Engine Mechanical (Coupe): Other Nissan Altima L33

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

The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are buckled or unbuckled.

Information necessary to service the system safely is included in the SRS AIRBAG (COUPE) and SEAT BELTS (COUPE) article of this Service Information.

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

Precaution 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 Tool

The actual shape of the tools may differ from those illustrated here.

Tool number (TechMate No.) Tool name Description KV10111100 (J-37228) Seal cutter Removing steel oil pan and rear timing chain case ST0501S000 Engine stand assembly ST05011000 (-) Engine stand ST05012000 (-) Base Disassembling and assembling KV10106500 (-) Engine stand shaft KV10115300 (-) Engine sub-attachment KV10116200 (J-26336-B) Valve spring compressor KV10115900 (J-26336-20) Attachment Disassembling valve mechanism KV10112100 (BT-8653-A) Angle wrench Tightening bolts for cylinder head, main bearing cap and connecting rod cap KV10107902 (J-38959) Valve oil seal puller Removing valve oil seal KV10115600 (J-39386) Valve oil seal drift Installing valve oil seal Use side A. 20 (0.79) dia. d: 8 (0.31) dia. 13 (0.51) dia. e: 10.7 (0.421) dia. 10.3 (0.406) dia. f: 5 (0.20) dia. Unit: mm (in) EM03470000 (J-8037) Piston ring compressor Installing piston assembly into cylinder bore ST16610001 (J-23907) Pilot bushing puller Removing crankshaft pilot bushing WS39930000 (-) Tube presser Pressing the tube of liquid gasket 16441 6N210 (J-45488) Quick connector release Removing fuel tube quick connectors in engine room (Available in SEC. 164 of PARTS CATALOG: Part No. 16441 6N210) KV10117100 (J-36471-A) Heated oxygen sensor wrench Loosening or tightening heated oxygen sensor For 22 mm (0.87 in) hexagon nut KV991J0050 (J-44626) Air fuel ratio (A/F) sensor wrench Loosening or tightening air fuel ratio (A/F) sensor 1 - (J-46535) Drive belt tension releaser Releasing drive belt tension

Scheme 674

Scheme 675

Scheme 676

Scheme 677

Scheme 678

Scheme 679

Scheme 680

Scheme 681

Commercial Service Tool

Tool number (TechMate No.) Tool name Description Pulley holder Crankshaft pulley removing and installing (Holding crankshaft pulley) 68 mm (2.68 in) dia. 8 mm (0.31 in) dia. Crank puller Crankshaft pulley removing Spark plug wrench Removing and installing spark plug Valve seat cutter set Finishing valve seat dimensions Piston ring expander Removing and installing piston ring Valve guide drift Removing and installing valve guide Intake & Exhaust: 9.5 mm (0.374 in) dia. 5.5 mm (0.217 in) dia. Valve guide reamer Reaming valve guide inner hole Reaming hole for oversize valve guide Intake & Exhaust: d1: 6.0 mm (0.236 in) dia. d2: 10.2 mm (0.402 in) dia. (J-43897-18) (J-43897-12) Oxygen sensor thread cleaner Reconditioning the exhaust system threads before installing a new heated oxygen sensor (Use with anti-seize lubricant shown below.) J-43897-18 [18 mm (0.71 in) dia.] for zirconia heated oxygen sensor J-43897-12 [12 mm (0.47 in) dia.] for titania heated oxygen sensor Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907) Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads Power tool Loosening nuts, screws and bolts (J-45816) E20 Socket Removing and installing CVT drive plate bolts

Scheme 682

Scheme 683

Scheme 684

Scheme 685

CHANGING THE AIR CLEANER FILTER

1. Remove the front air duct.
2. Unhook the air cleaner case side clips.
3. Remove the air cleaner case (front).
4. Remove the air cleaner filter.
5. Install a new air cleaner filter.
6. Install the air cleaner case (front).
7. Lock the air cleaner case side clips.
8. Install the front air duct.

Camshaft valve clearance

1. Perform this inspection as follows after removal, installation, or replacement of the camshaft or any valve-related parts, or if there are any unusual engine conditions due to changes in valve clearance over time (starting, idling, and/or noise).

Scheme 686

Scheme 687

Scheme 688

Scheme 689

Scheme 690

1. Warm up the engine, then stop it.
2. Remove the fender protector side cover RH using power tool. Refer to " «REMOVAL AND INSTALLATION»(ref-592019-S24442268552014010800000) ".
3. Remove the rocker cover using power tool. Refer to " «REMOVAL AND INSTALLATION»(ref-592016-S11030128812014010800000) ".
4. Turn crankshaft pulley in normal direction (clockwise when viewed from front) to align TDC identification mark (without paint mark) with timing indicator.
5. At this time, check that the both intake and exhaust cam lobes of No. 1 cylinder face outside. If they do not face outside, turn crankshaft pulley once more.
6. Measure valve clearances with a feeler gauge at locations marked (X) in the table below. No. 1 cylinder compression TDC. Cylinder No. 1 No. 2 No. 3 No. 4 Valve INT EXH INT EXH INT EXH INT EXH Measurable x x x x Use a feeler gauge to measure the clearance between valve and camshaft. Valve clearance standard: Cold Intake: 0.24 - 0.32 mm (0.009 - 0.013 in) Exhaust: 0.26 - 0.34 mm (0.010 - 0.013 in) Hot* Intake: 0.304 - 0.416 mm (0.012 - 0.016 in) Exhaust: 0.308 - 0.432 mm (0.012 - 0.017 in) *Approximately 80°C (176°F) CAUTION: If inspection was carried out with cold engine, check that values with fully warmed up engine are still within specifications.
7. Turn crankshaft one complete revolution (360°) and align mark on crankshaft pulley with pointer.
8. Measure valve clearances with a feeler gauge at locations marked (X) in the table below. No. 4 cylinder compression TDC. Cylinder No. 1 No. 2 No. 3 No. 4 Valve INT EXH INT EXH INT EXH INT EXH Measurable x x x x If out of specifications, make necessary adjustment.

Camshaft Journal Clearance

Outer Diameter of Camshaft Journal

Scheme 691

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)

Inner Diameter of Camshaft Bracket

Scheme 692

Scheme 693

1. Tighten the camshaft bracket bolts to the specified torque following the tightening pattern as shown below. Step 1 (bolts 9 - 11): 1.96 N.m (0.2 kg-m, 17 in-lb) Step 2 (bolts 1 - 8): 1.96 N.m (0.2 kg-m, 17 in-lb) Step 3 (bolts 1 - 11): 5.88 N.m (0.6 kg-m, 52 in-lb) Step 4 (bolts 1 - 11): 10.4 N.m (1.02 kg-m, 92 in-lb) CAUTION: After tightening camshaft bracket bolts, 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.
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 694

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 695

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 696

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

Valve Lifter Clearance

Outer Diameter of Valve Lifter

Scheme 697

1. Measure the outer diameter of the valve lifter. Valve lifter outer diameter: 33.977-33.987 mm (1.3377 - 1.3381 in)
2. If out of the specified range, replace the valve lifter.

Valve Lifter Bore Inner Diameter

Scheme 698

1. Using inside micrometer, measure diameter of valve lifter bore 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: 0.013 - 0.044 mm (0.0005 - 0.0017 in)
2. If out of specified range, replace either or both valve lifter and cylinder head assembly.

Scheme 699

Scheme 700

Scheme 701

Scheme 702

Scheme 703

Scheme 704

Scheme 705

Scheme 706

Scheme 707

Scheme 708

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: A: Exhaust B: Intake Signal plate for the camshaft position sensor (PHASE) Install camshafts so that the dowel pins on the front side are positioned as shown below.
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 below. Use Genuine Silicone RTV Sealant, or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-592010-S39097878722014010800000) ". 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. Dimension (A): 3.9 mm (0.154 in) 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 camshaft bracket bolts in four steps in the order as shown below. Step 1 (bolts 9 - 11): 1.96 N.m (0.2 kg-m, 17 in-lb) Step 2 (bolts 1 - 8): 1.96 N.m (0.2 kg-m, 17 in-lb) Step 3 (bolts 1 - 11): 5.88 N.m (0.6 kg-m, 52 in-lb) Step 4 (bolts 1 - 11): 10.4 N.m (1.02 kg-m, 92 in-lb) CAUTION: After tightening camshaft bracket bolts, 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 IVT control cover with the following procedure. Install IVT control solenoid valve to intake valve timing control cover. Install O-ring to front cover side. CAUTION: Do not reuse O-ring. Apply Genuine Silicone RTV Sealant to the positions as shown below. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-592010-S39097878722014010800000) ". Diameter (A): 3.0 - 4.0 mm (0.118 - 0.157 in) Install IVT control cover. Tighten the bolts in the numerical order as shown below.
9. Check and adjust valve clearances. Refer to " «VALVE CLEARANCE»(ref-592016-S00271725032014010800000) ".
10. Installation of the remaining components is in the reverse order of removal.

Timing Chain

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

Scheme 709

Scheme 710

1. Measure outer diameters (d1, d2) at the two positions as shown below.
2. Measure d2 within the range A.
3. If the value difference (d1 - d2) exceeds the limit, replace it with a new one. Limit: 0.15 mm (0. 0059 in) or more

VALVE DIMENSIONS

Check dimensions of each valve. Refer to " STANDARD AND LIMIT ".

Scheme 711

1. Measure diameter of valve stem using suitable tool (A) as shown below. Standard Intake: 5.965 - 5.980 mm (0.2348 - 0.2354 in) Exhaust: 5.955 - 5.970 mm (0.2344 - 0.2350 in)
2. Measure inner diameter of valve guide with a bore gauge as shown above. Standard Intake and Exhaust: 6.000 - 6.018 mm (0.2362 - 0.2369 in)
3. Valve guide clearance = (Valve guide inner diameter) - (Valve stem diameter) Valve guide clearance Standard Intake: 0.020 - 0.053 mm (0.0008 - 0.0021 in) Exhaust: 0.030 - 0.063 mm (0.0012 - 0.0025 in) Limit Intake: 0.08 mm (0.003 in) Exhaust: 0.09 mm (0.004 in)
4. If it exceeds the limit, replace valve guide and/or valve. When valve guide must be replaced, follow the "VALVE GUIDE REPLACEMENT" procedure.

VALVE SEAT CONTACT

Note. After confirming that the dimensions of valve guides and valves are within specifications, perform this procedure: Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve contact on the seat surface. Check if the contact area band is continuous all around the circumference. If not, grind to adjust valve fitting and check again. If the contacting surface still has NG conditions even after the re-check, replace the valve seat.

Scheme 712

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.

Limit: 1.9 mm (0.0748 in)

Scheme 713

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.

Scheme 714

Scheme 715

Note. When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.

Scheme 716

Scheme 717

1. Remove engine cover using power tool.
2. Release fuel pressure. Refer to " «INSPECTION»(ref-592022-S08111032412014010800000) " (California), " «INSPECTION»(ref-592023-S21357902862014010800000) " (Except California).
3. Disconnect the negative and positive battery terminal. Refer to " «REMOVAL AND INSTALLATION (BATTERY)»(ref-592011-S06046231102014010800000) ".
4. Disconnect the fuel rail at the fuel hose quick connector (engine side). Refer to «INTAKE MANIFOLD»(ref-592016-S05382354022014010800000) .
5. Drain the engine coolant. Refer to " «CHANGING ENGINE COOLANT»(ref-592018-S06646162382014010800000) ".
6. Remove the engine under cover. Refer to " «REMOVAL AND INSTALLATION»(ref-592019-S16772029082014010800000) ".
7. Drain power steering fluid. Refer to " «DRAINING»(ref-592021-S23018489882014010800000) ".
8. Remove hood assembly. Refer to " «HOOD ASSEMBLY: REMOVAL AND INSTALLATION»(ref-592031-S19273168122014010800000) ".
9. Remove the air duct and air cleaner case assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-592016-S14803150462014010800000) ".
10. Remove battery tray. Refer to " «REMOVAL AND INSTALLATION (BATTERY TRAY)»(ref-592011-S22806689062014010800000) ".
11. Disconnect the ECM.
12. Remove the ECM bracket.
13. Remove cowl top. Refer to " «REMOVAL AND INSTALLATION»(ref-592019-S27643968262014010800000) ".
14. Remove strut brace. Refer to " «EXPLODED VIEW»(ref-592024-S13535819192014010800000) ".
15. Disconnect EVAP hose and vacuum hose from intake manifold.
16. Disconnect and set aside the IPDM/ER and remove the IPDM/ER bracket. Refer to " «REMOVAL AND INSTALLATION»(ref-592032-S16925654782014010800000) ".
17. Remove upper and lower radiator hoses (engine side).
18. Remove CVT cooler lines.
19. Disconnect the heater hoses.
20. Remove front LR and RH wheels and tires. Refer to " «ADJUSTMENT»(ref-592020-S33110986762014010800000) ".
21. Remove the fender protector side covers RH and LH. Refer to " «REMOVAL AND INSTALLATION»(ref-592019-S24442268552014010800000) ".
22. Remove the lower side bolt of the lower steering shaft assembly.
23. Remove rear cover plate.
24. Remove the torque converter nuts.
25. Remove the rear engine mount torque rod.
26. Remove front exhaust tube. Refer to " «EXPLODED VIEW»(ref-592028-S05924199902014010800000) ".
27. Remove the LH and RH drive shafts. Refer to " «REMOVAL AND INSTALLATION (LEFT SIDE)»(ref-592033-S03772778212014010800000) ", " «REMOVAL AND INSTALLATION (RIGHT SIDE)»(ref-592033-S33853242632014010800000) ".
28. Remove the drive belt. Refer to " «REMOVAL AND INSTALLATION»(ref-592016-S23796880142014010800000) ".
29. Remove the front suspension member. Refer to " «REMOVAL AND INSTALLATION»(ref-592024-S24625802692014010800000) ".
30. Dismount the A/C compressor with piping connected and secure with wire to the radiator support.
31. Disconnect the power steering hose and tube from the power steering gear.
32. Disconnect the transaxle shift controls.
33. Install engine slingers into front left cylinder head (A) and rear right cylinder head (B). Use generator bracket bolt holes for the front slinger. Use the proper slingers and bolts as described in the Parts Catalog. Slinger bolts - front: 48 N.m (4.9 kg-m, 35 ft-lb) Slinger bolts - rear: 28 N.m (2.8 kg-m, 21 ft-lb)
34. Support engine and transaxle assembly with engine lifting equipment from the top with the vehicle raised on a hoist.
35. Remove the RH engine mount torque rod, RH engine support bracket and RH engine mounting insulator and bracket.
36. Remove LH transaxle mounting insulator through-bolts.
37. Lower the engine and transaxle assembly from the engine compartment using suitable tool. 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.
38. Remove the starter motor. Refer to " «REMOVAL AND INSTALLATION»(ref-592034-S15163134832014010800000) ".
39. Separate engine and transaxle. Refer to " «EXPLODED VIEW»(ref-592030-S26277472112014010800000) ".

Piston to Piston Pin Clearance

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

Scheme 718

1. A: Front mark
2. B: Piston pin bore grade
3. C: Piston grade I.D. stamp
4. D: Piston crown I.D. code stamp 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. Use the piston selection table to replace piston/piston pin assembly. Refer to " «HOW TO SELECT PISTON AND BEARING»(ref-592016-S09139647672014010800000) ".
3. Use the connecting rod bearing selection table to replace connecting rod. Refer to " «HOW TO SELECT PISTON AND BEARING»(ref-592016-S09139647672014010800000) ".

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. Follow the "CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)" procedure for the values for each grade at the plant.

Scheme 719

1. Measure side clearance of piston ring and piston ring groove using a feeler gauge. Refer to " «STANDARD AND LIMIT»(ref-592016-S42035231992014010800000) ".
2. If out of specification, replace piston and/or piston ring assembly.

Scheme 720

1. Check if inner diameter of cylinder bore is within specification. Follow the "PISTON TO CYLINDER BORE CLEARANCE" procedure.
2. Insert piston ring until middle of cylinder with piston, and measure gap using a feeler gauge. Refer to " «STANDARD AND LIMIT»(ref-592016-S42035231992014010800000) ".
3. If out of specification, replace piston ring.

Scheme 721

Scheme 722

1. Check with connecting rod aligner. Refer to " «STANDARD AND LIMIT»(ref-592016-S42035231992014010800000) ".
2. If it exceeds the limit, replace connecting rod assembly.

Scheme 723

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. Refer to " «STANDARD AND LIMIT»(ref-592016-S42035231992014010800000) ".

Scheme 724

1. Measure inner diameter of bushing. Refer to " «STANDARD AND LIMIT»(ref-592016-S42035231992014010800000) "

Scheme 725

1. Measure outer diameter of piston pin. Refer to " «STANDARD AND LIMIT»(ref-592016-S42035231992014010800000) ".

Piston Pin to Connecting Rod Bushing Clearance (Small End)

(Piston pin to connecting rod bushing clearance (small end)) = (Inner diameter of connecting rod small end) - (Outer diameter of piston pin)

Scheme 726

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, use 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 PISTON AND BEARING»(ref-592016-S09139647672014010800000) ".

Factory Installed Parts Grading

Scheme 727

1. Service parts apply only to grade 0 (B). Unit: mm (in) Piston Pin Grade (B) 0 1 Connecting rod small end inner bushing diameter 20.000 - 20.006 (0.7874 - 0.7876) 20.006 - 20.012 (0.7876 - 0.7879) Piston pin outer diameter 19.989 - 19.995 (0.7870 - 0.7872) 19.995 - 20. 001 (0.7872 - 0.7874) Piston pin bore diameter 19.993 - 19.999 (0.7871-0.7874) 19.999 - 20.005 (0.7874 - 0.7876)
2. A: Front mark
3. C: Piston grade I.D. stamp
4. D: Piston crown I.D. code stamp

Scheme 728

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 and lower block they are machined together as an assembly.

Scheme 729

1. Install the main bearing caps with the main bearings removed and tighten the bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-592016-S18735056612014010800000) ".
2. Using a bore gauge, measure the inner diameter of the main bearing housing. Standard: 58.944 - 58.968 mm (2.3206 - 2.3216 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 730

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. Refer to " «STANDARD AND LIMIT»(ref-592016-S42035231992014010800000) ".
2. If there are scratches and/or seizure on the cylinder inner wall, hone the inner wall.

Scheme 731

1. Measure piston skirt diameter using a micrometer. Refer to " «STANDARD AND LIMIT»(ref-592016-S42035231992014010800000) ".
2. Measure point (distance from the top): 37.5 mm (1.476 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 lower cylinder block, 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 732

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

Scheme 733

1. Measure the dimensions at four different points as shown below on each journal and pin using a micrometer.
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). Standard Out-of-round (X - Y): 0.005 mm (0.0002 in) Taper (A - B): 0.005 mm (0.0002 in)

Scheme 734

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 runout reading. Limit: Less than 0.05 mm (0.002 in)

Scheme 735

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: 0.035 - 0.045 mm (0.0014 - 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 PISTON AND BEARING»(ref-592016-S09139647672014010800000) ".

Scheme 736

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 PISTON AND BEARING»(ref-592016-S09139647672014010800000) ".

Scheme 737

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

Scheme 738

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 739

1. Perform only with M10 (0.39 in) bolts.
2. Measure outer diameters (d1, d2) at two positions as shown below.
3. Measure d2 at a point within area (A) as shown below.
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)

Scheme 740

1. Measure outer diameter (d) at position as shown below.
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

HOW TO SELECT A PISTON

When New Cylinder Block is Used

Scheme 741

Scheme 742

1. Check the cylinder bore grade on rear left side of cylinder block, and select a piston of the same grade (C). A: Front mark B: Piston pin bore grade D: Piston crown I.D. code stamp
2. If there is a corrected stamp mark on the cylinder block, use it as a correct reference.

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.

Piston Selection Table

1. For the piston selection table, refer to " «STANDARD AND LIMIT»(ref-592016-S42035231992014010800000) ".

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.

HOW TO SELECT A CONNECTING ROD BEARING

When New Connecting Rod and Crankshaft are Used

Scheme 743

Scheme 744

1. Apply big end inside diameter grade stamped on connecting rod side face to the row in the "Connecting Rod Bearing Selection Table".
2. Apply pin diameter grade (B) stamped on crankshaft front side to the column in the "Connecting Rod Bearing Selection Table". Journal diameter grade (A)
3. Read the symbol at the cross point of selected row and column in the "Connecting Rod Bearing Selection Table".
4. Apply the symbol obtained to 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.

Connecting Rod Bearing Selection Table

Scheme 745

Connecting Rod Bearing Grade Table. Refer to " STANDARD AND LIMIT ".

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.

BEARING UNDERSIZE TABLE

Scheme 746

HOW TO SELECT A MAIN BEARING

When New Cylinder Block and Crankshaft are Used

Scheme 747

Scheme 748

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 (A) stamped on crankshaft front side to column in "Main Bearing Selection Table". Pin diameter grade (B)
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".

Main Bearing Selection Table (No. 1, 3, and No. 5 journals)

Scheme 749

Main Bearing Selection Table (No. 2, and 4 journals)

Scheme 750

Main Bearing Grade Table (All Journals) Refer to " STANDARD AND LIMIT ".

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.

BEARING UNDERSIZE TABLE

Scheme 751

DRIVE BELTS

INTAKE MANIFOLD AND EXHAUST MANIFOLD

SPARK PLUG

CYLINDER HEAD

Unit: mm. (in) Description Limit Head surface distortion 0.1 (0.004) Description Standard Spark plug tube installation height 41.7 (1.642)

Unit: mm. (in) Valve head diameter (D) Intake 35.5 - 35.8 (1.398 - 1.409) Exhaust 30.3 - 30.6 (1.193 - 1.205) Valve length (L) Intake 96.84 (3.8136) Exhaust 97.9 (3.8553) Valve stem diameter (d) Intake 5.965 - 5.980 (0.2348 - 0.2354) Exhaust 5.955 - 5.970 (0.2344 - 0.2350) Valve seat angle α Intake 45°15' - 45°45' Exhaust Valve margin (T) Intake 1.08 (0.0425) Exhaust 1.38 (0.0543)

Scheme 752

Valve Clearance

Available Valve Lifter

Thickness mm. (in) Identification mark (Stamp) (1) 7.88 (0.310) 788U 7.90 (0.311) 790U 7.92 (0.312) 792U 7.94 (0.313) 794U 7.96 (0.313) 796U 7.98 (0.314) 798U 8.00 (0.315) 800U 8.02 (0.316) 802U 8.04 (0.317) 804U 8.06 (0.317) 806U 8.08 (0.318) 808U 8.10 (0.319) 810U 8.12 (0.320) 812U 8.14 (0.320) 814U 8.16 (0.321) 816U 8.18 (0.322) 818U 8.20 (0.323) 820U 8.22 (0.324) 822U 8.24 (0.324) 824U 8.26 (0.325) 826U 8.28 (0.326) 828U 8.30 (0.327) 830U 8.32 (0.328) 832U 8.34 (0.328) 834U 8.36 (0.329) 836U 8.38 (0.330) 838U (1) Always check with the Parts Department for the latest parts information. O

Valve Spring

Valve Lifter

Valve Oil Seal

Valve Guide

Unit: mm. (in) Description Standard Service Valve guide Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029) Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369) Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014) Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023) Standard Valve guide clearance (Standard) Intake 0.020 - 0.053 (0.0008 - 0.0021) Exhaust 0.030 - 0.063 (0.0012 - 0.0025) Valve guide clearance (Limit) Intake 0.08 (0.003) Exhaust 0.09 (0.004) Projection length (L) Intake 10.1 - 10.3 (0.398 - 0.406) Exhaust 10.0 - 10.4 (0.394 - 0.409)

Scheme 753

Valve Seat

Unit: mm. (in) Description Standard Service Cylinder head seat recess diameter (D) Intake 36.500 - 36.516 (1.4370 - 1.4376) 37.000 - 37.016 (1.4567 - 1.4573) Exhaust 31.500 - 31.516 (1.2402 - 1.2408) 32.000 - 32.016 (1.2598 - 1.2605) Valve seat interference fit Intake 0.081 - 0.113 (0.0032 - 0.0044) Exhaust 0.084 - 0.116 (0.0033 - 0.0046) Valve seat outer diameter (d) Intake 36.597 - 36.613 (1.4408 - 1.4415) 37.097 - 37.113 (1.4605 - 1.4611) Exhaust 31.600 - 31.616 (1.2441 - 1.2447) 32.100 - 32.116 (1.2638 - 1.2644) Diameter (d1) Intake 33.5 (1.319) Exhaust 28.0 (1.102) Diameter (d2) Intake 34.8 - 35.3 (1.370 - 1.390) Exhaust 29.6 - 30.1 (1.165 - 1.185) Angle (α1) Intake 60° Exhaust 60° Angle (α2) Intake 88° 46' - 90° 14' Exhaust 88° 46' - 90° 14' Angle (α3) Intake 120° Exhaust 120° Contacting width (W) (1) Intake 0.99 - 1.35 (0.0390 - 0.0531) Exhaust 1.19 - 1.55 (0.0469 - 0.0610) (1) Machining data

Scheme 754

CAMSHAFT AND CAMSHAFT BEARING

Unit: mm. (in) Standard Camshaft runout [TIR (1) ] Less than 0.04 (0.0016) Cam height (A) Intake 44.815 - 45.005 (1.7644 - 1.7718) Exhaust 43.975 - 44.165 (1.7313 - 1.7388) Outer diameter of camshaft journal No. 1 27.935 - 27.955 (1.0998 - 1.1006) No. 2, 3, 4, 5 23.435 - 23.455 (0.9226 - 0.9234) Inner diameter of camshaft bracket No. 1 28.000 - 28.021 (1.1024 - 1.1032) No. 2, 3, 4, 5 23.500 - 23.521 (0.9252 - 0.9260) Camshaft journal clearance 0.045 - 0.086 (0.0018 - 0.0034) Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) Camshaft sprocket runout [TIR (1) ] Less than 0.15 (0.0059) (1) Total indicator reading

Scheme 755

CYLINDER BLOCK

Unit: mm. (in) Surface distortion Limit 0.1 (0.004) Cylinder bore Inner diameter Standard Grade No. 2 89.010 - 89.020 (3.5043 - 3.5047) Grade No. 3 89.020 - 89.030 (3.5047 - 3.5051) Wear limit 0.2 (0.008) Out-of-round (X - Y) Less than 0.015 (0.0006) Taper (C - A) Less than 0.01 (0.0004) Main journal inner diameter grade (Without bearing) (1) Grade No. A 58.944 - 58.945 (2.3206 - 2.3207) Grade No. B 58.945 - 58.946 (2.3207 - 2.3207) Grade No. C 58.946 - 58.947 (2.3207 - 2.3207) Grade No. D 58.947 - 58.948 (2.3207 - 2.3208) Grade No. E 58.948 - 58.949 (2.3208 - 2.3208) Grade No. F 58.949 - 58.950 (2.3208 - 2.3209) Grade No. G 8.950 - 58.951 (2.3209 - 2.3209) Grade No. H 58.951 - 58.952 (2.3209 - 2.3209) Grade No. J 58.952 - 58.953 (2.3209 - 2.3210) Grade No. K 58.953 - 58.954 (2.3210 - 2.3210) Grade No. L 58.954 - 58.955 (2.3210 - 2.3211) Grade No. M 58.955 - 58.956 (2.3211 - 2.3211) Grade No. N 58.956 - 58.957 (2.3211 - 2.3211) Grade No. P 58.957 - 58.958 (2.3211 - 2.3212) Grade No. R 58.958 - 58.959 (2.3212 - 2.3212) Grade No. S 58.959 - 58.960 (2.3212 - 2.3213) Grade No. T 58.960 - 58.961 (2.3213 - 2.3213) Grade No. U 58.961 - 58.962 (2.3213 - 2.3213) Grade No. V 58.962 - 58.963 (2.3213 - 2.3214) Grade No. W 58.963 - 58.964 (2.3214 - 2.3214) Grade No. X 58.964 - 58.965 (2.3214 - 2.3215) Grade No. Y 58.965 - 58.966 (2.3215 - 2.3215) Grade No. 4 58.966 - 58.967 (2.3215 - 2.3215) Grade No. 7 58.967 - 58.968 (2.3215 - 2.3216) Difference in inner diameter between cylinders Standard Less than 0.03 (0.0012) (1) Always check with the Parts Department for the latest parts information

Available Piston

Unit: mm. (in) Piston skirt diameter (A) Standard Grade (1) Dimension Grade No. 1 88.990 - 88.995 (3.5035 - 3.5037) Grade No. 2 88.995 - 89.000 (3.5037 - 3.5039) Grade No. 3 89.000 - 89.005 (3.5039 - 3.5041) Grade No. 4 89.005 - 89.010 (3.5041 - 3.5043) (H) dimension 37.5 (1.476) Piston pin bore diameter Grade No. 0 19.993 - 19.999 (0.7871 - 0.7874) Grade No. 1 19.999 - 20.005 (0.7874 - 0.7876) Piston clearance to cylinder block Standard 0.010 - 0.030 (0.0004 - 0.0012) Limit 0.08 (0.0031) (1) Always check with the Parts Department for the latest parts information

Piston Ring

Piston Pin

CONNECTING ROD

CRANKSHAFT

Unit: mm. (in) Pin journal dia. (DP) Grade No. A 44.974 - 44.973 (1.7706 - 1.7706) Grade No. B 44.973 - 44.972 (1.7706 - 1.7705) Grade No. C 44.972 - 44.971 (1.7705 - 1.7705) Grade No. D 44.971 - 44.970 (1.7705 - 1.7705) Grade No. E 44.970 - 44.969 (1.7705 - 1.7704) Grade No. F 44.969 - 44.968 (1.7704 - 1.7704) Grade No. G 44.968 - 44.967 (1.7704 - 1.7704) Grade No. H 44.967 - 44.966 (1.7704 - 1.7703) Grade No. J 44.966 - 44.965 (1.7703 - 1.7703) Grade No. K 44.965 - 44.964 (1.7703 - 1.7702) Grade No. L 44.964 - 44.963 (1.7702 - 1.7702) Grade No. M 44.963 - 44.962 (1.7702 - 1.7702) Grade No. N 44.962 - 44.961 (1.7702 - 1.7701) Grade No. P 44.961 - 44.960 (1.7701 - 1.7701) Grade No. R 44.960 - 44.959 (1.7701 - 1.7700) Grade No. S 44.959 - 44.958 (1.7700 - 1.7700) Grade No. T 44.958 - 44.957 (1.7700 - 1.7700) Grade No. U 44.957 - 44.956 (1.7700 - 1.7699) Main journal dia. (Dm) grade Grade No. A 54.979 - 54.978 (2.1645 - 2.1645) Grade No. B 54.978 - 54.977 (2.1645 - 2.1644) Grade No. C 54.977 - 54.976 (2.1644 - 2.1644) Grade No. D 54.976 - 54.975 (2.1644 - 2.1644) Grade No. E 54.975 - 54.974 (2.1644 - 2.1643) Grade No. F 54.974 - 54.973 (2.1643 - 2.1643) Grade No. G 54.973 - 54.972 (2.1643 - 2.1642) Grade No. H 54.972 - 54.971 (2.1642 - 2.1642) Grade No. J 54.971 - 54.970 (2.1642 - 2.1642) Grade No. K 54.970 - 54.969 (2.1642 - 2.1641) Grade No. L 54.969 - 54.968 (2.1641 - 2.1641) Grade No. M 54.968 - 54.967 (2.1641 - 2.1641) Grade No. N 54.967 - 54.966 (2.1641 - 2.1640) Grade No. P 54.966 - 54.965 (2.1640 - 2.1640) Grade No. R 54.965 - 54.964 (2.1640 - 2.1639) Grade No. S 54.964 - 54.963 (2.1639 - 2.1639) Grade No. T 54.963 - 54.962 (2.1639 - 2.1639) Grade No. U 54.962 - 54.961 (2.1639 - 2.1638) Grade No. V 54.961 - 54.960 (2.1638 - 2.1638) Grade No. W 54.960 - 54.959 (2.1638 - 2.1637) Grade No. X 54.959 - 54.958 (2.1637 - 2.1637) Grade No. Y 54.958 - 54.957 (2.1637 - 2.1637) Grade No. 4 54.957 - 54.956 (2.1637 - 2.1636) Grade No. 7 54.956 - 54.955 (2.1636 - 2.1636) Center distance (r) 49.60 - 50.04 (1.9528 - 1.9701) Out-of-round (X - Y) Standard Less than 0.005 (0.0002) Taper (A - B) Standard Less than 0.005 (0.0002) Runout [TIR (1) ] Limit Less than 0.05 (0.002) Free end play Standard 0.10 - 0.26 (0.0039 - 0.0102) Limit 0.30 (0.0118) (1) Total indicator reading

Scheme 756

Scheme 757

MAIN BEARING

Unit: mm. (in) Grade number (1) Thickness Identification color Remarks 0 1.973 - 1.976 (0.0777 - 0.0778) Black Grade and color are the same for upper and lower bearings. 1 1.976 - 1.979 (0.0778 - 0.0779) Brown 2 1.979 - 1.982 (0.0779 - 0.0780) Green 3 1.982 - 1.985 (0.0780 - 0.0781) Yellow 4 1.985 - 1.988 (0.0781 - 0.0783) Blue 5 1.988 - 1.991 (0.0783 - 0.0784) Pink 6 1.991 - 1.994 (0.0784 - 0.0785) Purple 7 1.994 - 1.997 (0.0785 - 0.0786) White 01 UPR 1.973 - 1.976 (0.0777 - 0.0778) Black Grade and color are different for upper and lower bearings. LWR 1.976 - 1.979 (0.0778 - 0.0779) Brown 12 UPR 1.976 - 1.979 (0.0778 - 0.0779) Brown LWR 1.979 - 1.982 (0.0779 - 0.0780) Green 23 UPR 1.979 - 1.982 (0.0779 - 0.0780) Green LWR 1.982 - 1.985 (0.0780 - 0.0781) Yellow 34 UPR 1.982 - 1.985 (0.0780 - 0.0781) Yellow LWR 1.985 - 1.988 (0.0781 - 0.0783) Blue 45 UPR 1.985 - 1.988 (0.0781 - 0.0783) Blue LWR 1.988 - 1.991 (0.0783 - 0.0784) Pink 56 UPR 1.988 - 1.991 (0.0783 - 0.0784) Pink LWR 1.991 - 1.994 (0.0784 - 0.0785) Purple 67 UPR 1.991 - 1.994 (0.0784 - 0.0785) Purple LWR 1.994 - 1.997 (0.0785 - 0.0786) White (1) Always check with the Parts Department for the latest parts information

Scheme 758

Undersize

Bearing Clearance

CONNECTING ROD BEARING