Engine Mechanical (KA24DE): Other Nissan Frontier D22

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 seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint System consists of a driver air bag module (located in the center of the steering wheel), a front passenger air bag module (located on the instrument panel on the passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness, and spiral cable.

The vehicle (except Crew Cab model) is equipped with a passenger air bag deactivation switch. Because no rear seat exists where a rear-facing child restraint can be placed, the switch is designed to turn off the passenger air bag so that a rear-facing child restraint can be used in the front passenger seat. The switch is located in the center of the instrument panel, near the ashtray. When the switch is turned to the ON position, the passenger air bag is enabled and could inflate in a frontal collision. When the switch is turned to the OFF position, the passenger air bag is disabled and will not inflate in a frontal collision. A passenger air bag OFF indicator on the instrument panel lights up when the passenger air bag is switched OFF. The driver air bag always remains enabled and is not affected by the passenger air bag deactivation switch.

Information necessary to service the system safely is included in the AIR BAG RESTRAINT SYSTEMS article.

Special Service Tools

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

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Components

SEC. 120 . 130 . 135 . 210

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IDLER SPROCKET

1. Remove upper timing chain. Refer to " «UPPER TIMING CHAIN»(ref-183499-S05185609282005081400000) " .
2. Support lower timing chain by using a suitable tool to prevent chain tensioner spring from coming out. NOTE: This step is only to be applied when the lower cover is not being removed.
3. Remove the idler sprocket.

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1. Drain coolant by removing the cylinder block drain plug and opening the radiator drain cock. Refer to CHANGING ENGINE COOLANT .
2. Drain engine oil from drain plug of oil pan.
3. Remove the following parts. Alternator drive belt. A/C compressor drive belt. Cooling fan with coupling. Radiator shroud.
4. Remove A/C compressor and position it to the side. Remove the idler pulley and bracket as well.
5. Set No. 1 piston to TDC on its compression stroke.
6. Remove the distributor.
7. Remove the crankshaft pulley with suitable puller.
8. Remove oil pan. Refer to " «REMOVAL»(ref-183499-S15507775592005081400000) " .
9. Remove the oil pump and distributor drive shaft, then the oil pickup strainer.
10. Remove the front cover. CAUTION: Be careful not to tear or damage the cylinder head gasket.
11. Remove the following parts. Release the timing chain tensioner. Push piston in and insert a suitable pin into the pin hole. Chain tension arm Lower timing chain guide
12. Remove the upper timing chain and idler sprocket. Refer to " «UPPER TIMING CHAIN»(ref-183499-S05185609282005081400000) " and " «IDLER SPROCKET»(ref-183499-S38464183472005081400000) " .
13. Wipe off the links of the timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with the timing marks on the crankshaft sprocket and idler sprocket.
14. Remove the lower timing chain and sprocket.

1. Install lower timing chain. Refer to " «LOWER TIMING CHAIN»(ref-183499-S37349502212005081400000) " .
2. Install idler sprocket and bolt.

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1. Install lower timing chain and idler sprocket. Refer to " «LOWER TIMING CHAIN»(ref-183499-S37349502212005081400000) " and " «IDLER SPROCKET»(ref-183499-S04627584872005081400000) " .
2. Install upper timing chain and sprockets, referring to the painted marks made during removal.
3. Install chain tensioner. Remove the pin holding the tensioner piston in the bore of the tensioner.
4. Install camshaft sprocket cover: Use a scraper to remove all traces of liquid gasket from mating surfaces of the engine block and camshaft sprocket cover. Apply a continuous bead of RTV sealant to the cover. Refer to " «LIQUID GASKET APPLICATION PLACES»(ref-183499-S21514295742005081400000) " . Also place RTV sealant on the head gasket surface. NOTE: Use Genuine Silicone RTV or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ". CAUTION: Be careful not to tear or damage the cylinder head gasket. Be careful upper timing chain does not slip or jump when installing camshaft sprocket cover.
5. Install the rocker cover gasket on the rocker cover. Apply a continuous bead of RTV sealant to the cover. Refer to " «LIQUID GASKET APPLICATION PLACES»(ref-183499-S21514295742005081400000) " .
6. Install rocker cover. Tighten bolts in numerical order. : 8 -11 N.m (0.8 -1.1 kg-m, 69 - 95 in-lb).
7. Install distributor, aligning as shown.
8. Install vacuum hoses, electrical harnesses, connectors, and harness clamps.

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1. Remove rocker cover.
2. Remove camshaft. Refer to " «TIMING CHAIN»(ref-183499-S29150379742005081400000) " .
3. Remove valve spring and valve oil seal with Tool or a suitable tool. Piston concerned should be set at TDC to prevent valve from falling.
4. Apply engine oil to new valve oil seal and install it with Tool.

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1. Install new oil seal in the direction shown.

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1. Remove radiator shroud and crankshaft pulley.
2. Remove front oil seal Be careful not to scratch front cover.
3. Apply engine oil to new oil seal and install it using a suitable tool.

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1. Remove flywheel or drive plate.
2. Remove rear oil seal retainer
3. Remove rear oil seal from retainer. Be careful not to scratch rear oil seal retainer.
4. Apply engine oil to new oil seal and install it using suitable tool. Install new oil seal in the direction shown.
5. Install rear oil seal retainer. Before installing rear oil seal retainer, remove all traces of liquid gasket from mating surface using a scraper. Also remove traces of liquid gasket from mating surface of cylinder block. Apply a continuous bead of liquid gasket to mating surface of rear oil seal retainer. Use Genuine Silicone RTV or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ". Apply around inner side of bolt holes.

SEC. 111 . 130

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CYLINDER HEAD DISTORTION

Clean surface of cylinder head.

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

Check along six positions shown in the figure.

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1. Head surface flatness: Standard Less than 0.03 mm (0.0012 in) Limit 0.1 mm (0.004 in)

If beyond the specified limit, replace it or resurface it.

Resurfacing limit

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

Amount of cylinder head resurfacing is "A".

Amount of cylinder block resurfacing is "B".

1. The maximum limit: A + B = 0.2 mm (0.008 in)

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)

CAMSHAFT VISUAL CHECK

Check camshaft for scratches, seizure and wear.

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1. Measure camshaft runout at the center journal. Runout (Total indicator reading): Standard: Less than 0.02 mm (0.0008 in) Limit: 0.04 mm (0.0016 in)
2. If it exceeds the limit, replace camshaft.

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1. Measure camshaft cam height. Standard cam height: Intake 41.755 - 41.945 mm (1.644 -1.651 in). Exhaust 41.815 - 42.005 mm (1.646 -1.654 in) Cam height wear limit: Intake & Exhaust 0.2 mm (0.008 in)
2. If wear is beyond the limit, replace camshaft.

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1. Install camshaft bracket and tighten bolts to the specified torque.
2. Measure inner diameter of camshaft bearing. Standard inner diameter: No. 1 to No. 5 journals 28.000 - 28.025 mm (1.1024 -1.1033 in)
3. Measure outer diameter of camshaft journal. Standard outer diameter: No. 1 to No. 5 journals 27.935 - 27.955 mm (1.0998 - 1.1006 in)
4. If clearance exceeds the limit, replace camshaft and/or cylinder head. Camshaft journal clearance: Standard 0.045 - 0.090 mm (0.0018 - 0.0035 in) Limit 0.12 mm (0.0047 in)

Scheme 103

1. Install camshaft in cylinder head.
2. Measure camshaft end play. Camshaft end play: Standard 0.070 - 0.148 mm (0.0028 - 0.0058 in) Limit 0.2 mm (0.008 in)
3. If end play exceeds the limit, replace camshaft and remeasure camshaft end play.
4. If end play still exceeds the limit after replacing camshaft, replace cylinder head.

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1. Install sprocket on camshaft.
2. Measure camshaft sprocket runout. Runout (Total indicator reading): Limit 0.15 mm (0.0059 in)
3. If it exceeds the limit, replace camshaft sprocket.

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1. Measure valve deflection as shown in figure. (Valve and valve guide mostly wear in this direction.) Valve deflection limit (Dial gauge reading): Intake & Exhaust 0.2 mm (0.008 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 = Valve guide inner diameter - Valve stem diameter: If it exceeds the limit, replace valve and remeasure clearance. If clearance still exceeds the limit after replacing valve, replace the valve guide.

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1. To remove valve guide, heat cylinder head to 120 to 140°C (248 to 284°F) by soaking in heated oil.
2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US ton, 2.0 lmp ton) pressure] or hammer and suitable tool.
3. Ream cylinder head valve guide hole. Valve guide hole diameter (for service parts): Intake & Exhaust 11.175 -11.196 mm (0.4400 - 0.4408 in)
4. Heat cylinder head to 120 to 140°C (248 to 284°F) and press service valve guide onto cylinder head. Projection "L": 13.3 - 13.9 mm (0.524 - 0.547 in)
5. Ream valve guide. Finished size: Intake & Exhaust 7.000 - 7.018 mm (0.2756 - 0.2763 in)

VALVE SEATS

Check valve seats for pitting at contact surface. Resurface or replace if excessively worn.

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1. Before repairing valve seats, check valve and valve guide for wear. If they have worn, replace them. Then correct valve seat.
2. Use both hands to cut uniformly.

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1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess in cylinder head. Set the machine depth stop to ensure this.
2. Ream cylinder head recess. Reaming bore for service valve seat Oversize [0.5 mm (0.020 in)]: Intake 38.000 - 38.016 mm (1.4961 - 1.4967 in) Exhaust 32.700 - 32.716 mm (1.2874 - 1.2880 in) Use the valve guide center for reaming to ensure valve seat will have the correct fit.
3. Heat cylinder head to 120 to 140°C (248 to 284°F).
4. Press fit valve seat until it seats on the bottom.
5. Cut or grind valve seat using suitable tool to the specified dimensions. Refer to " «VALVE SEAT»(ref-183499-S39328071532005081400000) " .
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition. Seat face angle "alpha": 45°15' - 45°45' deg. Contacting width "W": Intake 1.48 - 1.63 mm (0.0583 - 0.0642 in) Exhaust 1.8 - 2.0 mm (0.071 - 0.079 in)
8. Use a depth gauge to measure the distance between the mounting surface of the cylinder head spring seat and the valve stem end. If the distance is shorter than specified, repeat step 5 above to adjust it. If it is longer, replace the valve seat with a new one. Valve seat resurface limit "L": Intake 42.02 - 42.52 mm (1.6543 - 1.6740 in) Exhaust 42.03 - 42.53 mm (1.6547 - 1.6744 in)

VALVE DIMENSIONS

Check dimensions of each valve. Refer to " VALVE " . When valve head has been worn down to 0.5 mm (0.020 in) in margin thickness, replace valve.

Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or less.

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1. Measure dimension "S". Out-of-square "S": Less than 2.2 mm (0.087 in)
2. If it exceeds the limit, replace spring.

Pressure

Check valve spring pressure at specified spring height.

1. Pressure: N (kg, lb) at height mm (in) Standard 418.0 (42.6, 93.9) at 29.17 (1.1484) Limit 393.0 (40.1, 88.4) at 29.17 (1.1484)

If not within specification, replace spring.

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1. Visually check contact and sliding surfaces for wear and scratches.
2. Check diameter of valve lifter and valve lifter guide bore. Valve lifter outer diameter: 33.960 - 33.975 mm (1.3370 - 1.3376 in) Lifter guide bore diameter: 34.000 - 34.021 mm (1.3386 - 1.3394 in) Valve lifter to valve lifter guide clearance: 0.025 - 0.061 mm (0.0010 - 0.0024 in) If it exceeds the standard diameter or clearance, replace valve lifter or cylinder head.

Scheme 124

1. Install valve component parts. Always use new valve oil seal. Refer to " «REPLACEMENT»(ref-183499-S41989774792005081400000) " . Before installing valve oil seal, install valve spring seat. Install outer valve spring (uneven pitch type) with its narrow pitch side toward cylinder head side. After installing valve component parts, tap valve stem tip with plastic hammer to assure a proper fit.

CHECKING

Check valve clearance while engine is warm but not running.

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1. Remove rocker cover and all spark plugs.
2. Set No. 1 cylinder at TDC on its compression stroke. Align pointer with TDC mark on crankshaft pulley. Check that valve lifters on No. 1 cylinder are loose and valve lifters on No. 4 are tight. If not, turn crankshaft one revolution (360°) and align as above.
3. Check only those valves shown in the figure.
4. Using a feeler gauge, measure clearance between valve lifter and camshaft. Record any valve clearance measurements which are out of specification. They will be used later to determine the required replacement adjusting shim. Valve clearance (Hot): Intake 0.31 - 0.39 mm (0.012 - 0.015 in) Exhaust 0.39 - 0.47 mm (0.015 - 0.019 in)
5. Turn crankshaft one revolution (360°) and align mark on crankshaft pulley with pointer.
6. Check those valves shown in the figure. Use the same procedure as mentioned in step 4.
7. If all valve clearances are within specification, install the following parts. Rocker cover All spark plugs

ADJUSTING

Adjust valve clearance while engine is cold.

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1. Turn crankshaft to position cam lobe on camshaft of valve that must be adjusted upward.
2. Place Tool (A) around camshaft as shown in figure.
3. Rotate Tool (A) so that lifter is pushed down. Before placing Tool (A), rotate notch toward center of cylinder head (See figure.), to simplify shim removal later. CAUTION: Be careful not to damage cam surface with Tool (A).
4. Place Tool (B) between camshaft and the edge of the valve lifter to retain valve lifter. CAUTION: Tool (B) must be placed as close to camshaft bracket as possible. Be careful not to damage cam surface with Tool (B).
5. Remove Tool (A).
6. Rotate adjusting shim until hole is visible. Blow air into the hole to separate adjusting shim from valve lifter.
7. Remove adjusting shim using a small screwdriver and a magnetic finger.
8. Determine replacement adjusting shim size as follows. Using a micrometer determine thickness of removed shim. Calculate thickness of new adjusting shim so valve clearance comes within specified values. R = Thickness of removed shim N = Thickness of new shim M = Measured valve clearance Intake & Exhaust: N = R + [M - 0.37 mm (0.0146 in)] Shims are available in thicknesses from 1.96 mm (0.0772 in) to 2.68 mm (0.1055 in), in steps of 0.02 mm (0.0008 in). Select new shim with thickness as close as possible to calculated value. Refer to " «AVAILABLE SHIMS»(ref-183499-S27121966102005081400000) " .
9. Install new shim using a suitable tool. Install with the surface on which the thickness is stamped facing down.
10. Place Tool (A) as mentioned in steps 2 and 3.
11. Remove Tool (B).
12. Remove Tool (A).
13. Recheck valve clearance. Refer to " «CHECKING»(ref-183499-S04134833062005081400000) " .

SEC. 110 . 120 . 135 . 150 . 210

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PISTON RING SIDE CLEARANCE

1. Side clearance: Top ring 0.04 - 0.08 mm (0.0016 - 0.0031 in) 2nd ring 0.03 - 0.07 mm (0.0012 - 0.0028 in)
2. Max. limit of side clearance: 0.1 mm (0.004 in)

If out of specification, replace piston ring.

If clearance exceeds maximum limit with new ring, replace piston.

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PISTON RING END GAP

1. End gap: Top ring 0.28 - 0.52 mm (0.0110 - 0.0205 in) 2nd ring 0.45 - 0.69 mm (0.0177 - 0.0272 in) Oil ring 0.20 - 0.69 mm (0.0079 - 0.0272 in) Max. limit of ring gap: Refer to " «PISTON RING»(ref-183499-S31547062112005081400000) " .

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If out of specification, replace piston ring. If gap exceeds maximum limit with a new ring, rebore cylinder and use oversized piston and piston rings. Refer to " PISTON RING " .

1. When replacing the piston, check cylinder block surface for scratches or seizure. If scratches or seizure are found, hone or replace the cylinder block.

CONNECTING ROD BEND AND TORSION

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

If it exceeds the limit, replace connecting rod assembly.

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1. Clean upper face of cylinder block. Use a reliable straightedge and feeler gauge to check the flatness of cylinder block surface. Check along six positions shown in figure. Limit: 0.1 mm (0.004 in)
2. If out of specification, resurface it. The limit for cylinder block resurfacing is determined by cylinder head resurfacing. Amount of cylinder head resurfacing is "A" Amount of cylinder block resurfacing is "B" The maximum limit is as follows: A + B = 0.2 mm (0.008 in) Nominal cylinder block height from crankshaft center: 246.95 - 247.05 mm (9.7224 - 9.7264 in)
3. If necessary, replace cylinder block.

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1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper. Standard inner diameter: Refer to " «CYLINDER BLOCK»(ref-183499-S14965705842005081400000) " . Wear limit: 0.2 mm (0.008 in) Out-of-round (X - Y) standard: 0.015 mm (0.0006 in) Taper (A - B) standard: 0.010 mm (0.0004 in) If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary.
2. Check for scratches and seizure. If seizure is found, hone it. If cylinder block and piston are replaced, match piston grade with grade number on cylinder block upper surface.
3. Measure piston skirt diameter. Piston diameter "A": Refer to " «PISTON»(ref-183499-S15958704152005081400000) " . Measuring point "a" (Distance from the top): Approximately 48 mm (1.89 in)
4. Check that piston-to-bore clearance is within specification. Piston-to-bore clearance "B": 0.020 - 0.040 mm (0.0008 - 0.0016 in)
5. Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. Refer to " «PISTON»(ref-183499-S15958704152005081400000) " .
6. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter "A". Rebored size calculation: A + B - C = D 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 bolts to the specified torque. This will prevent distortion of cylinder bores.
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 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.

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1. Check crankshaft main and pin journals for score, wear or cracks.
2. With a micrometer, measure journals for taper and out-of-round. Out-of-round (X - Y): Main journal Less than 0.01 mm (0.0004 i) Crank pin Less than 0.005 mm (0.0002 in) Taper (A - B): Main journal Less than 0.01 mm (0.0004 in) Crank pin Less than 0.005 mm (0.0002 in)
3. Measure crankshaft runout. Runout (Total indicator reading): Less than 0.10 mm (0.0039 in)

BEARING CLEARANCE

1. Use Method A or Method B. Method A is preferred because it is more accurate.

Method A (Using bore gauge and micrometer)

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1. Set main bearings in their proper positions on cylinder block and main bearing cap.
2. Install main bearing cap to cylinder block. Tighten all bolts in correct order in two or three stages. Refer to " «COMPONENTS»(ref-183499-S09511840232005081400000) " and " «CRANKSHAFT»(ref-183499-S27265482762005081400000) " .
3. Measure inner diameter "A" of each main bearing.
4. Measure outer diameter "Dm" of each crankshaft main journal.
5. Calculate main bearing clearance. Main bearing clearance = A - Dm Standard: 0.020 - 0.047 mm (0.0008 - 0.0019 in) Limit: 0.1 mm (0.004 in)
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearing. When grinding crankshaft journal, confirm that "L" dimension in fillet roll is more than the specified limit. "L": 0.1 mm (0.004 in) Grind crankshaft to use with available service parts. Refer to " «CRANKSHAFT»(ref-183499-S32117671102005081400000) " , and " «AVAILABLE MAIN BEARING»(ref-183499-S35577447742005081400000) " .
8. If crankshaft is reused, measure main bearing clearance and select thickness of main bearing. If crankshaft or cylinder block is replaced, select thickness of main bearings as follows: 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. Grade number of each crankshaft main journal is punched on crankshaft. These numbers are punched in either Arabic or Roman numerals. Select main bearing with suitable thickness according to the following example or table. For example: Main journal grade number: 1 Crankshaft journal grade number: 2 Main bearing grade number = 1 + 2 = 3 (Yellow) Main bearing grade number and identification color

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1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod. Tighten bolts to the specified torque.
3. Measure inner diameter "C" of each bearing.
4. Measure outer diameter "Dp" of each crankshaft pin journal.
5. Calculate connecting rod bearing clearance. Connecting rod bearing clearance = C - Dp: Standard 0.010 - 0.035 mm (0.0004 - 0.0014 in) Limit 0.09 mm (0.0035 in)
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearing. Refer to step 5 of " «BEARING CLEARANCE»(ref-183499-S27658905322005081400000) " .
8. If crankshaft is replaced, select connecting rod bearing according to the following table.

Connecting rod bearing grade number

These numbers are punched in either Arabic or Roman numerals.

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Method B (Using plastigage)

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1. Measure inner diameter "C" of bushing.
2. Measure outer diameter "Dp" of piston pin.
3. Calculate connecting rod bushing clearance. C - Dp = 0.005 - 0.017 mm (0.0002 - 0.0007 in) (Standard) 0.023 mm (0.0009 in) (Limit) If out of specification, replace connecting rod assembly and/or piston set with pin.

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1. Drive in small end bushing until it is flush with end surface of rod. Be sure to align the oil holes.
2. Ream the bushing until clearance with piston pin is within specification. Clearance between connecting rod bushing and piston pin: 0.005 - 0.017 mm (0.0002 - 0.0007 in)

FLYWHEEL RUNOUT

1. Runout (Total indicator reading): Flywheel Less than 0.15 mm (0.006 in)

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1. Heat piston to 60 to 70°C (140 to 158°F) and assemble piston, piston pin and connecting rod. Align the direction of piston and connecting rod. Numbers stamped on connecting rod and cap correspond to each cylinder. After assembly, make sure connecting rod swings smoothly.
2. Set piston rings as shown. CAUTION: When piston rings are not replaced, make sure that piston rings are mounted in their original positions. When piston rings are being replaced and no punchmark is present, piston rings can be mounted with either side up.
3. Align piston rings so that end gaps are positioned as shown.

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1. Set main bearings in their proper positions on cylinder block and main bearing caps. Confirm that correct main bearings are used. Refer to " «BEARING CLEARANCE»(ref-183499-S27658905322005081400000) " . Apply new engine oil to bearing surfaces.
2. Install crankshaft and main bearing caps and tighten bolts to the specified torque. Refer to " «COMPONENTS»(ref-183499-S09511840232005081400000) " . Apply new engine oil to the bolt threads and seat surface. Prior to tightening bearing cap bolts, place bearing cap in its proper position by shifting crankshaft in the axial direction. Tighten bearing cap bolts gradually in two or three stages. Start with center bearing and move outward as shown in figure. After securing bearing cap bolts, make sure crankshaft turns smoothly by hand.
3. Measure crankshaft end play. Crankshaft end play: Standard 0.05 - 0.18 mm (0.0020 - 0.0071 in) Limit 0.3 mm (0.012 in) If beyond the limit, replace No. 3 bearing with a new one.
4. Install connecting rod bearings in connecting rods and connecting rod caps. Confirm that correct bearings are used. Refer to " «CONNECTING ROD BEARING (BIG END)»(ref-183499-S23629112302005081400000) " . Install bearings so that oil hole in connecting rod aligns with oil hole of bearing. Apply new engine oil to bearing surfaces, bolt threads and seating surfaces.
5. Install pistons with connecting rods. Install them into corresponding cylinders with Tool. Arrange so that front mark on piston head faces toward front of engine. Make sure connecting rod does not scratch cylinder wall. Make sure connecting rod bolts do not scratch crankshaft journals. Apply new engine oil to piston rings and sliding surface of piston. Install connecting rod bearing caps. Tighten connecting rod bearing cap nuts using the following procedure. Connecting rod bearing nut: (1) Tighten to 14 - 16 N.m (1.4 - 1.6 kg-m, 10 - 12 ft-lb). (2) Tighten nuts 60 to 65 degrees clockwise with an angle wrench. If an angle wrench is not available, tighten them to 38 - 44 N.m (3.9 - 4.5 kg-m, 28 - 33 ft-lb).
6. Measure connecting rod side clearance. Connecting rod side clearance: Standard 0.2 - 0.4 mm (0.008 - 0.016 in) Limit 0.6 mm (0.024 in) If beyond the limit, replace connecting rod and/or crankshaft.

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1. Remove pilot bushing.
2. Install pilot bushing.

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CONNECTING RODS

CONNECTING RODS

ENGINE PISTONS, ENGINE PISTON PINS & ENGINE PISTON RINGS

ENGINE PISTONS, ENGINE PISTON PINS & ENGINE PISTON RINGS

CYLINDER BLOCK

CYLINDER BLOCK

OIL PUMP

OIL PUMP

ENGINE VALVES & ENGINE VALVE SPRINGS

ENGINE VALVES & ENGINE VALVE SPRINGS

CYLINDER HEAD

CYLINDER HEAD

CAMSHAFT

CAMSHAFT

ENGINE LIFTERS

ENGINE LIFTERS