Engine Mechanical: Other Nissan Armada I рестайлинг

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 belted or unbelted.

Information necessary to service the system safely is included in the SRS AIRBAG article and SEAT BELTS article.

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

Precaution Necessary for Steering Wheel Rotation After Battery Disconnect

Note. This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT SYSTEM). Remove and install all control units after disconnecting both battery cables with the ignition knob in the "LOCK" position. Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work. If DTC is detected, perform trouble diagnosis according to self-diagnostic results.

For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mechanism is adopted on the key cylinder.

For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and steering wheel rotation will become impossible.

If steering wheel rotation is required when battery power is interrupted, follow the procedure below before starting the repair operation.

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 disconnecting and disassembly.
3. After disconnecting pipes, plug openings to stop fuel leakage.

Special Service Tool

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

SPECIAL SERVICE TOOL SPECIFICATION Tool number (Kent-Moore No.) Tool name Description KV10111100 (J-37228) Seal cutter Removing steel oil pan and rear timing chain case - (J-44626) Air fuel sensor Socket Loosening or tightening air fuel ratio A/F sensor 22 mm (0.87 in) EG15050500 (J-45402) Compression gauge adapter Inspecting compression pressure KV10116200 (J-26336-A) Valve spring compressor KV10115900 (J-26336-20) Attachment KV10109220 (-) Adapter Disassembling valve mechanism Part (1) is a component of KV10116200 (J-26336-A), but part (2) is not. 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-38958) Valve oil seal drift Installing valve oil seal Use side A. 20 (0.79) dia. 13 (0.51) dia. 10.3 (0.406) dia. 8 (0.31) dia. 10.7 (0.421) dia. 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 - (J-47245) Ring gear stopper Removing and installing crankshaft pulley 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) - (J-46535) Drive belt tension releaser Releasing drive belt tension

Scheme 149

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Scheme 154

Commercial Service Tool

COMMERCIAL SERVICE TOOL SPECIFICATION (Kent-Moore No.) Tool name Description Power tool Loosening bolts and nuts Spark plug wrench Removing and installing spark plug (J-24239-01) Cylinder head bolt wrench Loosening and tightening cylinder head bolt, and use with angle wrench [SST: KV10112100 (BT-8653-A)] 13 (0.51) dia. 12 (0.47) 10 (0.39) Unit: mm (in) Valve seat cutter set Finishing valve seat dimensions Pulley puller Removing crankshaft pulley 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 hole Reaming hole for oversize valve guide Intake & Exhaust: d1: 6.0 mm (0.236 in) dia. d2: 10.175 - 10.196 mm (0.4006 - 0.4014 in) dia. Front oil seal drift Installing front oil seal Rear oil seal drift Installing rear oil seal (J-43897-18) (J-43897-12) Oxygen sensor thread cleaner Reconditioning the exhaust system threads before installing a new A/F sensor and heated oxygen sensor (use with anti-seize lubricant shown below.) J-43897-18 (18 mm dia.) (0.71 in) for zirconia heated oxygen sensor J-43897-12 (12 mm dia.) (0.55 in) for Titania heated oxygen sensor Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907) Lubricating A/F sensors and heated oxygen sensor thread cleaning tool when reconditioning exhaust system threads

Scheme 155

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Scheme 160

DRIVE BELT TENSION

There is no manual drive belt tension adjustment. The drive belt tension is automatically adjusted by the drive belt auto tensioner.

Scheme 161

1. Remove the air duct and resonator assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-382166-S41619510092011011400000) ".
2. Install Tool on drive belt auto tensioner pulley bolt, move in the direction of arrow (loosening direction of tensioner) as shown in the figure. Tool number : - (J-46535) CAUTION: Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off.
3. Remove the drive belt.

Camshaft Journal Clearance

Camshaft Journal Diameter

Scheme 162

1. Measure the diameter of the camshaft journal. Standard diameter : 25.950 - 25.970 mm (1.0217 - 1.0224 in)

Camshaft Bracket Inner Diameter

1. Tighten the camshaft bracket bolt to the specified torque.
2. Measure the inner diameter of the camshaft bracket. Standard : 26.000 - 26.021 mm (1.0236 - 1.0244 in)

Calculation of Camshaft Journal Clearance

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

Standard : 0.030 - 0.071 mm (0.0012 - 0.0028 in)

Scheme 163

1. If measurement is not within specification, replace either or both camshaft and cylinder head. NOTE: The inner diameter of the camshaft bracket is manufactured together with the cylinder head. Replace the whole cylinder head as an assembly.

Scheme 164

Scheme 165

1. Install dial gauge in the thrust direction on the front end of the camshaft. Measure the end play when the camshaft is moved forward/backward (in direction to axis). Standard : 0.115 - 0.188 mm (0.0045 - 0.0074 in)
2. If measurement is out of the specified range, replace the camshaft and measure again.
3. If measurement is still out of the specified range, replace the cylinder head.
4. Measure the following parts if end play is outside the specified value. Dimension "A" for camshaft No. 1 journal Standard : 30.500 - 30.548 mm (1.2008-1.2027 in) Dimension "B" for cylinder head No. 1 journal Standard : 30.360 - 30.385 mm (1.1953-1.1963 in)
5. If measurements are not within specification, replace the camshaft and/or cylinder head.

Scheme 166

1. Install the camshaft in the cylinder head.
2. Install the camshaft sprocket to the camshaft.
3. Measure the camshaft sprocket runout. Runout : Less than 0.15 mm (0.0059 in) If measurement exceeds the specification, replace the camshaft sprocket.

Valve Lifter

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

Scheme 167

1. If any damage is found, replace the valve lifter.
2. Select the thickness of the head so that the valve clearance is within the standard when replacing. Refer to " «VALVE CLEARANCE»(ref-382166-S33641870782011011400000) ".

Valve Lifter Clearance

Valve Lifter Diameter

Scheme 168

1. Measure the diameter of the valve lifter. Standard : 33.977 - 33.987 mm (1.3377 - 1.3381 in)

Valve Lifter Hole Diameter

1. Measure the diameter of the valve lifter hole of the cylinder head, using suitable tool. Standard : 34.000 - 34.016 mm (1.3386 - 1.3392 in)

Calculation of Valve Lifter Clearance

(Valve lifter clearance) = (valve lifter hole diameter) - (valve lifter diameter)

Standard : 0.013 - 0.039 mm (0.0005 - 0.0015 in)

Scheme 169

1. If the measurement is not within specification, referring to each specification of the valve lifter diameter and hole diameter, replace either or both the valve lifter and cylinder head.

Scheme 170

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Scheme 173

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Scheme 176

1. Install the valve lifters if removed. Install removed parts in their original locations.
2. Install the camshafts. Refer to the table below for identification of the RH and LH, and intake and exhaust. INTAKE AND EXHAUST REFERENCE Bank INT EXH Identification paint (front) Identification paint (rear) Identification rib RH INT Pink - Yes EXH - Orange Yes LH INT Pink - No EXH - Orange No Install so that the RH bank (B) dowel pins (A) and LH bank (C) dowel pins (A) at the front of the camshaft face are in the direction shown in the figure.
3. Install the RH bank (B) and LH bank (D) camshaft brackets (A). Install by referring to the installation location mark (E) on the upper surface. Install so that the installation location mark (E) can be correctly read when viewed from the intake manifold side (C). <--: Front Install No. 1 camshaft bracket using the following procedure: C: 11 mm (0.43 in) D: 2.0 - 3.0 mm (0.079 - 0.118 in) dia. Apply liquid gasket to No. 1 camshaft bracket (A) and (B) as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-382152-S15373783892011011400000) ". CAUTION: After installation, be sure to wipe off any excessive liquid gasket leaking from part (C) and (D) both on RH and LH sides. Remove completely any excess of liquid gasket inside bracket. Apply liquid gasket (C) to the back side of the LH (A) bank front cover and RH (B) bank front cover as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-382152-S15373783892011011400000) ". C: 2.6 - 3.6 mm (0.102 - 0.142 in) dia. Position No. 1 camshaft bracket close to the mounting position, and then install it to prevent from touching liquid gasket applied to each surface. Temporarily tighten the RH (A) and LH (B) front cover bolts (4 for each bank) as shown in the figure.
4. Tighten the camshaft bracket bolts as follows: Camshaft bracket bolts Step 1 (bolts 9 - 12) : 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 (all bolts) : 5.88 N.m (0.6 kg-m, 52 in-lb) Step 4 (all bolts) : 10.4 N.m (1.1 kg-m, 92 in-lb) CAUTION: After tightening the camshaft bracket bolts, be sure to wipe off excessive liquid gasket from the parts listed below. Mating surface of rocker cover Mating surface of front cover A: RH bank B: Exhaust side C: LH bank D: Intake side <--: Front Tighten the RH (A) and LH (B) front cover bolts (4 for each bank) as shown in the figure to the specified torque. Front cover bolts : 11.0 N.m (1.1 kg-m, 8 ft-lb)
5. Install the camshaft sprockets using the following procedure: A: LH bank shown in the figure Install the camshaft sprockets aligning them with the matching marks painted on the timing chain (B) and the camshaft sprockets (C) before removal. Align the camshaft sprocket key groove with the dowel pin on the camshaft front edge at the same time. Then temporarily tighten camshaft sprocket bolts. Install the intake (VTC) (A) and exhaust (B) side camshaft sprockets by selectively using the groove of the dowel pin according to the bank for the exhaust (B) side camshaft sprockets. (Common part used for both exhaust banks.) NOTE: Use the groove marked "R" for RH bank and "L" for LH bank. Lock the hexagonal part of the camshaft in the same way as for removal, and tighten the camshaft sprocket bolts. Check again that the timing alignment mark on the timing chain and on each sprocket are aligned.
6. Install the chain tensioner using the following procedure: NOTE: LH is shown in the figure. Install the chain tensioner. Compress the plunger and hold it using a stopper pin when installing. Loosen the slack guide side timing chain by rotating the camshaft hexagonal part if mounting space is small. Chain tensioner bolts : 6.9 N.m (0.70 kg-m, 61 in-lb) Remove the stopper pin and release the plunger, and then apply tension to the timing chain. Install the chain tensioner cover onto the front cover. Apply liquid gasket as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-382152-S15373783892011011400000) ". Chain tensioner cover bolts : 9.0 N.m (0.92 kg-m, 80 in-lb)
7. Check and adjust valve clearances. Refer to " «VALVE CLEARANCE»(ref-382166-S33641870782011011400000) ".
8. Installation of the remaining components is in the reverse order of removal.

Valve Stem Diameter

Measure the diameter of the valve stem using suitable tool.

Standard

Intake : 5.965 - 5.980 mm (0.2348 - 0.2354 in)

Exhaust : 5.955 - 5.970 mm (0.2344 - 0.2350 in)

Scheme 177

Valve Guide Inside Diameter

Measure the inside diameter of the valve guide using suitable tool.

Standard

Intake and Exhaust : 6.000 - 6.018 mm (0.2362 - 0.2369 in)

Valve Guide Clearance

1. (Valve guide clearance) = (Valve guide inside 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 (0.0031 in) Exhaust : 0.09 mm (0.0035 in)
2. If the calculated value exceeds the limit, replace valve and/or valve guide. When the valve guide must be replaced, follow the valve guide replacement procedure.

Piston and Piston Pin Clearance

(Piston pin clearance) = (Piston pin hole diameter) - (Piston pin diameter)

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

Scheme 178

1. If clearance exceeds specification, replace either or both the piston/piston pin assembly and the connecting rod assembly with reference to the specification of each part.
2. Use the piston selection table to replace piston/piston pin assembly. Refer to " «HOW TO SELECT PISTON AND BEARING»(ref-382166-S03124123922011011400000) ".
3. Use the connecting rod bearing selection table to replace connecting rod. Refer to " «HOW TO SELECT PISTON AND BEARING»(ref-382166-S03124123922011011400000) ". 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).
4. Follow "Connecting Rod Bushing Oil Clearance (Small End)" for the values for each grade at the plant.

Scheme 179

1. Measure side clearance of the piston ring and piston ring groove using suitable tool. Standard: Top ring : 0.035 - 0.085 mm (0.0014 - 0.0033 in) 2nd ring : 0.030 - 0.070 mm (0.0012 - 0.0028 in) Oil ring : 0.015 - 0.185 mm (0.0006 - 0.0073 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 180

1. Check if the diameter of the cylinder bore is within specification. Refer to " «STANDARD AND LIMIT»(ref-382166-S15428287382011011400000) ".
2. Insert the piston ring into the middle of the cylinder using the piston, and measure the gap. Standard Top ring : 0.23 - 0.33 mm (0.0091 - 0.0130 in) 2nd ring : 0.25 - 0.40 mm (0.0098 - 0.0157 in) Oil ring : 0.20 - 0.60 mm (0.0079 - 0.0236 in) Limit: Top ring : 0.56 mm (0.0220 in) 2nd ring : 0.52 mm (0.0205 in) Oil ring : 0.96 mm (0.0378 in)
3. If out of specification, replace piston ring.

Scheme 181

Scheme 182

1. Check connecting rod alignment using suitable tool. Limit: Bend : 0.15 mm (0.0059 in) per 100 mm (3.94 in) length Torsion : 0.30 mm (0.0118 in) per 100 mm (3.94 in) length
2. If measurement exceeds the limit, replace connecting rod assembly.

Scheme 183

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 large end inside diameter. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-382166-S15446676812011011400000) ". Standard : 57.000 - 57.013 mm (2.2441 - 2.2446 in)
2. If measurement exceeds the standard, replace connecting rod.

Scheme 184

1. Measure inside diameter of bushing using suitable tool. Standard : 22.000 - 22.006 mm (0.8661 - 0.8664 in)

Piston Pin Diameter

1. Measure diameter of piston pin using suitable tool. Standard : 21.989 - 21.995 mm (0.8657 - 0.8659 in)

Connecting Rod Bushing Oil Clearance (Small End)

(Connecting rod small end oil clearance) = (Inside diameter of connecting rod small end) - (Piston pin diameter)

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

1. If 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 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 " «HOW TO SELECT PISTON AND BEARING»(ref-382166-S03124123922011011400000) ".

Factory installed parts grading

1. Only grade 0 is available. CONNECTING ROD BUSHING INSIDE DIAMETER SPECIFICATION Unit: mm (in) Grade 0 Connecting rod bushing inside diameter 22.000 - 22.006 (0.8661 - 0.8664) Piston pin diameter 21.989 - 21.995 (0.8657 - 0.8659) Piston pin hole diameter 21.993 - 21.999 (0.8659 - 0.8661)

Scheme 185

1. Remove any oil, scale, gasket, sealant and carbon deposits from the cylinder block surface. CAUTION: Do not allow any debris to enter the oil or coolant passages.
2. Measure block upper face for distortion in six directions as shown in the figure below. Standard : 0.03 mm (0.0012 in) Limit : 0.1 mm (0.004 in)
3. If measurement exceeds the limit, replace cylinder block.

Scheme 186

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-382166-S15446676812011011400000) ".
2. Measure inside diameter of main bearing housing. Standard : 68.944 - 68.968 mm (2.7143 - 2.7153 in)
3. If out of the standard, replace cylinder block and main bearing caps as an assembly. NOTE: These components must be replaced as a single unit, because they were processed together.

Scheme 187

Scheme 188

1. Measure the cylinder bore for wear, out-of-round and taper at six different points on each cylinder ("X" and "Y" directions at "A", "B" and "C"). NOTE: When determining cylinder bore grade, measure cylinder bore at "B" position. Standard diameter: 98.000 - 98.030 mm (3.8583 - 3.8594 in) Wear limit: 0.20 mm (0.0079 in) Out-of-round (Difference between "X" and "Y"): Limit: 0.015 mm (0.0006 in) Taper limit (Difference between "A" and "C"): Limit: 0.010 mm (0.0004 in)
2. If measured value exceeds the repair limit, or if there are scratches and/or seizure on the cylinder inner wall, hone or bore the inner wall.

Scheme 189

Scheme 190

1. Measure piston skirt diameter using suitable tool. Standard : 97. 980 - 98. 010 mm (3.8575 - 3.8587 in)
2. Measure point "H". Distance from the top : 39 mm (1.54 in)

Piston to Cylinder Bore Clearance

1. Calculate by using diameter of the piston skirt and the cylinder bore diameter (direction X, position B). (Clearance) = (Cylinder bore diameter) - (piston skirt diameter) Standard : 0.010 - 0.030 mm (0.0004 - 0.0012 in) Limit : 0.08 mm (0.0031 in)
2. If calculation 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 where, 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 them to the specified torque. Otherwise, cylinder bores may be distorted in final assembly.
3. Cut the cylinder bores. NOTE: When any cylinder needs boring, all other cylinders must also be bored. Do not cut too much out of cylinder bore at one time. Cut only 0.05 mm (0.0020 in) or so in diameter at a time.
4. Hone cylinders to obtain the specified piston-to-bore clearance.
5. Measure finished cylinder bore for out-of-round and taper. NOTE: Measurement should be done after cylinder bore cools down.

CRANKSHAFT JOURNAL DIAMETER

1. Measure diameter of crankshaft journals. Standard : 63.940 - 63.964 mm (2.5173 - 2.5183 in)
2. If measurement is out of standard, measure the main bearing oil clearance. Then use the undersize bearing.

Scheme 191

1. Measure diameter of crankshaft pin using suitable tool. Standard : 53.956 - 53.974 mm (2.1243 - 2.1250 in)
2. If measurement is out of standard, measure connecting rod bearing oil clearance. Then use undersize bearing.

Scheme 192

1. Measure dimensions at four different points as shown in the figure below on each journal and pin.
2. Out-of-roundness is indicated by the difference in dimension 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 (Difference between "X" and "Y") : 0.002 mm (0.0001 in) Taper (Difference between "A" and "B") : 0.002 mm (0.0001 in)
4. If measured value exceeds the standard, correct or replace crankshaft.
5. If corrected, measure the bearing oil clearance of the corrected journal or pin. Then select the main bearing or connecting rod bearing.

Scheme 193

1. Place a V-block on a precise flat table to support the journals on both ends of the crankshaft.
2. Measure at No. 3 journal using suitable tool.
3. While rotating crankshaft, read the movement of the pointer.
4. Half of the movement shows the runout. Limit : Less than 0.05 mm (0.002 in)
5. If measurement exceeds the limit, replace crankshaft.

Scheme 194

1. Install connecting rod bearings to the connecting rod and cap. Tighten connecting rod bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-382166-S15446676812011011400000) ". Measure inside diameter of connecting rod bearing. (Oil clearance) = (Inside diameter of connecting rod bearing) - (Crankshaft pin diameter) Standard : 0.020 - 0.039 mm (0.0008 - 0.0015 in) Limit : 0.055 mm (0.0022 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-382166-S03124123922011011400000) ".

Scheme 195

1. Remove oil and dust on the crankshaft pin and surfaces of each bearing completely.
2. Cut a plastigage slightly shorter than the bearing width, and place it in the crankshaft axial direction, avoiding oil holes.
3. Install the connecting rod bearings to the connecting rod and connecting rod bearing cap, and tighten the connecting rod bolts to the specified torque. CAUTION: Do not rotate crankshaft with plastigage installed.
4. Remove the connecting rod bearing cap and bearings. Measure the plastigage width using the scale on the plastigage bag. NOTE: The procedure when the measured value exceeds the repair limit is the same as that described in "Method of Measurement".

Scheme 196

1. Install the main bearings to the cylinder block and main bearing cap. Measure the main bearing inside diameter with the bearing cap bolts tightened to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-382166-S15446676812011011400000) ". (Oil clearance) = (Inside diameter of main bearing) - (Crankshaft journal diameter) Standard: No. 1 and 5 journals : 0.001 - 0.011 mm (0.00004 - 0.0004 in) No. 2, 3 and 4 journals : 0.007 - 0.017 mm (0.0003 - 0.0007 in) Limit: No. 1 and 5 journals : 0.021 mm (0.0008 in) No. 2, 3 and 4 journals : 0.027 mm (0.0011 in)
2. If measured value exceeds the repair limit, select main bearings referring to the main bearing inside diameter and crankshaft journal diameter, so that the oil clearance satisfies the standard. Refer to " «HOW TO SELECT PISTON AND BEARING»(ref-382166-S03124123922011011400000) ".

Method of Using Plastigage

1. Remove oil and dust on the crankshaft journal and 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 main bearings to the cylinder block and main bearing cap, and tighten the main bearing bolts to the specified torque. CAUTION: Do not rotate crankshaft with plastigage installed.
4. Remove bearing cap and bearings. Measure plastigage width using the scale on the plastigage bag. NOTE: The procedure when the measured value exceeds the repair limit is the same as that described in "Method of Measurement".

Scheme 197

Scheme 198

1. When the bearing cap is removed after being tightened to the specified torque with main bearings installed, the tip end of the bearing must protrude. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-382166-S15446676812011011400000) " for the tightening procedure. Standard : There must be crush height
2. If standard is not met, replace main bearings.

Scheme 199

Scheme 200

1. When connecting rod bearing cap is removed after being tightened to the specified torque with the connecting rod bearings installed, the tip end of the bearing must protrude. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-382166-S15446676812011011400000) " for tightening procedure. Standard : There must be crush height.
2. If standard is not met, replace connecting rod bearings.

MAIN BEARING CAP BOLT DIAMETER

1. Check for bolts (M9 and M12) installed from lower side using the following procedure. NOTE: Side bolt (M10) is outside the target. Figure shows M12 bolt.
2. Measure bolt diameter "d1" from tip of the bolt to dimension "a".
3. Measure bolt diameter "d2" from the dimension between tip of the bolt and dimension "b" as base station to dimension "c". NOTE: If a narrower part in the threads is determined by visual check, measure "d2" at that point.
4. Calculate the difference between "d1" and "d2". M9 bolt Dimension "a" : 9 mm (0.35 in) Dimension "b" : 15 mm (0.59 in) Dimension "c" : 20 mm (0.79 in) Limit : 0.15 mm (0.0059 in) M12 bolt Dimension "a" : 12 mm (0.47 in) Dimension "b" : 55 mm (2.17 in) Dimension "c" : 20 mm (0.79 in) Limit : 0.15 mm (0.0059 in)
5. Replace applicable bolts if outside the limit.

Scheme 201

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

HOW TO SELECT PISTON

Piston Selective Fitting When New Cylinder Block is Used

Scheme 202

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

When Cylinder Block is Reused

1. Measure cylinder block bore diameter.
2. Determine the bore grade by comparing the measurement with the values under the "Cylinder bore diameter" of the piston selection table. PISTON SELECTION Unit: mm (in) Grade number (Mark) 1 2 3 Cylinder bore diameter 98.000-98.010 (3.8583-3.8587) 98.010-98.020 (3.8587-3.8590) 98.020-98.030 (3.8590-3.8594) Piston diameter 97.980-97.990 (3.8575-3.8579) 97.990-98.000 (3.8579-3.8583) 98.000-98.010 (3.8583-3.8587) 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 CONNECTING ROD BEARING

When New Connecting Rod and Crankshaft are Used

Scheme 203

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

When Crankshaft and Connecting Rod are Reused

1. Measure dimensions of the big end inside diameter of the connecting rod and diameter of the crankshaft pin individually.
2. Apply the measured dimension to the "Connecting Rod Bearing Selection Table".
3. The following steps are the same as in "When New Connecting Rod and Crankshaft are Used".

Connecting Rod Bearing Selection Table

Scheme 204

CONNECTING ROD BEARING GRADE

Undersize Bearings Usage Guide

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

BEARING UNDERSIZE THICKNESS SPECIFICATION

Fillet R : 1.5 - 1.7 mm (0.059 - 0.067 in)

Scheme 205

HOW TO SELECT MAIN BEARING

When New Cylinder Block and Crankshaft are Used

1. Apply the main bearing housing grade on the bottom face of the cylinder block to the row in "Main Bearings Selection Table".
2. Apply the journal diameter grade on the crankshaft front to the column in "Main Bearings Selection Table".
3. Read the symbol at the cross point of the selected row and column in the "Main Bearings Selection Table". CAUTION: Initial clearance for No. 1, 5 journal and No. 2, 3, 4 journal is different. Use two different selection lists for each part. No. 1, 5 journal and No. 2, 3, 4 journal have the same signs but different measures. Do not confuse them.
4. Apply the symbol to the "Main Bearings Grade Table" to select. NOTE: Grade list applies to all journals. Service parts are available as a set of both upper and lower.

When Cylinder Block and Crankshaft are Reused

1. Measure the inside diameter of the cylinder block main bearings housing and the outside diameter of the crankshaft journal.
2. Apply measurement in above step 1 to "Main Bearings Selection Table".
3. The following steps are same as in "When New Cylinder Block and Crankshaft are Used".

Main Bearings Selection Table (No. 1 and No. 5 journal)

Scheme 206

Main Bearings Selection Table (No. 2, 3 and 4 journal)

Scheme 207

Main Bearings Grade Table (All Journals)

MAIN BEARINGS GRADE

Use Undersize Bearing Usage Guide

1. Use undersize (US) bearing when the oil clearance with standard size main bearing is not within specification.
2. When using undersize (US) bearing, measure the inside diameter of the bearing installed and grind the journal until the oil clearance falls within specification. BEARING UNDERSIZE Unit: mm (in) Undersize Thickness 0.25 (0.0098) 2.618 - 2.626 (0.1031 - 0.1034) CAUTION: Do not damage fillet R when grinding crankshaft journal in order to use undersized bearing (All journals). Fillet R : 1.5 - 1.7 mm (0.059 - 0.067 in)

DRIVE BELTS

DRIVE BELTS SPECIFICATION

EXHAUST MANIFOLD

EXHAUST MANIFOLD SPECIFICATION

SPARK PLUG

SPARK PLUG SPECIFICATION

CAMSHAFT AND CAMSHAFT BEARING

CAMSHAFT AND CAMSHAFT BEARING SPECIFICATION Unit: mm (in) Items Standard Camshaft runout [TIR (1) ] Less than 0.02 (0.0008) Camshaft cam height "A" Intake 44.865 - 45.055 (1.7663 - 1.7738) Exhaust 45.075 - 45.265 (1.7746 - 1.7821) Cam wear limit 0.02 (0.0008) Outside diameter of camshaft journal 25.950 - 25.970 (1.0217 - 1.0224) Camshaft bracket inside diameter 26.000 - 26.021 (1.0236 - 1.0244) Camshaft journal clearance 0.030 - 0.071 (0.0012 - 0.0028) Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) Camshaft dimension "A" for #1 journal 30.500 - 30.548 (1.2008 - 1.2027) Cylinder head dimension "B" for #1 journal 30.360 - 30.385 (1.1953 - 1.1963) Camshaft sprocket runout [TIR (1) ] Less than 0.15 (0.0059) (1) Total indicator reading

Valve Seal

VALVE SEAL SPECIFICATION

VALVE LIFTER SPECIFICATION

Valve Clearance

VALVE CLEARANCE SPECIFICATION

Available Valve Lifter

AVAILABLE VALVE LIFTER SPECIFICATION Unit: mm (in) Identification (stamped) Mark Thickness N788 7.88 (0.3102) N790 7.90 (0.3110) N792 7.92 (0.3118) N794 7.94 (0.3126) N796 7.96 (0.3134) N798 7.98 (0.3142) N800 8.00 (0.3150) N802 8.02 (03.157) N804 8.04 (0.3165) N806 8.06 (0.3173) N808 8.08 (0.3181) N810 8.10 (0.3189) N812 8.12 (0.3197) N814 8.14 (0.3205) N816 8.16 (0.3213) N818 8.18 (0.3220) N820 8.20 (0.3228) N822 8.22 (0.3236) N824 8.24 (0.3244) N826 8.26 (0.3252) N828 8.28 (0.3260) N830 8.30 (0.3268) N832 8.32 (0.3276) N834 8.34 (0.3283) N836 8.36 (0.3291)

CYLINDER HEAD

CYLINDER HEAD SPECIFICATION Unit: mm (in) Items Standard Limit Head surface distortion 0.03 (0.0012) 0.1 (0.004) Nominal cylinder head height "H" 126.3 (4.97)

Scheme 208

Spark Plug Tube

SPARK PLUG TUBE SPECIFICATION Unit: mm (in) Items Standard Press fit height "H" 38.400 - 39.400 (1.512 - 1.551)

Valve Dimensions

VALVE DIMENSIONS SPECIFICATION Unit: mm (in) Standard model FFV model Valve head diameter "D" Intake 37.0 - 37.3 (1.457 - 1.469) Exhaust 31.2 - 31.5 (1.228 - 1.240) Valve length "L" Intake 96.21- 96.71 (3.7878 - 3.8075) Exhaust 93.74 - 94.24 (3.6905 - 3.7102) Valve stem diameter "d" Intake 5.965 - 5.980 (0.2348 - 0.2354) Exhaust 5.955 - 5.970 (0.2344 - 0.2350) Valve seat angle "α" Intake 45°15' - 45°45' Exhaust Valve margin "T" Intake 1.1 (0.043) 0.6 (0.024) Exhaust 1.3 (0.051)

Scheme 209

Valve Guide

VALVE GUIDE SPECIFICATION Unit: mm (in) Items Standard Oversize [0.2 (0.008)] (service) Valve guide Outside diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029) Inside 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) Items Standard Limit Stem to guide clearance Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031) Exhaust 0.030 - 0.063 (0.0012 - 0.0025) 0.09 (0.0035) Projection length "L" Intake 12.6 - 12.8 (0.496 - 0.504) Exhaust 12.5 - 12.9 (0.492 - 0.508)

Scheme 210

Valve Seat

VALVE SEAT SPECIFICATION Unit: mm (in) Items Standard Oversize [0.5 (0.020)] (Service) Cylinder head seat recess diameter (D) Intake 38.000 - 38.016 (1.4961 - 1.4967) 38.500 - 38.516 (1.5157 - 1.5164) Exhaust 32.200 - 32.216 (1.2677 - 1.2683) 32.700 - 32.716 (1.2874 - 1.2880) Valve seat interference fit Intake 0.081 - 0.113 (0.0032 - 0.0044) Exhaust 0.064 - 0.096 (0.0025 - 0.0038) Valve seat diameter (d) Intake 38.097 - 38.113 (1.4999 - 1.5005) 38.597 - 38.613 (1.5196 - 1.5202) Exhaust 32.280 - 32.296 (1.2709 - 1.2715) 32.780 - 32.796 (1.2905 - 1.2912)

Scheme 211

Valve Spring

VALVE SPRING SPECIFICATION

CYLINDER BLOCK

CYLINDER BLOCK SPECIFICATION Unit: mm (in) Surface flatness Standard 0.03 (0.0012) Limit 0.1 (0.004) Main bearing housing inside diameter Standard 68.944 - 68.968 (2.7143 - 2.7153) Cylinder bore diameter Standard Grade No. 1 98.000 - 98.010 (3.8583 - 3.8587) Grade No. 2 98.010 - 98.020 (3.8587 - 3.8590) Grade No. 3 98.020 - 98.030 (3.8590 - 3.8594) Wear limit 0.20 (0.0079) Out-of-round (Difference between X and Y) Limit 0.015 (0.0006) Taper (Difference between A and C) 0.010 (0.0004) Main journal inside diameter grade (Without bearing) Grade No. A 68.944 - 68.945 (2.7143 - 2.7144) Grade No. B 68.945 - 68.946 (2.7144 - 2.7144) Grade No. C 68.946 - 68.947 (2.7144 - 2.7144) Grade No. D 68.947 - 68.948 (2.7144 - 2.7145) Grade No. E 68.948 - 68.949 (2.7145 - 2.7145) Grade No. F 68.949 - 68.950 (2.7145 - 2.7146) Grade No. G 68.950 - 68.951 (2.7146 - 2.7146) Grade No. H 68.951 - 68.952 (2.7146 - 2.7146) Grade No. J 68.952 - 68.953 (2.7146 - 2.7147) Grade No. K 68.953 - 68.954 (2.7147 - 2.7147) Grade No. L 68.954 - 68.955 (2.7147 - 2.7148) Grade No. M 68.955 - 68.956 (2.7148 - 2.7148) Grade No. N 68.956 - 68.957 (2.7148 - 2.7148) Grade No. P 68.957 - 68.958 (2.7148 - 2.7149) Grade No. R 68.958 - 68.959 (2.7149 - 2.7149) Grade No. S 68.959 - 68.960 (2.7149 - 2.7150) Grade No. T 68.960 - 68.961 (2.7150 - 2.7150) Grade No. U 68.961 - 68.962 (2.7150 - 2.7150) Grade No. V 68.962 - 68.963 (2.7150 - 2.7151) Grade No. W 68.963 - 68.964 (2.7151 - 2.7151) Grade No. X 68.964 - 68.965 (2.7151 - 2.7152) Grade No. Y 68.965 - 68.966 (2.7152 - 2.7152) Grade No. 4 68.966 - 68.967 (2.7152 - 2.7152) Grade No. 7 68.967 - 68.968 (2.7152 - 2.7153) Difference in bore diameter between cylinders Standard Less than 0.03 (0.0012)

Available Piston

PISTON SKIRT DIAMETER SPECIFICATION Unit: mm (in) Items Standard Limit Piston skirt diameter "A" Grade No. 1 97.980 - 97.990 (3.8575 - 3.8579) - Grade No. 2 97.990 - 98.000 (3.8579 - 3.8583) - Grade No. 3 98.000 - 98.010 (3.8583 - 3.8587) - "H" dimension 39 (1.54) - Piston pin hole diameter Grade No. 0 21.993 - 21.999 (0.8659 - 0.8661) - Piston to cylinder bore clearance 0.010 - 0.030 (0.0004 - 0.0012) 0.08 (0.0031)

Piston Ring

PISTON RING SPECIFICATION

Piston Pin

PISTON PIN SPECIFICATION

CONNECTING ROD

CONNECTING ROD SPECIFICATION

CRANKSHAFT

CRANKSHAFT SPECIFICATION Unit: mm (in) Main journal dia. "Dm" grade (No. 1 and 5) Standard Grade No. G 63.963 - 63.964 (2.5182 - 2.5183) Grade No. H 63.962 - 63.963 (2.5182 - 2.5182) Grade No. J 63.961 - 63.962 (2.5181 - 2.5182) Grade No. K 63.960 - 63.961 (2.5181 - 2.5181) Grade No. L 63.959 - 63.960 (2.5181 - 2.5181) Grade No. M 63.958 - 63.959 (2.5180 - 2.5181) Grade No. N 63.957 - 63.958 (2.5180 - 2.5180) Grade No. P 63.956 - 63.957 (2.5179 - 2.5180) Grade No. R 63.955 - 63.956 (2.5179 - 2.5179) Grade No. S 63.954 - 63.955 (2.5179 - 2.5179) Grade No. T 63.953 - 63.954 (2.5178 - 2.5179) Grade No. U 63.952 - 63.953 (2.5178 - 2.5178) Grade No. V 63.951 - 63.952 (2.5178 - 2.5178) Grade No. W 63.950 - 63.951 (2.5177 - 2.5178) Grade No. X 63.949 - 63.950 (2.5177 - 2.5177) Grade No. Y 63.948 - 63.949 (2.5176 - 2.5177) Grade No. 1 63.947 - 63.948 (2.5176 - 2.5176) Grade No. 2 63.946 - 63.947 (2.5176 - 2.5176) Grade No. 3 63.945 - 63.946 (2.5175 - 2.5176) Grade No. 4 63.944 - 63.945 (2.5175 - 2.5175) Grade No. 5 63.943 - 63.944 (2.5174 - 2.5175) Grade No. 6 63.942 - 63.943 (2.5174 - 2.5174) Grade No. 7 63.941 - 63.942 (2.5174 - 2.5174) Grade No. 9 63.940 - 63.941 (2.5173 - 2.5174) Main journal dia. "Dm" grade (No. 2, 3 and 4) Standard Grade No. A 63.963 - 63.964 (2.5182 - 2.5183) Grade NO. B 63.962 - 63.963 (2.5182 - 2.5182) Grade NO. C 63.961 - 63.962 (2.5181 - 2.5182) Grade No. D 63.960 - 63.961 (2.5181 - 2.5181) Grade No. E 63.959 - 63.960 (2.5181 - 2.5181) Grade No. F 63.958 - 63.959 (2.5180 - 2.5181) Grade No. G 63.957 - 63.958 (2.5180 - 2.5180) Grade No. H 63.956 - 63.957 (2.5179 - 2.5180) Grade No. J 63.955 - 63.956 (2.5179 - 2.5179) Grade No. K 63.954 - 63.955 (2.5179 - 2.5179) Grade No. L 63.953 - 63.954 (2.5178 - 2.5179) Grade No. M 63.952 - 63.953 (2.5178 - 2.5178) Grade No. N 63.951 - 63.952 (2.5178 - 2.5178) Grade No. P 63.950 - 63.951 (2.5177 - 2.5178) Grade No. R 63.949 - 63.950 (2.5177 - 2.5177) Grade No. S 63.948 - 63.949 (2.5176 - 2.5177) Grade No. T 63.947 - 63.948 (2.5176 - 2.5176) Grade No. U 63.946 - 63.947 (2.5176 - 2.5176) Grade No. V 63.945 - 63.946 (2.5175 - 2.5176) Grade No. W 63.944 - 63.945 (2.5175 - 2.5175) Grade No. X 63.943 - 63.944 (2.5174 - 2.5175) Grade No. Y 63.942 - 63.943 (2.5174 - 2.5174) Grade No. 1 63.941 - 63.942 (2.5174 - 2.5174) Grade No. 2 63.940 - 63.941 (2.5173 - 2.5174) Pin journal dia. "Dp" Standard Grade No. 0 53.968 - 53.974 (2.1247 - 2.1250) Grade No. 1 53.962 - 53.968 (2.1245 - 2.1247) Grade No. 2 53.956 - 53.962 (2.1243 - 2.1245) Center distance "r" 45.96 - 46.04 (1.8094 - 1.8126) Out-of-round (Difference between X and Y) Limit 0.002 (0.0001) Taper (Difference between A and B) 0.002 (0.0001) Runout [TIR (1) ] Less than 0.05 (0.002) Crankshaft end play Standard 0.10 - 0.26 (0.0039 - 0.0102) Limit 0.30 (0.0118) (1) Total indicator reading

Scheme 212

MAIN BEARING

MAIN BEARING SPECIFICATION Unit: mm (in) Grade number UPR/LWR Thickness Identification color Remarks 0 - 2.483 - 2.486 (0.0978 - 0.0979) Black Grade is the same for upper and lower bearings 1 - 2.486 - 2.489 (0.0979 - 0.0980) Brown 2 - 2.489 - 2.492 (0.0980 - 0.0981) Green 3 - 2.492 - 2.495 (0.0981 - 0.0982) Yellow 4 - 2.495 - 2.498 (0.0982 - 0.0983) Blue 5 - 2.498 - 2.501 (0.0983 - 0.0985) Pink 6 - 2.501 - 2.504 (0.0985 - 0.0986) Purple 7 - 2.504 - 2.507 (0.0986 - 0.0987) White 8 - 2.507 - 2.510 (0.0987 - 0.0988) Red 01 UPR 2.483 - 2.486 (0.0978 - 0.0979) Black Grade is different for upper and lower bearings. LWR 2.486 - 2.489 (0.0979 - 0.0980) Brown 12 UPR 2.486 - 2.489 (0.0979 - 0.0980) Brown LWR 2.489 - 2.492 (0.0980 - 0.0981) Green 23 UPR 2.489 - 2.492 (0.0980 - 0.0981) Green LWR 2.492 - 2.495 (0.0981 - 0.0982) Yellow 34 UPR 2.492 - 2.495 (0.0981 - 0.0982) Yellow LWR 2.495 - 2.498 (0.0982 - 0.0983) Blue 45 UPR 2.495 - 2.498 (0.0982 - 0.0983) Blue LWR 2.498 - 2.501 (0.0983 - 0.0985) Pink 56 UPR 2.498 - 2.501 (0.0983 - 0.0985) Pink LWR 2.501 - 2.504 (0.0985 - 0.0986) Purple 67 UPR 2.501 - 2.504 (0.0985 - 0.0986) Purple LWR 2.504 - 2.507 (0.0986 - 0.0987) White 78 UPR 2.504 - 2.507 (0.0986 - 0.0987) White LWR 2.507 - 2.510 (0.0987 - 0.0988) Red

Undersize

UNDERSIZE SPECIFICATION

Main Bearing Oil Clearance

MAIN BEARING OIL CLEARANCE SPECIFICATION

Connecting Rod Bearing

CONNECTING ROD BEARING SPECIFICATION

UNDERSIZE SPECIFICATION

Connecting Rod Bearing Oil Clearance

CONNECTING ROD BEARING OIL CLEARANCE SPECIFICATION