Engine Mechanical - 3.5L: 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 disassembly.
3. After disconnecting pipes, plug openings to stop fuel leakage.

SPECIAL SERVICE TOOLS

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

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1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source. Repair or replace the identified part as necessary.

Scheme 425

1. Inspect belt for cracks, fraying, wear or oil adhesion. If necessary, replace with a new one.
2. Inspect drive belt deflections by pushing on the belt midway between pulleys as shown.
3. Rotate the crankshaft pulley two times then check the belt tension using the Tool. NOTE: Inspect drive belt deflection or tension when engine is cold. Adjust if belt deflections exceed the limit or if belt tension is not within specifications.

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Changing Air Cleaner Element

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

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Surface Distortion

1. Use a reliable straightedge and feeler gauge to check the flatness of the exhaust manifold mating surfaces. Distortion limit: 0.3 mm (0.012 in)

Check on Fuel Leakage

1. Start the engine, and run it for a few minutes with the engine at idle.
2. Stop the engine, and check for fuel leakage both visually and by door.

Note. Use mirrors for checking at points out of clear sight.

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Scheme 430

1. Remove the engine cover, using power tool.
2. Drain engine coolant. Refer to «CHANGING ENGINE COOLANT»(ref-183495-S21164635392005081400000) .
3. Disconnect the mass air flow sensor electrical connector and remove the air cleaner assembly and air intake tubes. Refer to «Removal and Installation»(ref-163530-S39534864752005050200000) .
4. Remove the windshield wiper arms and motor assembly and the front cowl panel. Refer to «WIPER MOTOR & LINKAGE»(ref-153096-S35040121102003031400000) .
5. Remove the intake manifold collector using power tool. Remove gasket and the electric throttle control actuator. Refer to «Removal and Installation»(ref-163530-S37214515072005050200000) .
6. Remove the six ignition coils. Refer to «Removal and Installation»(ref-163530-S21908219952005050200000) .
7. Remove the two intake valve timing control solenoid valves and gaskets.
8. Remove RH and LH rocker covers from cylinder head. Follow the loosening sequence for each side rocker cover bolts as shown.

Scheme 431

1. Installation is in the reverse order of removal. Apply sealant to the areas on the front corners. Refer to «POSITION FOR APPLYING LIQUID GASKET»(ref-163530-S13436444312005050200000) . Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-177331-S04337218152005052600000) . Tighten the rocker cover bolts in two stages and in the numerical order as shown. Stage 1 rocker cover bolts: 0.96 - 2.96 N.m (0.10 - 0.30 kg-m, 9 - 26 in-lb) Stage 2 rocker cover bolts: 7.33 - 9.33 N.m (0.75 - 0.95 kg-m, 65 - 82 in-lb)

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1. Remove the timing chains. Refer to «Removal»(ref-163530-S34037374582005050200000) .
2. Remove the fuel rail and injectors. Refer to «Removal and Installation»(ref-163530-S21666907452005050200000) .
3. Remove the IVTC (intake valve timing control) solenoid valves. Discard the IVTC solenoid valve gaskets and use new gaskets for installation.
4. Remove the intake and exhaust camshaft brackets and the camshafts. Mark the camshafts, camshaft brackets, and bolts so they are placed in the same position and direction for installation. Equally loosen the camshaft bracket bolts in several steps in the numerical order shown.

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1. Before installation, remove any old RTV Silicone Sealant from component mating surfaces using a scraper. Remove the old RTV Silicone Sealant from the bolt holes and threads. Do not scratch or damage the mating surfaces.
2. Before installing the front cam bracket, remove the old RTV Silicone Sealant from the mating surface using a scraper. Do not scratch or damage the mating surface.
3. Turn the crankshaft until No. 1 piston is set at TDC on the compression stroke. The crankshaft key should line up with the right bank cylinder center line as shown.
4. Install camshaft chain tensioners on both sides of cylinder head. Camshaft chain tensioner bolts: 7 - 10 N.m (0.7 - 1.0 kg-m, 62 - 89 in-lb)
5. Install exhaust and intake camshafts and camshaft brackets. Intake camshaft has a drill mark on camshaft sprocket mounting flange. Follow your identification marks made during removal, or follow the identification marks that are present on the new camshafts components for proper placement and direction of the components. Position the camshafts: RH exhaust camshaft dowel pin at about 10 o'clock. LH exhaust camshaft dowel pin at about 2 o'clock.
6. Before installing camshaft brackets, apply sealant to mating surface of No. 1 camshaft bracket. Use Genuine RTV Silicone Sealant, or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-177331-S04337218152005052600000) . Before installation, wipe off any protruding sealant. Refer to «LIQUID GASKET APPLICATION PROCEDURE»(ref-163530-S13956263772005050200000) . Install camshaft brackets in their original positions and direction. Align the stamp marks as shown. If checking and adjusting any part of valve assembly or camshaft, check valve clearance according to the reference data. Refer to «Valve Clearance»(ref-163530-S18021023242005050200000) . Valve clearance (cold) Intake: 0.26 - 0.34 mm (0.010 - 0.013 in) Valve clearance (cold) Exhaust: 0.29 - 0.37 mm (0.011 - 0.015 in) Lubricate the threads and seat surfaces of the camshaft bracket bolts with new engine oil before installation. Tighten the camshaft brackets in the following steps, in numerical order as shown.
7. Install the IVTC solenoid valves with new gaskets. IVTC solenoid valve bolts: 10 - 12 N.m (1.0 - 1.3 kg-m, 87 - 112 in-lb)
8. Install the fuel rail and injectors. Refer to «Removal and Installation»(ref-163530-S21666907452005050200000) .
9. Install the timing chains. Refer to «Installation»(ref-163530-S38848944172005050200000) .

Camshaft Visual Check

Check camshaft for scratches, seizure and wear. Replace if necessary.

Scheme 450

1. Measure the camshaft runout at "A" and "B" as shown.
2. Set dial gauges vertically as shown.
3. Turn camshaft in one direction slowly by hand, measure the camshaft runout on the dial gauges. Runout is the largest indicator reading after one full revolution. Maximum runout limit: 0.05 mm (0.0020 in)
4. If actual runout exceeds the limit, replace the camshaft.

Scheme 451

1. Measure camshaft cam lobe height as shown. Standard cam lobe height - intake and exhaust: 44.865 - 44.055 mm (1.7763 - 1.7738 in) Cam lobe wear limit: 0.2 mm (0.008 in)
2. If wear has reduced the lobe height below specifications, replace the camshaft.

Scheme 452

1. Measure outer diameter of camshaft journal as shown. Standard outer diameter, No. 1: 25.935 - 25.955 mm (1.0211 - 1.0218 in) Standard outer diameter, No. 2, 3, 4: 23.455 - 23.465 mm (0.9230 - 0.9238 in)

Scheme 453

1. Tighten camshaft bracket bolt with specified torque.
2. Using inside micrometer, measure inner diameter "A" of camshaft bearing. Standard inner diameter No. 1: 26.000 - 26.021 mm (1.0236 - 1.0244 in) Standard inner diameter No. 2, 3, 4: 23.500 - 23.521 mm (0.9252 - 0.9260 in)

Calculation of Camshaft Journal Clearance

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

1. Standard No. 1: 0.045 - 0.086 mm (0.0018 - 0.0034 in)
2. Standard No. 2, 3, 4: 0.035 - 0.076 mm (0.0014 - 0.0030 in)
3. Limit: 0.15 mm (0.0059 in)

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

Scheme 454

1. Install the camshaft in the cylinder head.
2. Install dial gauge in thrust direction on front end of camshaft. Measure end play when camshaft is moved forward/backward (in direction to axis) as shown. Standard: 0.115 - 0.188 mm (0.0045 - 0.0074 in) Limit: 0.24 mm (0.0094 in) If out of the specified range, replace with new camshaft and measure again. If out of the specified range again, replace with new cylinder head.

Scheme 455

1. Install camshaft sprocket on camshaft.
2. Measure camshaft sprocket runout. Runout: Less than 0.15 mm (0.0059 in)
3. If sprocket runout exceeds the limit, replace camshaft sprocket.

Checking

Check valve clearance while engine is cold and not running.

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1. Remove the air duct with air cleaner case, collectors, hoses, wires, harnesses, and connectors.
2. Remove the intake manifold collectors.
3. Remove the ignition coils and spark plugs.
4. Remove the rocker covers.
5. Set No. 1 cylinder at TDC on its compression stroke. Align pointer with TDC mark on crankshaft pulley. Check that the valve lifters on No. 1 cylinder are loose and valve lifters on No. 4 are tight. If not, turn the crankshaft one full revolution (360°) and align as above.
6. Check only the valves as shown. Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Record any valve clearance measurements which are out of specification. They will be used later to determine the required replacement lifter size. Valve Clearance for Checking (cold) Intake: 0.26-0.34 mm (0.010-0.013 in) Exhaust: 0.29-0.37 mm (0.011-0.015 in)
7. Turn crankshaft 240° and align as above.
8. Set No. 3 cylinder at TDC on its compression stroke.
9. Check only those valves as shown.
10. Turn the crankshaft 240° and align as above.
11. Set No. 5 cylinder at TDC on its compression stroke.
12. Check only those valves as shown.
13. If all valve clearances are within specification, install the following components. If the valve clearances are out of specification, adjust the valve clearances. Intake manifold collectors Rocker covers All spark plugs All ignition coils

Adjusting

Adjust valve clearance while engine is cold.

Perform adjustment by selecting the correct head thickness of the valve lifter (adjusting shims are not used).

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1. Remove the camshaft.
2. Remove the valve lifter that was measured as being outside the standard specifications.
3. Measure the center thickness of the removed lifter with a micrometer, as shown.
4. Use the equation below to calculate the replacement valve lifter thickness. Valve lifter thickness calculation equation: t=t1+(C1-C2) t=thickness of the replacement lifter t1=thickness of the removed lifter C1=measured valve clearance C2=standard valve clearance The thickness of the new valve lifter can be identified by the stamp mark on the reverse side (inside the lifter). Available thickness of the valve lifter (factory setting): 7.88 - 8.36 mm (0.3102 - 0.3291 in), in 0.02 mm (0.0008 in) increments, in 25 sizes (intake / exhaust). Value lifter thickness: Intake: 0.30 mm (0.012 in) Exhaust: 0.33 mm (0.013 in)
5. Install the selected replacement valve lifter.
6. Install the camshaft.
7. Rotate the crankshaft a few turns by hand.
8. Confirm that the valve clearances are within specification.
9. After the engine has been run to full operating temperature, confirm that the valve clearances are within specification.

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1. Refer to «Precautions for Liquid Gasket»(ref-163530-S34092382182005050200000) .
2. Before installation, wipe off any protruding sealant. CAUTION: After removing timing chain, do not turn the crankshaft and camshaft separately, or the valves will strike the pistons. When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil.
3. Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprockets, camshaft brackets, and crankshaft pulley.
4. Before disconnecting fuel hose, release fuel pressure. Refer to «FUEL PRESSURE RELEASE»(ref-135504-S01957061042002022200000) .
5. Before removing the upper oil pan, remove the crankshaft position sensor (POS).
6. Be careful not to damage sensor edges.
7. Do not spill engine oil or coolant on drive belts.

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1. Release the fuel pressure. Refer to «FUEL PRESSURE RELEASE»(ref-135504-S01957061042002022200000) .
2. Remove the battery.
3. Drain the engine cooling system. Refer to «CHANGING ENGINE COOLANT»(ref-183495-S21164635392005081400000) .
4. Drain engine oil. Refer to «CHANGING ENGINE OIL»(ref-183494-S02145343722005081400000) .
5. Remove engine cover with power tool.
6. Remove the intake air duct with the air cleaner case lid and mass air flow sensor.
7. Remove the engine coolant reservoir.
8. Disconnect the fuel rail quick connector at the vehicle piping side. Refer to «REMOVAL AND INSTALLATION»(ref-163530-S21666907452005050200000) .
9. Remove the cowl top grille and the windshield wiper assembly.
10. Remove the front RH wheel and tire with power tool.
11. Remove the engine undercovers with power tool.
12. Remove the inner fender splash shield with power tool.
13. Remove the drive belts and idler pulley.
14. Recover the A/C system R134a and remove the A/C compressor. Refer to «MANUAL AIR CONDITIONER»(ref-206581) .
15. Dismount the power steering oil pump and reservoir tank. Tie them down with wire to reposition them out of the way.
16. Remove the lower and upper oil pans. Refer to «REMOVAL AND INSTALLATION»(ref-163530-S34252391802005050200000) .
17. Remove the A/C high pressure line. Refer to «MANUAL AIR CONDITIONER»(ref-206581) article .
18. Remove the alternator. Refer to «VG35DE»(ref-209053-S23276315512005120700000) .
19. Disconnect the engine harness and set aside.
20. Support the engine and remove the RH engine mount and bracket.
21. Remove the IVTC valve covers, bank 1 and bank 2. Loosen the bolts in the numerical order as shown. NOTE: The shaft in the cover is inserted into the center hole of the intake camshaft sprocket. Remove the cover by pulling straight out until the cover disengages from the camshaft sprocket.
22. Remove the starter motor. Refer to «REMOVAL & INSTALLATION»(ref-152835-S38871372672003022800000) .
23. Set the ring gear stopper using the mounting bolt hole. CAUTION: Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear, when setting the stopper.
24. Remove the crankshaft pulley.
25. Remove the front timing chain case. Loosen the bolts in the numerical order as shown. Insert the appropriate size tool into the notch at the top of the front timing chain case as shown (1). Pry off the case by moving the tool as shown (2).
26. Disconnect the power brake booster vacuum hose.
27. Disconnect the electric throttle control actuator.
28. Disconnect the coolant hoses at the electric throttle control actuator.
29. Disconnect the PCV hose.
30. Disconnect the EVAP canister purge volume control solenoid vacuum hose.
31. Remove the intake manifold collector. Loosen the bolts and nuts in the numerical order as shown.
32. Remove the six ignition coils.
33. Remove the six spark plugs.
34. Remove the engine oil dipstick.
35. Remove the IVTC (intake valve timing control) solenoid valve bank 1 and bank 2. Discard the gaskets and use new gaskets for installation.
36. Remove the rocker covers. Loosen the bolts in the numerical order as shown.
37. Remove the internal chain guide.
38. Remove the timing chain tensioner and slack side chain guide. Place paint marks on the timing chain and sprockets to indicate the position of the components for installation. Pull lever down and release plunger stopper tab. Plunger stopper tab can be pushed up to release (coaxial structure with lever). Insert stopper pin into tensioner body hole to hold lever, and keep the tab released. An Allen wrench [2.5 mm (0.098 in)] is used for a stopper pin as an example. Insert plunger into tensioner body by pressing the slack side chain guide. Keep the slack side chain guide pressed and hold it by pushing the stopper pin through the lever hole and body hole. Remove the mounting bolts and remove the timing chain tensioner.
39. Attach a suitable stopper pin to the RH and LH camshaft chain tensioners (for secondary timing chains).
40. Remove the intake and exhaust camshaft sprocket bolts. Apply paint to the timing chain and camshaft sprockets for alignment during installation. Secure the hexagonal portion of the camshaft using a wrench to loosen the mounting bolts.
41. Remove the primary and secondary timing chains with camshaft sprockets. Intake camshaft sprocket is two-for-one structure of primary and secondary sprockets. Handle the intake sprockets as an assembly. CAUTION: Avoid impact or dropping the intake sprockets. Do not disassemble the intake sprockets (never loosen bolts A and B as shown).
42. Remove the chain tension guide and crankshaft sprocket.
43. Remove the rear timing chain case. CAUTION: Do not remove the metal plate cover for the oil passage. After removing the chain case, do not apply any load to the case that might bend it. Loosen and remove the mounting bolts in the order shown. Cut the sealant with an appropriate tool and remove the rear timing chain case.
44. Use a scraper to remove all of the old RTV Silicone Sealant from the front timing chain case. CAUTION: Do not damage the mating surfaces.
45. Remove all old RTV Silicone Sealant from all the bolt holes and bolts. CAUTION: Do not damage the threads or mating surfaces.
46. Use a scraper to remove all the old RTV Silicone Sealant from the water pump cover and IVTC valve covers. CAUTION: Do not damage the mating surfaces.
47. Remove the front oil seal from the front timing chain case using a suitable tool. CAUTION: Do not damage the front cover.

Cylinder Head Distortion

Clean the surface of the cylinder head. Use a reliable straightedge and feeler gauge to check the flatness of cylinder head surface.

Check along six positions as shown.

1. Head surface flatness: Limit 0.1 mm (0.004 in)

If beyond the specified limit, resurface or replace it.

The limit for cylinder head resurfacing is determined by the cylinder block resurfacing.

1. Resurfacing Limit
2. Amount of cylinder head resurfacing is "A".
3. Amount of cylinder block resurfacing is "B".
4. The maximum limit: A + B = 0.2 mm (0.008 in)

Scheme 487

After resurfacing cylinder head, check that camshaft rotates freely by hand. If resistance is felt, cylinder head must be replaced.

1. Nominal cylinder head height: 126.3 - 126.5 mm (4.972 - 4.980 in)

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1. Measure valve deflection as shown in the figure. (Valve and valve guide mostly wear in this direction.) Valve deflection limit (dial gauge reading) Intake: 0.24 mm (0.0094 in) Exhaust: 0.28 mm (0.0110 in)
2. If it exceeds the limit, check valve to valve guide clearance. Measure valve stem diameter and valve guide inner diameter. Check that clearance is within specification. Valve to valve guide clearance limit Intake: 0.08 mm (0.0031 in) Exhaust: 0.1 mm (0.004 in) If it exceeds the limit, replace valve or valve guide.

Valve Spring Squareness

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

1. Out-of-square limit: Less than 2.0 mm (0.079 in)

Scheme 490

Valve Spring Dimensions And Valve Spring Pressure Load

Check valve spring pressure at specified spring height.

1. Standard: 196 N (20.0 kg, 44.1 lb) at height 37.0 mm (1.457 in)
2. Limit: More than 433 N (44.2 kg, 97.3 lb) at height 27.8 mm (1.094 in)

If it is not within specifications, replace the spring.

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1. Release fuel pressure. Refer to «FUEL PRESSURE RELEASE»(ref-135504-S01957061042002022200000) .
2. Remove the engine cover, and the engine undercover using power tool.
3. Drain coolant. Refer to «CHANGING ENGINE COOLANT»(ref-183495-S21164635392005081400000) .
4. Remove the following parts: Hood assembly Front tower bar using power tools Battery and tray using power tools Air inlet duct Air intake duct and air cleaner case assembly with mass air flow sensor Power brake booster vacuum hose Drive belts Radiator assembly, coolant reservoir, and system hoses Front cowl grille and windshield wiper assembly
5. Disconnect engine room harness from the engine side and set it aside.
6. Disconnect heater hoses.
7. Remove the front wheel and tires.
8. Remove the front drive shafts. Refer to «REMOVAL AND INSTALLATION»(ref-214677-S37977583402006010500000) .
9. Remove the A/C compressor using power tools. Discharge and recover the R134a refrigerant. Refer to «HFC-134A (R-134A) SERVICE PROCEDURE»(ref-206580-S14035544632005112500000) .
10. Disconnect fuel hose quick connection at vehicle piping side. Refer to «REMOVAL AND INSTALLATION»(ref-163530-S21666907452005050200000) .
11. Disconnect the transaxle shift controls.
12. Remove the starter motor. Refer to «REMOVAL & INSTALLATION»(ref-152835-S38871372672003022800000) .
13. Remove the front exhaust tube using power tools. Refer to «EXHAUST SYSTEM (VQ35DE)»(ref-183496-S33542195382005081400000) .
14. Disconnect reservoir tank for the power steering from engine compartment bracket and position it aside.
15. Remove the front suspension member. Disconnect the power steering line bracket. Remove the steering gear bolts. Disconnect the lower ball joints Refer to «TRANSVERSE LINK & BALL JOINT»(ref-165758-S13064975352004090300000) . Disconnect the upper sway bar connecting rod Refer to «STABILIZER BAR»(ref-165758-S42769306462004090300000) . Remove the LH and RH drive axles. Refer to «REMOVAL AND INSTALLATION»(ref-214677-S37977583402006010500000) .
16. Disconnect the power steering pump, without disconnecting the piping, from the engine and move it aside and secure with wire.
17. Position a suitable transmission jack under the engine and transaxle assembly.
18. Install engine slingers into front of left bank cylinder head and rear of right bank cylinder head.
19. For additional safety, secure the engine in position with a hoist.
20. Disconnect the LH transaxle mount and the RH engine mount.
21. Carefully lower the engine and transaxle assembly with the transmission jack, avoiding interference with the vehicle body. CAUTION: Before and during this procedure, always check if any harnesses are left connected. Avoid any damage to, or any oil/grease smearing or spills onto the engine mounting insulators.
22. Remove the crankshaft position sensor (POS).
23. Separate the engine and transaxle and mount the engine on a suitable engine stand.

Piston and Piston Pin Interference Fit

Standard Interference Fit = "Dp"-"dp"

1. Standard: [0.002 mm (0.0001 in)]-[0.006 mm (0.0002 in)] = [-0.0004 mm (-0.0001 in)]

1. If clearance is exceeds specification, replace either or both of piston/piston pin assembly and connecting rod assembly with reference to specification of each part.

Scheme 495

1. Measure side clearance of piston ring and piston ring groove with feeler gauge. Standard Side Clearance 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) Maximum Limit Top ring: 0.11 mm (0.0043 in) 2nd ring: 0.1 mm (0.004 in)
2. If out of specification, replace piston ring assembly. If clearance exceeds maximum limit with new rings, replace piston

Scheme 496

1. Insert piston ring until it is in the middle of the cylinder bore and measure the end gap. 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: 0.20-0.80 mm (0.0079-0.0315 in) Limit: Top ring: 0.54 mm (0.0213 in) 2nd ring: 0.80 mm (0.0315 in) Oil ring: 0.50 mm (0.0197 in)
2. 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 497

1. Bend: Limit 0.15 mm (0.0059 in) per 100 mm (3.94 in) length
2. Torsion: Limit 0.30 mm (0.0118 in) per 100 mm (3.94 in) length

Scheme 498

1. If it exceeds the limit, replace connecting rod assembly.

Scheme 499

1. Install the connecting rod cap without the connecting rod bearing installed. After tightening the connecting rod nut to the specified torque, measure the connecting rod large end inner diameter using an inside micrometer. Standard: 55.000-55.013 mm (2.1654-2.1659 in)

Scheme 500

1. Measure inner diameter of bushing. Standard Grade No. 0 : 22.000-22.006 mm (0.8661-0.8664 in) Grade No. 1 : 22.006-00.012 mm (0.8664-0.8666 in)

Scheme 501

1. Measure outer diameter of piston pin. Standard Grade No. 0 : 21.989-21.995 mm (0.8657-0.8659 in) Grade No. 1 : 21.995-22.001 mm (0.8659-0.8662 in)

Connecting Rod Bushing Oil Clearance (Small End)

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

1. Standard: 0.005-0.017 mm (0.0002-0.007 in)
2. Limit: 0.030-mm (0.0012 in)

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1. If the measured value exceeds the standard, replace the connecting rod assembly and/or piston and piston pin assembly.
2. If replacing the piston and piston pin assembly, refer to the Table for Selective Fitting for Piston to select the piston corresponding to the applicable bore grade of the cylinder block to be used. Refer to «PISTON-TO-BORE CLEARANCE»(ref-163530-S37287490052005050200000) . Factory installed parts grading
3. Service parts apply only to grade 0.

Scheme 505

1. Using a scraper, remove any old gasket material on the cylinder block surface, and remove any oil, scale, carbon, or other contamination. CAUTION: Be careful not to allow gasket flakes to enter the oil or coolant passages.
2. Measure the distortion on the block upper face at different points in six directions. Distortion limit: 0.10 mm (0.0039 in)
3. If out of specification, resurface the cylinder block. The allowable amount of resurfacing is dependent on the amount of any cylinder head resurfacing. The resurfacing limit is [amount of cylinder head resurfacing] + [amount of cylinder head resurfacing] = 0.2 mm (0.008 in). Resurfacing limit: 214.95-215.05 mm (8.4626-8.4665 in)

Scheme 506

1. Install the main bearing caps with the main bearings removed, and tighten the mounting bolts to the specified torque.
2. Using a bore gauge, measure the inner diameter of the main bearing housing. Standard: 63.993-64.017 mm (2.5194-2.5203 in)
3. If out of the standard, replace the cylinder block and main bearing caps as an assembly. NOTE: These components cannot be replaced as a single unit, because they were processed together.

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1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper. The X axis is in the longitudinal direction of the engine. Cylinder bore inner diameter If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary. Out-of-round (Y-X): limit 0.015 mm (0.0006 in) Taper (C-A): limit 0.015 mm (0.0006 in)
2. Check for scratches and seizure. If seizure is found, hone it. If both cylinder block and piston are replaced with new ones, select piston of the same grade number punched on cylinder block rear position. These numbers are punched in either Arabic or Roman numerals.
3. Measure piston skirt diameter. Piston diameter "A": Refer to «PISTON, PISTON RING AND PISTON PIN»(ref-163530-S24894733382005050200000) . Measuring point "a" (Distance from the top): 41.0 mm (1.61 in)
4. Check that piston-to-bore clearance is within specification. Piston-to-bore: 0.010-0.030 mm (0.0004-0.0012 in) clearance at "B" The piston-to-bore clearance is measured at the "B" level in the cylinder as shown.
5. Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. Refer to «PISTON, PISTON RING AND PISTON PIN»(ref-163530-S24894733382005050200000) .
6. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter "A". Rebored size calculation: D = A + B - C where, D: Bored diameter A: Piston diameter as measured B: Piston-to-bore clearance C: Honing allowance 0.02 mm (0.0008 in)
7. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted in final assembly.
8. 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.
9. Hone cylinders to obtain specified piston-to-bore clearance.
10. Measure finished cylinder bore for out-of-round and taper. Measurement should be done after cylinder bore cools down.

Scheme 513

Scheme 514

1. Check the crankshaft main and pin journals for scoring, wear, or cracks.
2. Measure the journals for taper and out-of-round. Standard Out-of-round (X-Y): 0.002 mm (0.0001 in) Taper (A-B): 0.002 mm (0.0001 in)
3. Measure crankshaft runout. Place a V-block on a precise flat table to support the journals on the both ends of the crankshaft. Place a dial gauge straight up on the No. 3 journal. While rotating the crankshaft, read the movement of the pointer on the dial gauge. Runout limit (total indicator reading): 0.10 mm (0.0039 in)

Bearing Clearance

1. Use either of the following two methods, however method "A" gives more reliable results and so is the preferred method.

Scheme 515

Scheme 516

Scheme 517

Scheme 518

Scheme 519

1. Set the main bearings in their proper positions on the cylinder block and the main bearing cap.
2. Install the main bearing caps and bearing beam to the cylinder block. Tighten all bolts in the numerical order as specified. Refer to «Disassembly and Assembly»(ref-163530-S31805669302005050200000) .
3. Measure the inner diameters "A" of each main bearing as shown.
4. Measure the outer diameters "Dm" of each crankshaft main journal as shown.
5. Calculate the main bearing clearance. Main bearing clearance = "A"-"Dm" Standard: 0.035-0.045 mm (0.0014-0.0018 in) Limit: 0.065 mm (0.0026 in) If it exceeds the limit, replace the bearing. If clearance cannot be adjusted using any standard bearing grade, grind crankshaft journal and use an undersized bearing. When grinding the crankshaft journal, confirm that the "L" dimension in the fillet role is more than the specified limit. "L": 0.1 mm (0.004 in)
6. If the crankshaft or the cylinder block is replaced with a new one, select thickness of the main bearings as follows: The grade number of each cylinder block main journal is punched on the respective cylinder block. These numbers are punched in either Arabic or Roman numerals. If measured diameter is out of the grade punched, decide suitable grade from available main bearings. The grade number of each crankshaft main journal is punched on the crankshaft end. These numbers are punched in either Arabic or Roman numerals. If measured diameter is out of grade punched, decide the suitable grade from available main bearings. Select the main bearing suitable thickness according to the following table

Scheme 520

Scheme 521

Scheme 522

1. Install the connecting rod bearing to the connecting rod and cap.
2. Install the connecting rod cap to the connecting rod. Tighten to specification. Refer to «DISASSEMBLY AND ASSEMBLY»(ref-163530-S31805669302005050200000) .
3. Measure the inner diameter "C" of each connecting rod (big end) as shown.
4. Measure the outer diameter "Dp" of each crankshaft pin journal.
5. Calculate the connecting rod bearing clearance. Connecting rod bearing clearance = C-Dp Standard: 0.034-0.059 mm (0.0013-0.0023 in) Limit: 0.070 mm (0.0028 in)
6. If the calculated clearance exceeds the specified limit, replace the bearings.
7. If the clearance cannot be adjusted within the standard of any bearing, grind the crankshaft journal and use undersized bearings.
8. If the crankshaft is replaced with a new one, select the connecting rod bearings according to the following table: Connecting Rod Bearing Grade Number (Identification Color) These numbers are punched in either Arabic or Roman numerals.

Scheme 523

1. Remove oil and dust on the crankshaft pin and the surfaces of each bearing completely.
2. Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
3. Install the connecting rod bearings to the connecting rod cap, and tighten the connecting rod nuts to the specified torque. CAUTION: Never rotate the crankshaft.
4. Remove the connecting rod cap and bearings, and using the scale on the plastigage bag, measure the plastigage width. NOTE: The procedure when the measured value exceeds the repair limit is same as that described in "Method A (Using Bore Gauge and Micrometer)".

Scheme 524

1. Measure the inner diameter "C" of the connecting rod bushing (small end).
2. Measure the outer diameter "Dp" of the piston pin.
3. Calculate the connecting rod bushing clearance. Connecting Rod Bushing Clearance = "C"-"Dp" Standard: 0.005-0.017 mm (0.0002-0.0007 in) Limit: 0.030 mm (0.0012 in)
4. If the calculated clearance exceeds the limit, replace the connecting rod assembly, or the connecting rod bushing, or the piston and pin set.

Drive Plate Runout (A/T)

Runout (Total Indicator Reading)

1. Drive plate (A/T): less than 0.15 mm (0.0059 in)

Scheme 525

Scheme 526

Flywheel Runout (M/T)

Note. This inspection is for double mass flywheel only. Do not disassemble the double mass flywheel.

Scheme 527

1. Measure the deflection of the flywheel contact surface to the clutch with a dial gauge.
2. Measure the deflection at 210 mm (8.27 in) diameter. 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 Around in Radial (Rotation) Direction

Check the movement amount with the following procedure

Scheme 528

1. Install a bolt to clutch cover mounting hole and place a torque wrench on the extended line of the flywheel center line. Tighten the bolt at a force of 9.8 N.m (1 kg-m, 87 in-lb) to keep it from loosening.
2. Put a mating mark on the circumference 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 transaxle side. Standard: 24 mm (0.94 in) or less
4. Measure dimensions of movement amounts A and B on the circumference of the flywheel on the transaxle side.
5. When the measured value exceeds the standard, replace the flywheel.