Engine Mechanical - 2.5L: Other Nissan Altima L31

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 any removal or disassembly.
3. After disconnecting pipes, plug openings to stop fuel leakage.

SPECIAL SERVICE TOOLS

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

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Changing The Air Cleaner Element

1. Unhook the air cleaner case side clips and raise the air cleaner case (upper).
2. Remove the air cleaner element.

Scheme 157

Connecting the Quick Connector for the Fuel Hose (Engine Side)

1. Install the fuel tube quick connector (engine side) as follows.

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1. Make sure no foreign substances are deposited in and around tube and quick connector and there is no damage on them.
2. Thinly apply new engine oil around the fuel tube tip end.
3. Align center to insert quick connector straight into fuel tube. Insert fuel tube into quick connector until the top spool on fuel tubes is inserted completely and the second level spool is positioned slightly below the quick connector bottom end. CAUTION: Hold A position in illustration when inserting fuel tube into quick connector. Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick connector. Insert until you hear a "click" sound and actually feel the engagement. To avoid misidentification of engagement with a similar sound, be sure to perform the next step.
4. Before clamping fuel hose with hose clamp, pull quick connector hard by hand holding at the "A" position, as shown. Make sure it is completely engaged (connected) so that it does not come off of the fuel tube. NOTE: Recommended pulling force is 50 N (5.1 kg, 11.2 lb).
5. Install quick connector cap on quick connector joint. Direct arrow mark on quick connector cap to upper side (fuel hose side).
6. Install fuel hose to hose clamp. Connecting the Quick Connector for the Fuel Hose (Vehicle Piping Side) Install the fuel tube quick connector (vehicle piping side side) as follows.
7. Make sure no foreign substances are deposited in and around tube and quick connector and there is no damage on them.
8. Thinly apply new engine oil around the fuel tube tip end.
9. Align center to insert quick connector straight into fuel tube. Insert fuel tube into quick connector until the top spool on fuel tubes is inserted completely and the paint mark is positioned slightly below the quick connector bottom end. CAUTION: Hold A position in illustration when inserting fuel tube into quick connector. Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick connector. Insert until you hear a "click" sound and actually feel the engagement. To avoid misidentification of engagement with a similar sound, be sure to perform the next step.
10. Before clamping fuel hose with hose clamp, pull quick connector hard by hand. Make sure it is completely engaged (connected) so that it does not come off of the fuel tube. NOTE: Recommended pulling force is 50 N (5.1 kg, 11.2 lb).

Check Connections for Fuel Leakage

1. Start the engine and run it for a few minutes with engine at idle.
2. Stop the engine and check for fuel leakage both visually and by odor of gasoline. NOTE: Use mirrors for checking on connections out of the direct line of sight. CAUTION: Do not touch the engine immediately after stopping as engine is extremely hot.

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Scheme 162

1. Remove the ignition coils. Refer to «REMOVAL AND INSTALLATION»(ref-159291-S21443364292005042600000) .
2. Disconnect the PCV hose and breather hose from the rocker cover.
3. Loosen the bolts in the numerical order as shown using power tool.
4. Remove the rocker cover. Remove the oil filler cap and PCV valve if necessary, to transfer to the new rocker cover.

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Scheme 164

1. Apply RTV Silicone Sealant to the joint part of the cylinder head and camshaft bracket following the steps below: Refer to illustration "a" to apply sealant to joint part of No. 1 camshaft bracket and cylinder head. Refer to illustration "b" to apply sealant in a 90° degree angle to the illustration "a". Use Genuine RTV Silicone Sealant, or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS .
2. Install the rocker cover. The rocker cover gasket must be securely installed in the groove in the rocker cover.
3. Tighten the rocker cover bolts in two steps, in the numerical order as shown. Rocker cover bolt tightening 1st step :1.0 - 2.9 N.m (0.1 - 0.3 kg-m, 9 - 26 in-lb) Rocker cover bolt tightening 2nd step :7.4 - 9.3 N.m (0.75 - 0.95 kg-m, 65 - 82 in-lb)
4. Connect the PCV hose and breather hose to the rocker cover. If necessary, install the oil filler cap and PCV valve and lubricate the PCV valve O-ring with new engine oil.
5. Install the ignition coils. Refer to «REMOVAL AND INSTALLATION»(ref-159291-S21443364292005042600000) .

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1. Remove the rocker cover. Refer to «REMOVAL AND INSTALLATION»(ref-159291-S12621124542005042600000) .
2. Remove the front right side tire and wheel using power tool.
3. Remove the RH splash shield using power tool.
4. Remove the auxiliary drive belt.
5. Remove the coolant overflow reservoir tank.
6. Remove the IVTC (intake valve timing control) cover by cutting the sealant using the Tool. Loosen the bolts in the order shown.
7. Set the No. 1 cylinder at TDC on its compression stroke with the following procedure: Open the splash cover on RH under cover. Rotate crankshaft pulley clockwise, and align mating marks for TDC with timing indicator on front cover, as shown. At the same time, make sure that the mating marks on camshaft sprockets are lined up with the yellow links in the timing chain, as shown. If not, rotate crankshaft pulley one more turn to line up the mating marks to the yellow links, as shown.
8. Pull the timing chain guide out between the camshaft sprockets through front cover.
9. Remove camshaft sprockets with the following procedure. CAUTION: Do not rotate the crankshaft or camshaft while the timing chain is removed. It causes interference between valve and piston. NOTE: Chain tension holding work is not necessary. Crank sprocket and timing chain do not disconnect structurally while front cover is attached. Line up the mating marks on camshaft sprockets with the yellow links in the timing chain, and paint an indelible mating mark on the sprocket and timing chain link plate. Push in the tensioner plunger and hold. Insert a stopper pin into the hole on tensioner body to hold the chain tensioner. Remove the timing chain tensioner. Use a wire with 0.5 mm (0.02 in) diameter for a stopper pin. Secure the hexagonal part of camshaft with a suitable tool. Loosen the camshaft sprocket mounting bolts and remove the camshaft sprockets.
10. Loosen the camshaft bracket bolts in the order shown, and remove the camshaft brackets and camshafts. Remove No. 1 camshaft bracket by slightly tapping it with a rubber mallet.
11. Remove the valve lifters. Check mounting positions, and set them aside in the order removed.

Scheme 172

1. Put the camshaft on a V-block supporting the No. 2 and No. 5 journals.
2. Set the dial gauge vertically on the No. 3 journal.
3. Turn camshaft in one direction by hand, and measure the camshaft runout on the dial gauge total indicator reading. Standard :Less than 0.04 mm (0.0016 in)

Scheme 173

1. Measure the camshaft cam height. Standard intake cam height :45.665 - 45.855 mm (1.7978 - 1.8053 in) Standard exhaust cam height :43.975 - 44.165 mm (1.7313 - 1.7388 in)
2. If wear is beyond the limit, replace the camshaft.

Scheme 174

1. Measure the outer diameter of the camshaft journal. Standard No. 1 outer diameter : 27.935 - 27.955 mm (1.0998 - 1.1006 in) Standard No. 2, 3, 4, 5, outer diameter : 23.435 - 23.455 mm (0.9226 - 0.9234 in)

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Scheme 176

1. Tighten the camshaft bracket bolts to the specified torque following the tightening pattern as shown. Refer to Step 4 of, "INSTALLATION", of "CAMSHAFT" for the specified torque sequence.
2. Using inside micrometer, measure inner diameter of camshaft bracket. Standard No. 1 : 28.000 - 28.021 mm (1.1024 - 1.1032 in) Standard No. 2, 3, 4, 5 : 23.500 - 23.521 mm (0.9252 - 0.9260 in)

Calculation of Camshaft Journal Clearance

1. (Journal clearance) = (inner diameter of camshaft bracket) - (outer diameter of camshaft journal) Standard :0.045 - 0.086 mm (0.0018 - 0.0034 in)
2. When out of the specified range above, replace either or both the camshaft and the cylinder head assembly. NOTE: Inner diameter of the camshaft bracket is manufactured together with the cylinder head. If the camshaft bracket is out of specification, replace the whole cylinder head assembly.

Scheme 177

1. Install a dial gauge in the thrust direction on the front end of the camshaft. Measure the end play with the dial gauge while moving the camshaft forward and backward (in direction to axis). Standard end play :0.115 - 0.188 mm (0.0045 - 0.0074 in)
2. If out of the specified range, replace with new camshaft and measure again.
3. If out of the specified range again, replace with new cylinder head assembly.

Scheme 178

1. Install the camshaft in the cylinder head.
2. Install the camshaft sprocket on the camshaft.
3. Measure camshaft sprocket runout while turning the camshaft by hand. Runout :Less than 0.15 mm (0.0059 in)
4. If it exceeds the specification, replace camshaft sprocket.

Scheme 179

1. Check if the surface of the valve lifter has any excessive wear or cracks, replace as necessary.

Scheme 180

1. Measure the outer diameter of the valve lifter. Valve lifter outer diameter :33.965 - 33.980 mm (1.3372 - 1.3378 in)
2. If out of the specified range, replace the valve lifter.

Scheme 181

1. Using inside micrometer, measure diameter of valve lifter hole of cylinder head. Standard :34.000 - 34.021 mm (1.3386 - 1.3394 in)
2. If out of the specified range, replace the cylinder head assembly.

Calculation of Valve Lifter Clearance

1. (Valve lifter clearance) = (hole diameter for valve lifter) - (outer diameter of valve lifter) Standard :0.020 - 0.056 mm (0.0008 - 0.0022 in)
2. If out of specified range, replace either or both valve lifter and cylinder head assembly.

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1. Install the valve lifter. Install them in the same position from which they were removed.
2. Install the camshafts. The distinction between the intake and exhaust camshafts is in a difference of shapes of the back end: Intake: Signal plate for the camshaft position sensor (PHASE) Exhaust: Cone end shape Install camshafts so that the dowel pins on the front side are positioned as shown.
3. Install camshaft brackets. Install by referring to identification mark on upper surface mark. Install so that identification mark can be correctly read when viewed from the exhaust side. Install No. 1 camshaft bracket as follows. Apply sealant to No. 1 camshaft bracket as shown. Use Genuine RTV Silicone Sealant, or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS . CAUTION: After installation, be sure to wipe off any excessive sealant leaking from part "A" (both on right and left sides). Apply sealant to camshaft bracket contact surface on the front cover backside. Apply sealant to the outside of bolt hole on front cover. Position the No. 1 camshaft bracket near the mounting position, and install it without disturbing the sealant applied to the surfaces.
4. Tighten fixing bolts of camshaft brackets as follows. Tighten in the order from 9 to 11 with tightening torque 2.0 N.m (0.2 kg-m, 17 in-lb). Tighten in the order from 1 to 8 with tightening torque 2.0 N.m (0.2 kg-m, 17 in-lb). Tighten all bolts in specified order with tightening torque 5.9 N.m (0.6 kg-m, 52 in-lb). Tighten in the order from 1 to 11 with tightening torque 9.0 to 11.8 N.m (0.92 to 1.2 kg-m, 80 to 104 in-lb). CAUTION: After tightening fixing bolts of camshaft brackets, be sure to wipe off excessive sealant from the parts listed below. Mating surface of rocker cover. Mating surface of front cover, when installed without the front cover.
5. Install camshaft sprockets. Install them by lining up the mating marks on each camshaft sprocket with the ones painted on the timing chain during removal. Before installation of chain tensioner, it is possible to re-match the marks on timing chain with the ones on each sprocket. CAUTION: Aligned mating marks could slip. Therefore, after matching them, hold the timing chain in place by hand. Before and after installing chain tensioner, check again to make sure that mating marks have not slipped.
6. Install chain tensioner. CAUTION: After installation, pull the stopper pin off completely, and make sure that the tensioner is fully released.
7. Install chain guide.
8. Install IVTC (intake valve timing control) cover with the following procedure. Install IVTC solenoid valve to intake valve timing control cover. Install O-ring to front cover side. Apply Genuine RTV Silicone Sealant to the positions shown in the figure. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS . Install IVTC cover. Tighten the bolts in the numerical order as shown.
9. Check and adjust valve clearances. Refer to «VALVE CLEARANCE»(ref-159291-S12945120872005042600000) .
10. For the following operations, perform steps in the reverse order of removal.

Timing Chain

Check the timing chain for cracks or serious wear. If a defect is detected, replace it.

Scheme 192

1. Measure outer diameters (d1, d2) at the two positions shown in the figure.
2. Measure d2 within the range A.
3. If the valve difference (d1 - d2) exceeds the limit (a dimension difference is large), replace it with a new one. Limit :0.15 mm (0.0059 in) or more

Valve Dimensions

Check dimensions of each valve. Refer to VALVE .

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Valve Guide Clearance

Perform this inspection before removing the valve guide.

Scheme 194

1. Make sure that the valve stem diameter is within the specification.
2. Push the valve out by approximately 15 mm (0.59 in) toward the combustion chamber side to measure the valve's runout volume (in the direction of dial gauge) with dial gauge.
3. Half of the runout volume accounts for the valve guide clearance. Intake runout :0.020 - 0.053 mm (0.0008 - 0.0021 in) or less Exhaust runout :0.030 - 0.063 mm (0.0012 - 0.0025 in) or less

Valve Seat Contact

After confirming that the dimensions of valve guides and valves are within specifications, perform this procedure

Scheme 195

1. Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve contact on the seat surface.
2. Check if the contact area band is continuous all around the circumference.
3. If not, grind to adjust valve fitting and check again. If the contacting surface still has N.G. conditions even after the re-check, replace the valve seat.

Valve Spring Squareness

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

1. Limit : 1.9 mm (0.0748 in)

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Valve Spring Dimensions And Valve Spring Pressure Load

Check valve spring pressure with valve spring seat installed at specified spring height. Replace if not within specifications.

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1. Release fuel pressure. Refer to «FUEL PRESSURE RELEASE»(ref-135504-S01957061042002022200000) .
2. Disconnect the fuel rail at the fuel hose quick connector (engine side). Refer to «INTAKE MANIFOLD»(ref-159291-S18472004342005042600000) .
3. Drain the engine oil.
4. Drain the engine coolant.
5. Remove the engine hood assembly.
6. Remove the battery, battery hold downs, and battery tray
7. Disconnect the MAF sensor electrical connector.
8. Remove the air duct and air cleaner case assembly. Refer to «REMOVAL AND INSTALLATION»(ref-159291-S42638134952005042600000) .
9. Disconnect the heater hoses.
10. Remove the radiator and radiator fan assembly. Refer to Removal and Installation .
11. Remove the alternator. Refer to «REMOVAL»(ref-209053-S30441832652005120700000) .
12. Remove the left and right drive shafts. Refer to «REMOVAL AND INSTALLATION»(ref-214677-S37977583402006010500000) .
13. Remove the engine under covers and splash shield, using power tool.
14. Dismount the A/C compressor with piping connected and secure with wire to the radiator support.
15. Disconnect the following engine compartment electrical harness connectors: Heated oxygen sensors Starter assembly Coolant temperature sensor Camshaft position sensor (PHASE) EVAP canister purge volume control solenoid Backup lamp switch Vehicle speed sensor Electric throttle control actuator Ignition coils Fuel injector harness Engine ground straps Intake valve timing control solenoid Brake booster vacuum hose Transaxle sensors (A/T only) Transaxle shift cables Crankshaft position sensor (POS) Knock sensor. Oil pressure switch Swirl control valve Power steering pressure switch
16. Remove clutch operating cylinder from transaxle, and move it aside (M/T models).
17. Remove engine coolant reservoir tank.
18. Remove front exhaust tube. Refer to Removal and Installation .
19. Dismount the power steering pump with piping connected and position it aside with wire.
20. Install engine slingers into front left cylinder head and rear right cylinder head. Use alternator bracket mounting bolt holes for the front slinger. Use the proper slingers and bolts as described in the Parts Catalog. Slinger bolts - front : 51.0 - 64.7 N.m (5.2 - 6.5 kg-m, 38 - 47 ft-lb) Slinger bolts - rear : 24.5 - 31.4 N.m (2.5 - 3.2 kg-m, 18 - 23 ft-lb)
21. Support engine and transaxle assembly with engine lifting equipment from the top and a suitable platform jack under the front suspension member with the vehicle raised on a hoist.
22. Remove RH engine mounting insulator.
23. Remove front and rear engine mounting insulator through-bolt.
24. Remove LH transaxle mounting insulator through-bolts.
25. Lower the front suspension member with the engine and transaxle assembly from the engine compartment on the platform jack, steady it safely with the lifting equipment.
26. Remove the starter motor. Refer to «REMOVAL & INSTALLATION»(ref-152835-S01317063512003030300000) .
27. Separate engine and transaxle.

When a Cylinder Block is Reused

1. Measure the cylinder block bore inner diameter.
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner diameter of the "Piston Selection Table". Select the piston of the same grade.

Scheme 201

Note. The piston is available together with piston pin as an assembly. The piston pin (piston pin bore) grade is provided only for the parts installed at the plant. For service parts, no grades can be selected. Only 0 grade is available.

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Scheme 203

1. Apply big end inside diameter grade stamped on connecting rod side face to the row in the «CONNECTING ROD BEARING SELECTION TABLE»(ref-159291-S00711714522005042600000) .
2. Apply pin diameter grade stamped on crankshaft front side to the column in the «CONNECTING ROD BEARING SELECTION TABLE»(ref-159291-S00711714522005042600000) .
3. Read the symbol at the cross point of selected row and column in the «CONNECTING ROD BEARING SELECTION TABLE»(ref-159291-S00711714522005042600000) .
4. Apply the symbol obtained to connecting rod bearing grade table to select.

When Crankshaft and Connecting Rod are Reused

1. Measure dimensions of the big end inner diameter of connecting rod and outer diameter of crankshaft pin individually.
2. Apply the dimension measured to the "Connecting Rod Bearing Selection Table" below.

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Undersize Bearing Usage Guide

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

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When New Cylinder Block and Crankshaft are Used

1. "Main Bearing Selection Table" rows correspond to bearing housing grade on rear left side of cylinder block. If there is a corrected stamp mark on the cylinder block, use it as a correct reference.
2. Apply journal diameter grade stamped on crankshaft front side to column in "Main Bearing Selection Table".
3. Find value at crossing of row and column in "Main Bearing Selection Table". CAUTION: There are two main bearing selection tables. One is for odd-numbered journals (1, 3, and 5) and the other is for even-numbered journals (2 and 4). Make certain to use the appropriate table. This is due to differences in the specified clearances.
4. Apply the symbol obtained to "Main Bearing Grade Table" to select. NOTE: Service parts are available as a set of both upper and lower.

When Cylinder Block and Crankshaft are Reused

1. Measure inner diameter of cylinder block main bearing housing and outer diameter of crankshaft journal.
2. Apply measurement in above step 1 to the "Main Bearing Selection Table".
3. Follow steps 3 and 4 in "When New Cylinder Block and Crankshaft are Used".

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Use Undersize Bearing Usage Guide

1. Use undersize (U.S.) bearing when oil clearance with standard size main bearing is not within specification.
2. When using undersize (U.S.) bearing, measure the bearing inner diameter with the bearing installed and grind journal until oil clearance falls within specification.

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1. Using a dial gauge, measure the clearance between the thrust bearings and the crankshaft arm when the crankshaft is moved fully forward or backward. Standard : 0.10 - 0.26 mm (0.0039 - 0.0102 in) Limit : 0.30 mm (0.0118 in)
2. If the measured value exceeds the limit, replace the thrust bearings, and measure again. If it still exceeds the limit, replace the crankshaft.

Scheme 215

1. Measure side clearance between connecting rod and crankshaft arm with feeler gauge. Standard : 0.20 - 0.35 mm (0.0079 - 0.0138 in) Limit : 0.50 mm (0.0197 in)
2. If the measured value exceeds the limit, replace the connecting rod bearings, and measure again. If it still exceeds the limit, replace the crankshaft also.

Scheme 216

1. Measure the inner diameter of piston pin bore with an inside micrometer. Standard : 19.993 - 20.005 mm (0.7871 - 0.7876 in)

Scheme 217

1. Measure outer diameter of piston pin with a micrometer. Standard : 19.989 - 20.001 mm (0.7870 - 0.7874 in)

Piston And Piston Pin Clearance

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

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

1. If clearance exceeds specification, replace either or both of piston/piston pin assembly and connecting rod assembly with reference to specification of each parts.
2. Refer to piston selection table to replace piston/piston pin assembly. Refer to «HOW TO SELECT A PISTON»(ref-159291-S40260816282005042600000) .
3. Refer to connecting rod bearing selection table to replace connecting rod. Refer to «HOW TO SELECT A CONNECTING ROD BEARING»(ref-159291-S21239871772005042600000) .

Note. The connecting rod small end grade and piston pin hole (piston pin) grade are provided only for the parts installed at the plant. For service parts, no grades can be selected. Only 0 grade is available. Refer to CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END) for the values for each grade at the plant. Regarding marks on piston head, Refer to HOW TO SELECT A PISTON .

Scheme 218

1. Measure side clearance of piston ring and piston ring groove with feeler gauge. Standard Top ring : 0.045 - 0.080 mm (0.0018 - 0.0031 in) 2nd ring : 0.030 - 0.070 mm (0.0012 - 0.0028 in) Oil ring : 0.065 - 0.135 mm (0.0026 - 0.0053 in) Limit Top ring : 0.11 mm (0.0043 in) 2nd ring : 0.10 mm (0.0039 in)
2. If out of specification, replace piston and/or piston ring assembly.

Scheme 219

1. Check if inner diameter of cylinder bore is within specification. Refer to «PISTON TO CYLINDER BORE CLEARANCE»(ref-159291-S40452111102005042600000) .
2. Insert piston ring until middle of cylinder with piston, and measure gap. Standard Top ring : 0.21 - 0.31 mm (0.0083 - 0.0122 in) 2nd ring : 0.32 - 0.47 mm (0.0126 - 0.0185 in) Oil ring : 0.20 - 0.60 mm (0.0079 - 0.0236 in) Limit Top ring : 0.54 mm (0.0213 in) 2nd ring : 0.67 mm (0.0264 in) Oil ring : 0.95 mm (0.0374 in)
3. If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylinder and use oversized piston and piston ring.

Scheme 220

Scheme 221

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 222

1. Install the connecting rod cap without the connecting rod bearing installed. After tightening the connecting rod bolt to the specified torque, measure the connecting rod big end inner diameter using an inside micrometer. Standard : 48.000 - 48.013 mm (1.8898 - 1.8903 in)

Scheme 223

1. Measure inner diameter of bushing. Standard : 20.000 - 20.012 mm (0.7874 - 0.7879 in)

Scheme 224

1. Measure outer diameter of piston pin. Standard : 19.989 - 20.001 mm (0.7870 - 0.7874 in)

Connecting Rod Bushing Oil Clearance (Small End)

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

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

1. If the measured value exceeds the standard, replace the connecting rod assembly and/or piston and piston pin assembly.
2. If replacing the piston and piston pin assembly, refer to the "Piston Selection Table" to select the piston corresponding to the applicable bore grade of the cylinder block to be used. Refer to «HOW TO SELECT A PISTON»(ref-159291-S40260816282005042600000) .

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1. Service parts apply only to grade 0.

Scheme 227

1. Using a scraper, remove gasket on the cylinder block surface, and also remove oil, scale, carbon, or other contamination. CAUTION: Be careful not to allow gasket debris to enter the oil or coolant passages.
2. Measure the distortion on the block upper face at some different points in 6 directions. Limit : 0.1 mm (0.004 in)
3. If out of the distortion limit, replace the cylinder block.

Scheme 228

1. Install the main bearing caps with the main bearings removed and tighten the mounting bolts to the specified torque. Refer to «ASSEMBLY»(ref-159291-S06363167902005042600000) .
2. Using a bore gauge, measure the inner diameter of the main bearing housing. Standard : 58.944 - 58.967 mm (2.3206 - 2.3215 in)
3. If out of the standard, replace the cylinder block and lower cylinder block assembly. NOTE: These components cannot be replaced as a single unit because they were processed together.

Scheme 229

1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper at 6 different points on each cylinder. (X and Y directions at A, B and C). The Y axis is in the longitudinal direction of the engine. NOTE: When determining cylinder bore grade, measure cylinder bore at B position. Standard inner diameter: 89.000 - 89.030 mm (3.5039 - 3.5051 in) Wear limit: 0.2 mm (0.008 in) Out-of-round (difference between X - Y): 0.015 mm (0.0006 in) Taper limit (difference between C - A): 0.01 mm (0.0004 in)
2. If the measured value rebore exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, hone the inner wall.
3. An oversize piston is provided. When using an oversize piston, rebore the cylinder so that the clearance of the piston cylinder satisfies the standard. Over size (OS) : 0.2 mm (0.008 in)

Scheme 230

1. Measure piston skirt diameter. Standard : 88.980 - 89.010 mm (3.5031 - 3.5043 in)
2. Measure point (distance from the top): 42 mm (1.65 in)

Piston to Cylinder Bore Clearance

1. Calculate by outer diameter of piston skirt and inner diameter of cylinder (direction X, position B). (Clearance) = (Inner diameter of cylinder) - (Outer diameter of piston skirt). Standard : 0.010 - 0.030 mm (0.0004 - 0.0012 in) Limit : 0.08 mm (0.0031 in)
2. If it exceeds the limit, replace piston/piston pin assembly.

Reboring Cylinder Bore

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

Outer Diameter Of Crankshaft Journal

1. Measure outer diameter of crankshaft journals. Standard : 54.955 - 54.979 mm (2.1636 - 2.1645 in)

Scheme 231

1. Measure outer diameter of crankshaft pin. Standard : 44.956 - 44.974 mm (1.7699 - 1.7706 in)

Scheme 232

1. Using a micrometer, measure the dimensions at four different points shown in the figure on each journal and pin.
2. Out-of-round is indicated by the difference in dimensions between "X" and "Y" at "A" and "B".
3. Taper is indicated by the difference in dimension between "A" and "B" at "X" and "Y". Limit Out-of-round (X-Y) : 0.005 mm (0.0002 in) Taper (A - B) : 0.005 mm (0.0002 in)

Scheme 233

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

Scheme 234

1. Install the connecting rod bearings to the connecting rod and the cap, and tighten the connecting rod bolts to the specified torque. Using a inside micrometer measure the inner diameter of connecting rod bearing. (Oil clearance) = (Inner diameter of connecting rod bearing) - (Outer diameter of crankshaft pin) Standard : 0.028 - 0.045 mm (0.0011 - 0.0018 in) Limit : 0.10 mm (0.0039 in)
2. If clearance cannot be adjusted within the standard, grind crankshaft pin and use undersized bearing. Refer to «HOW TO SELECT A CONNECTING ROD BEARING»(ref-159291-S21239871772005042600000) .

Scheme 235

1. Remove oil and dust on the crankshaft pin and the surfaces of each bearing completely.
2. Cut the Plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
3. Install the connecting rod bearings to the connecting rod cap, and tighten the connecting rod bolts to the specified torque. CAUTION: Never rotate the crankshaft.
4. Remove the connecting rod cap and bearings, and using the scale on the Plastigage bag, measure the Plastigage width. NOTE: The procedure when the measured value exceeds the limit is same as that described in the method by calculation.

Method of Measurement

1. Install the main bearings to the cylinder block and bearing cap. Measure the main bearing inner diameter with the bearing cap bolt tightened to the specified torque. (Oil clearance) = (Inner diameter of main bearing) - (Outer diameter of crankshaft journal) Standard: No. 1, 3, and 5 journals : 0.012 - 0.022 mm (0.0005 - 0.0009 in) No. 2 and 4 journals : 0.018 - 0.028 mm (0.0007 - 0.0011 in) Limit : 0.1 mm (0.004 in)
2. If the measured value exceeds the limit, select main bearings referring to the main bearing inner diameter and crankshaft journal outer diameter, so that the oil clearance satisfies the standard. Refer to «HOW TO SELECT A MAIN BEARING»(ref-159291-S26142363712005042600000) .

Method of Using Plastigage

1. Remove oil and dust on the crankshaft journal and the surfaces of each bearing completely.
2. Cut the Plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
3. Tighten the main bearing bolts to the specified torque. CAUTION: Never rotate the crankshaft.
4. Remove the bearing cap and bearings, and using the scale on the plastigage bag, measure the plastigage width. (Scheme 240) NOTE: The procedure when the measured value exceeds the limit is same as that described in the "Method by Calculation".

Scheme 236

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

Scheme 237

1. Perform only with M10 (0.39 in) bolts.
2. Measure outer diameters (d1, d2) at two positions as shown.
3. Measure d2 at a point within block A.
4. When the value of d1-d2 exceeds the limit (a large difference in dimensions), replace the bolt with a new one. Limit : 0.13 mm (0.0051 in) or more

Scheme 238

1. Measure outer diameter (d) at position shown in the figure.
2. When "d" exceeds the limit (when it becomes thinner), replace the bolt with a new one. Limit : 7.75 mm (0.3051 in) or less

Movement Amount Of Flywheel (M/T Model)

Note. Inspection for double mass flywheel only. Do not disassemble double mass flywheel.

Scheme 239

1. Measure deflection of flywheel contact surface to the clutch with a dial gauge.
2. Measure deflection at 210 mm (8.27 in) dia. Standard : 0.45 mm (0.0177 in) or less Limit : 1.3 mm (0.051 in) or less
3. When measured value exceeds the limit, replace the flywheel with a new one.

Movement Amount in Radial (Rotation) Direction

1. Check the movement amount in the following procedure.

Scheme 240

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 to keep it from loosening at a force of 9.8 N.m (1 kg-m, 87 in-lb).
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 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 the flywheel on the transmission side. Standard : 28.3 mm (1.114 in) or less When measured value is outside the standard, replace flywheel.