0.083 in)
2. If it exceeds the limit, replace valve spring.

Scheme 339

Scheme 340

1. Check valve spring pressure at specified spring height. Standard: Intake and exhaust Free height : 47.07 mm (1.8531 in) Installation height : 37.00 mm (1.4567 in) Installation load : 166 - 188 N (16.9 - 19.2 kg, 37 - 42 lb) Height during valve open : 27.2 mm (1.0709 in) Load with valve open : 373 - 421 N (38.0 - 42.9 kg, 84 - 95 lb)
2. If the installation load or load with valve open is out of the standard, replace valve spring.

Scheme 341

Outline

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

Preparation

1. Release fuel pressure, Refer to "FUEL PRESSURE RELEASE ".
2. Drain engine coolant from radiator, Refer to "Changing Engine Coolant ". CAUTION: Perform this step when engine is cold. Do not spill engine coolant on drive belts.
3. Disconnect both battery terminals.
4. Remove the following parts: Hood assembly. Tower bar; Refer to "TOWER BAR ". Engine cover; Refer to " «INTAKE MANIFOLD COLLECTOR»(ref-170482-S00157874672005011000000) ". Front wiper arm and cowl top cover; Refer to "COWL TOP ". Undercover Drive belts; Refer to " «DRIVE BELTS»(ref-170482-S00068043942005011000000) ". Front road wheels and tires
5. Drain engine coolant from radiator, Refer to "Changing Engine Coolant ".
6. Remove air cleaner case and air duct, Refer to " «AIR CLEANER AND AIR DUCT»(ref-170482-S13775754652005011000000) ".
7. Discharge refrigerant from A/C circuit, Refer to "REFRIGERANT LINES ".
8. Remove radiator cooling fan assembly, reservoir tank and hoses, Refer to "COOLING FAN " and "RADIATOR ".

Scheme 342

1. Disconnect heater hose at engine-side, and fit a plug onto hose end to prevent engine coolant leak.
2. Disconnect ground cable (between vehicle to left cylinder head).
3. Disconnect battery positive cable harness at vehicle side and temporarily fasten it on engine.
4. Disconnect A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope.
5. Remove engine room harness connectors (Scheme 342)
6. Disconnect two body ground cables.
7. Disconnect brake booster vacuum hose.
8. Disconnect fuel feed hose (with damper) and EVAP hose, Refer to " «FUEL INJECTOR AND FUEL TUBE»(ref-170482-S02503672052005011000000) ". CAUTION: Fit plugs onto disconnected hoses to prevent fuel leak.
9. Remove reservoir tank of power steering oil pump, and piping from vehicle, and temporarily secure them on engine.

Passenger Room Side

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

Scheme 343

1. Remove passenger-side kicking plate inner, dash side finisher, and instrument passenger panel lower, Refer to "INSTRUMENT PANEL ASSEMBLY ".
2. Disconnect engine room harness connectors at unit sides TCM (A/T models), ECM and other.
3. Disengage intermediate fixing point. Pull out engine room harnesses to engine room side, and temporarily secure them on engine.

Vehicle Underbody

1. Remove exhaust front tube, Refer to "EXHAUST SYSTEM ".
2. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft, Refer to "STEERING COLUMN ".
3. Remove propeller shaft, Refer to "REAR PROPELLER SHAFT ". CAUTION: Do not impact or damage propeller shaft tube.
4. Disengage shift lever and clutch operating cylinder (M/T models), Refer to "TRANSMISSION ASSEMBLY " and "OPERATING CYLINDER ".
5. Disengage A/T control rod at control device assembly side. Then, temporarily secure it on transmission, so that it does not sag (A/T models), Refer to "SHIFT CONTROL SYSTEM ".
6. Remove rear plate from oil pan (upper). Then remove bolts fixing drive plate to torque converter (A/T models), Refer to " «OIL PAN AND OIL STRAINER»(ref-170482-S08611620792005011000000) " and "TRANSMISSION ASSEMBLY ".
7. Remove bolts fixing transmission to lower rear side of oil pan (upper), Refer to "TRANSMISSION ASSEMBLY " (M/T models) or "TRANSMISSION ASSEMBLY " (A/T models).
8. Remove front stabilizer, Refer to " «STABILIZER BAR»(ref-165835-S30171565152004090700000) ".
9. Remove outer sockets from steering knuckle, Refer to "POWER STEERING GEAR AND LINKAGE ".
10. Remove transverse links from suspension member, Refer to " «TRANSVERSE LINKTRANSVERSE LINK & BALL JOINT»(ref-165835-S04697021632004090700000) ".

Scheme 344

1. Use a manual lift table caddy (commercial service tool) or equivalently rigid tool such as transmission jack. Securely support bottom of suspension member and transmission. CAUTION: Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.
2. Remove rear engine mounting member bolts.
3. Remove suspension member mounting bolts and nuts, Refer to " «FRONT SUSPENSION MEMBER»(ref-165835-S01357350592004090700000) ".
4. Carefully lower jack, or raise lift to remove engine, transmission and suspension member assembly. When performing work, observe the following caution

Scheme 345

Scheme 346

1. Install engine slingers into front of right bank cylinder head and rear of left bank cylinder head. Slinger bolts:: 24.5 - 31.4 N.m (2.5 - 3.2 kg-m, 18 - 23 ft-lb) To protect rocker cover against damage caused by tilting of engine slinger, insert spacer between cylinder head and engine rear lower slinger, in direction (Scheme 346) NOTE: Spacer is a component part of engine rear upper slinger assembly.
2. Remove power steering oil pump from engine side, Refer to "POWER STEERING OIL PUMP ".
3. Remove engine mounting insulators (RH and LH) under side nut.
4. Lift with hoist and separate engine and transmission assembly from suspension member. CAUTION: Before and during this lifting, always make sure that any harnesses are left connected. Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
5. Remove alternator, Refer to " «GENERATOR»(ref-165597-S35450882872004083000000) ".
6. Remove starter motor, Refer to " «STARTERS»(ref-166478) ".
7. Separate engine from transmission, Refer to "TRANSMISSION ASSEMBLY " (M/T models) or "TRANSMISSION ASSEMBLY " (A/T models).
8. Remove engine mounting insulators (RH and Lh) and brackets (RH and LH) from engine.
9. Remove rear engine mounting member and engine mounting insulator (rear) from transmission.

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.

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

Scheme 347

Scheme 348

1. Measure the cylinder bore inner diameter, Refer to " «Cylinder Bore Inner Diameter»(ref-170482-S15371330132005011000000) ".
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.

Scheme 349

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.

When New Connecting Rod and Crankshaft are Used

Check pin diameter grade ("0", "1" or "2") on front of crankshaft, and select connecting rod bearing of the same grade.

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

Scheme 350

When Crankshaft and Connecting Rod are Reused

1. Measure the connecting rod big end diameter, Refer to " «CONNECTING ROD BIG END DIAMETER»(ref-170482-S38026390622005011000000) ".
2. Make sure that the connecting rod big end diameter is within the standard value.
3. Measure the crankshaft pin journal diameter, Refer to " «CRANKSHAFT PIN JOURNAL DIAMETER»(ref-170482-S16863323422005011000000) ".
4. Determine the grade of crankshaft pin diameter grade by corresponding to the measured dimension in "Crankshaft pin journal diameter" column of "Connecting Rod Bearing Selection Table".
5. Select connecting rod bearing of the same grade.

Scheme 351

Scheme 352

Undersize Bearings Usage Guide

1. When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod bearings, use undersize (US) bearings.
2. When using undersize (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 353

Bearing undersize table

Scheme 354

Scheme 355

Scheme 356

1. "Main Bearing Selection Table" rows correspond to bearing housing grade on rear left 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".

When Cylinder Block and Crankshaft are Reused

1. Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter, Refer to " «MAIN BEARING HOUSING INNER DIAMETER»(ref-170482-S36678541252005011000000) " and " «CRANKSHAFT MAIN JOURNAL DIAMETER»(ref-170482-S32373070912005011000000) ".
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. Select main bearing grade at the point where selected row and column meet in following selection table.

Scheme 357

Scheme 358

Undersize Bearing Usage Guide

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.

Scheme 359

Scheme 360

CRANKSHAFT END PLAY

1. Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with dial indicator. Standard: 0.10 - 0.25 mm (0.0039 - 0.0098 in) Limit: 0.30 mm (0.0118 in)
2. If the measured value exceeds the limit, replace thrust bearings, and measure again. If it still exceeds the limit, replace crankshaft also.

Scheme 361

CONNECTING ROD SIDE CLEARANCE

1. Measure the side clearance between connecting rod and crankshaft arm with feeler gauge. Standard: 0.20 - 0.35 mm (0.0079 - 0.0138 in) Limit: 0.40 mm (0.0157 in)
2. If the measured value exceeds the limit, replace connecting rod, and measure again. If it still exceeds the limit, replace crankshaft also.

Scheme 362

Piston Pin Hole Diameter

Measure the inner diameter of piston pin hole with inside micrometer.

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

Scheme 363

Piston to Piston Pin Oil Clearance

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

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

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 " «HOW TO SELECT PISTON»(ref-170482-S05936492762005011000000) ". 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 364

1. Measure the side clearance of piston ring and piston ring groove with feeler gauge. Standard: Top ring: 0.045 - 0.080 mm (0.0018 - 0.0031 in) 2nd ring: 0.030 - 0.070 mm (0.0012 - 0.0028 in) Oil ring: 0.065 - 0.135 mm (0.0026 - 0.0053 in) Limit: Top ring: 0.11 mm (0.0043 in) 2nd ring: 0.10 mm (0.0039 in)
2. If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, replace piston also.

Scheme 365

1. Make sure that cylinder bore inner diameter is within the specification, Refer to " «Cylinder Bore Inner Diameter»(ref-170482-S15371330132005011000000) ".
2. Lubricate with new engine oil to piston and piston ring, and then insert piston ring until middle of cylinder with piston, and measure the piston ring end gap with feeler gauge. Standard: Top ring: 0.23 - 0.33 mm (0.0091 - 0.0130 in) 2nd ring: 0.33 - 0.48 mm (0.0130 - 0.0189 in) Oil ring: 0.20 - 0.50 mm (0.0079 - 0.0197 in) Limit: Top ring: 0.54 mm (0.0213 in) 2nd ring: 0.80 mm (0.0315 in) Oil ring: 0.95 mm (0.0374 in)
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.

CONNECTING ROD BEND AND TORSION

1. Check with connecting rod aligner. Bend: Limit: 0.15 mm (0.0059 in) per 100 mm (3.94 in) length Torsion: Limit: 0.30 mm (0.0118 in) per 100 mm (3.94 in) length
2. If it exceeds the limit, replace connecting rod assembly.

Scheme 366

CONNECTING ROD BIG END DIAMETER

1. Install connecting rod bearing cap without installing connecting rod bearing, and tightening connecting rod bolts to the specified torque, Refer to " «ASSEMBLY»(ref-170482-S33999023902005011000000) " for the tightening procedure.
2. Measure the inner diameter of connecting rod big end with inside micrometer. Standard: 55.000 - 55.013 mm (2.1654 - 2.1659 in)
3. If out of the standard, replace connecting rod assembly.

Scheme 367

Connecting Rod Bushing Inner Diameter

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

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

Scheme 368

Connecting Rod Bushing Oil Clearance

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

1. Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 in)
2. Limit: 0.030 mm (0.0012 in)

Scheme 369

1. If the measured 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 " «HOW TO SELECT PISTON»(ref-170482-S05936492762005011000000) ".
3. If replacing connecting rod assembly, refer to " «CONNECTING ROD BEARING OIL CLEARANCE»(ref-170482-S21452921392005011000000) " to select the connecting rod bearing. Factory installed parts grading
4. Service parts apply only to grade "0".

Scheme 370

Scheme 371

CYLINDER BLOCK DISTORTION

1. Using 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 with straightedge and feeler gauge. Limit: 0.1 mm (0.004 in)
3. If it exceeds the limit, replace cylinder block.

Scheme 372

MAIN BEARING HOUSING INNER DIAMETER

1. Install main bearing caps and main bearing beam without installing main bearings, and tighten main bearing cap bolts to the specified torque, Refer to " «ASSEMBLY»(ref-170482-S33999023902005011000000) " for the tightening procedure.
2. Measure the inner diameter of main bearing housing with bore gauge. Standard: 63.993 - 64.017 mm (2.5194 - 2.5203 in)
3. If out of the standard, replace cylinder block and main bearing caps as assembly.

Note. Cylinder block cannot be replaced as a single part, because it is machined together with main bearing caps.

Scheme 373

Scheme 374

1. Using bore gauge, measure cylinder bore for wear, out-of-round and taper at six different points on each cylinder. ("X" and "Y" directions at "A", "B" and "C") ("Y" is in longitudinal direction of engine) Standard inner diameter: 95.500 - 95.530 mm (3.7598 - 3.7610 in) Wear limit: 0.2 mm (0.008 in) Out-of-round (Difference between "X" and "Y"): 0.015 mm (0.0006 in) Taper limit (Difference between "A" and "C"): 0.01 mm (0.0004 in)
2. If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, hone or 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.

1. Oversize (OS): 0.2 mm (0.008 in)

Scheme 375

Piston Skirt Diameter

Measure the outer diameter of piston skirt with micrometer.

1. Measure point
2. Distance from the top 41.0 mm (1.614 in)
3. Standard
4. 95.480 - 95.510 mm (3.7590 - 3.7602 in)

Scheme 376

Piston to Cylinder Bore Clearance

Calculate by piston skirt diameter and cylinder bore inner diameter (direction "Y", position "B").

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

1. Standard: 0.010 - 0.030 mm (0.0004 - 0.0012 in)
2. Limit: 0.08 mm (0.0031 in)

1. If calculated value exceeds the limit, replace piston and piston pin assembly, Refer to " «HOW TO SELECT PISTON»(ref-170482-S05936492762005011000000) ".

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 caps and main bearing beam, 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. Measurement should be done after cylinder bore cools down.

CRANKSHAFT MAIN JOURNAL DIAMETER

1. Measure the outer diameter of crankshaft main journals with micrometer. Standard: 59.951 - 59.975 mm (2.3603 - 2.3612 in) dia.
2. If out of the standard, measure the main bearing oil clearance. Then use undersize bearing, Refer to " «MAIN BEARING OIL CLEARANCE»(ref-170482-S16779391502005011000000) ".

CRANKSHAFT PIN JOURNAL DIAMETER

1. Measure the outer diameter of crankshaft pin journal with micrometer. Standard: 51.956 - 51.974 mm (2.0455 - 2.0462 in) dia.
2. If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing, Refer to " «CONNECTING ROD BEARING OIL CLEARANCE»(ref-170482-S21452921392005011000000) ".

Scheme 377

Scheme 378

1. Measure the dimensions at four different points (Scheme 378)on each main journal and pin journal with micrometer.
2. Out-of-round is indicated by the difference in the dimensions between "X" and "Y" at "A" and "B".
3. Taper is indicated by the difference in the dimensions between "A" and "B" at "X" and "Y". Limit: Out-of-round (Difference between "X" and "Y"): 0.002 mm (0.0001 in) Taper (Difference between "A" and "B"): 0.002 mm (0.0001 in)
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 OIL CLEARANCE»(ref-170482-S16779391502005011000000) " and/or " «CONNECTING ROD BEARING OIL CLEARANCE»(ref-170482-S21452921392005011000000) ".

Scheme 379

1. Place V-block on precise flat table, and support the journals on the both end of crankshaft.
2. Place dial indicator straight up on the No. 3 journal.
3. While rotating crankshaft, read the movement of the pointer on dial indicator. (Total indicator reading) Standard: Less than 0.05 mm (0.002 in) Limit: 0.10 mm (0.0039 in)
4. If it exceeds the limit, replace crankshaft.

Scheme 380

1. Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified torque, Refer to " «ASSEMBLY»(ref-170482-S33999023902005011000000) " for the tightening procedure.
2. Measure the inner diameter of connecting rod bearing with inside micrometer. (Bearing oil clearance) = (Connecting rod bearing inner diameter) - (Crankshaft pin journal diameter) Standard: 0.034 - 0.059 mm (0.0013 - 0.0023 in) (actual clearance) Limit: 0.070 mm (0.0028 in)
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 " «HOW TO SELECT CONNECTING ROD BEARING»(ref-170482-S05290328832005011000000) ".

Method of Using Plastigage

1. Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely.
2. Cut 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 cap, and tighten connecting rod bolts to the specified torque, Refer to " «ASSEMBLY»(ref-170482-S33999023902005011000000) " for the tightening procedure. CAUTION: Do not rotate crankshaft.
4. Remove connecting rod bearing cap and bearing, and using scale on plastigage bag, measure the plastigage width.

Note. The procedure when the measured value exceeds the limit is same as that described in the "Method by Calculation".

Scheme 381

Scheme 382

1. Install main bearings to cylinder block and main bearing caps, and tighten main bearing cap bolts with main bearing beam to the specified torque, Refer to " «ASSEMBLY»(ref-170482-S33999023902005011000000) " for the tightening procedure.
2. Measure the inner diameter of main bearing with bore gauge. (Bearing clearance) = (Main bearing inner diameter) - (Crankshaft main journal diameter) Standard: 0.035 - 0.045 mm (0.0014 - 0.0018 in) (actual clearance) Limit: 0.065 mm (0.0026 in)
3. If the clearance 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 " «HOW TO SELECT MAIN BEARING»(ref-170482-S04944662252005011000000) ".

1. Remove oil and dust on crankshaft main journal and the surfaces of each bearing completely.
2. Cut plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
3. Install main bearings to cylinder block and main bearing caps, and tighten main bearing bolts with main bearing beam to the specified torque, Refer to " «ASSEMBLY»(ref-170482-S33999023902005011000000) " for the tightening procedure. CAUTION: Do not rotate crankshaft.
4. Remove main bearing caps and bearings, and using scale on plastigage bag, measure the plastigage width.

Note. The procedure when the measured value exceeds the limit is same as that described in the "Method by Calculation".

Scheme 383

CRUSH HEIGHT OF MAIN BEARING

1. When main bearing cap is removed after being tightened to the specified torque with main bearings installed, the tip end of bearing must protrude, Refer to " «ASSEMBLY»(ref-170482-S33999023902005011000000) " for the tightening procedure. Standard: There must be crush height.
2. If the standard is not met, replace main bearings.

Scheme 384

CRUSH HEIGHT OF CONNECTING ROD BEARING

1. When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings installed, the tip end of bearing must protrude, Refer to " «ASSEMBLY»(ref-170482-S33999023902005011000000) " for the tightening procedure. Standard: There must be crush height.
2. If the standard is not met, replace connecting rod bearings.

Scheme 385

MAIN BEARING CAP BOLT OUTER DIAMETER

1. Measure the outer diameters ("d1 ", "d2 ") at two positions (Scheme 386)
2. If reduction appears in "A" range, regard it as "d2". Limit ("d1" - "d2 "): 0.11 mm (0.0051 in)
3. If it exceeds the limit (large difference in dimensions), replace main bearing cap bolt with new one.

Scheme 386

CONNECTING ROD BOLT OUTER DIAMETER

1. Measure the outer diameter "d" at position (Scheme 387)
2. If the reduction appears in a position other than "d", regard it as "d". Standard: 7.90 - 8.00 mm (0.3110 - 0.3150 in) Limit: 7.75 mm (0.3051 in)
3. When "d" exceeds the limit (when it becomes thinner), replace bolt with new one.

Scheme 387

FLYWHEEL DEFLECTION (M/T MODELS)

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

Scheme 388

MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS)

Movement Amount of Thrust (Fore-and-Aft) Direction

1. Measure the movement amount of thrust (fore-and-aft) direction when 100 N (10.2 kg, 22 lb) force is added at the portion of 125 mm (4.92 in) radius from the center of flywheel. Standard: 1.3 mm (0.051 in) or less
2. If measured value is out of the standard, replace flywheel.

Movement Amount of Radial (Rotation) Direction

Check the movement amount of radial (rotation) direction as follows

1. Install 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 (1.0 kg-m, 87 in-lb) to keep it from loosening.
2. Put a mating mark on circumferences of the two flywheel masses without applying any load (Measurement standard points).
3. Apply a force of 9.8 N.m (1.0 kg-m, 87 in-lb) in each direction, and mark the movement amount on the mass on the transmission side.
4. Measure dimensions of movement amounts "A" and "B" on circumference of flywheel on the transmission side. Standard: 24 mm (0.94 in) or less If the measured value is out of the standard, replace flywheel.

Scheme 389

DRIVE PLATE (A/T MODELS)

1. Check drive plate and signal plate for deformation or cracks. CAUTION: Do not disassemble drive plate. Do not 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.

Scheme 390

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.

OIL JET RELIEF VALVE

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

Scheme 391