Engine Mechanical (Vq): Other Nissan Frontier D40

Precautions 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. Information necessary to service the system safely is included in SUPPLEMENTAL RESTRAINT SYSTEM and SEAT BELTS article.

Precautions for Disconnecting Fuel Piping

1. Before starting work, make sure no fire or spark producing items are in the work area.
2. Release fuel pressure before disconnecting and disassembly.
3. After disconnecting pipes, plug openings to stop fuel leakage.

Special Service Tools

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

SPECIAL SERVICE TOOLS REFERENCE Tool number (Kent-Moore No.) Tool name Description ST0501S000 ( - ) Engine stand assembly 1. ST05011000 ( - ) Engine stand 2. ST05012000 ( - ) Base Disassembling and assembling engine KV10116200 (J-26336-A) Valve spring compressor 1. KV10115900 (J-26336-20) Attachment 2.KV10109220 ( - ) Adapter Disassembling valve mechanism Part (1) is a component of KV10116200 (J-26336-A), but Part (2) is not so. KV10107902 (J-38959) Valve oil seal puller Replacing valve oil seal - (J-39386) Valve oil seal drift Installing valve oil seal EM03470000 (J-8037) Piston ring compressor Installing piston assembly into cylinder bore ST16610001 (J-23907) Pilot bushing puller Removing pilot converter (A/T models) KV10111100 (J-37228) Seal cutter Removing oil pan (lower and upper), front and rear timing chain case, etc. WS39930000 ( - ) Tube presser Pressing the tube of liquid gasket KV10112100 (BT-8653-A) Angle wrench Tightening bolts for bearing cap, cylinder head, etc. in angle - (J-44626) Air fuel sensor Socket Loosening or tightening air fuel ratio A/F sensor a: 22 mm (0.87 in) KV10114400 (J-38365) Heated oxygen sensor wrench Loosening or tightening heated oxygen sensor 1 a: 22 mm (0.87 in) KV10117700 (J-44716) Ring gear stopper Removing and installing crankshaft pulley - (J-45488) Quick connector release Removing fuel tube quick connectors in engine room (Available in SEC. 164 of PARTS CATALOG: Part No. 16441 6N210)

Scheme 411

Scheme 412

Scheme 413

Scheme 414

Scheme 415

Commercial Service Tools

COMMERCIAL SERVICE TOOLS REFERENCE (Kent-Moore No.) Tool name Description ( - ) Power tool Loosening nuts and bolts ( - ) TORX socket Removing and installing flywheel Size: T55 (J-24239-01) Cylinder head bolt wrench Loosening and tightening cylinder head bolt, and used with angle wrench [SST: KV10112100 (BT-8653-A)] a: 13 (0.51) dia. b: 12 (0.47) c: 10 (0.39) Unit: mm (in) ( - ) 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 and Exhaust: a: 9.5 mm (0.374 in) dia. b: 5.5 mm (0.217 in) dia. ( - ) Valve guide reamer (1): Reaming valve guide inner hole (2): Reaming hole for oversize valve guide Intake and 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.) a: J-43897-18 [18 mm (0.71 in) dia.] for zirconia heated oxygen sensor b: 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

Scheme 416

Scheme 417

Scheme 418

Scheme 419

Scheme 420

Scheme 421

Intake Manifold Collector

1. If stud bolts were removed from intake manifold, install them and tighten to the specified torque.
2. Tighten nuts and bolts in numerical order as shown. Intake manifold collector bolts and nuts: 11.0 N.m (1.1 kg-m, 8 ft-lb) Stud bolts: 6.9 N.m (7.0kg-m, 61 in-lb) (Scheme 421): Intake Manifold Collector Mounting Nut & Bolt Tightening Sequence

Electric Throttle Control Actuator

1. Tighten bolts in numerical order as shown.
2. Perform the "Throttle Valve Closed Position Learning" when harness connector of electric throttle control actuator is disconnected. Refer to " «THROTTLE VALVE CLOSED POSITION LEARNING»(ref-272339-S05201535002007111800000) ".
3. Perform the "Idle Air Volume Learning" and "Throttle Valve Closed Position Learning" when electric throttle control actuator is replaced. Refer to " «IDLE AIR VOLUME LEARNING»(ref-272339-S10908079512007111800000) ". see scheme 16: Identifying Bolts Loosening Sequence

Identifying Intake Manifold Components Specifications. Scheme 422

Scheme 423

1. Release fuel pressure. Refer to " «FUEL PRESSURE RELEASE»(ref-272339-S38622562782007111800000) ".
2. Remove intake manifold collector. Refer to " «REMOVAL»(ref-272352-S31411112212007111800000) ".
3. Remove fuel tube and fuel injector assembly. Refer to " «REMOVAL»(ref-272352-S23473630872007111800000) ".
4. Loosen nuts and bolts with power tool in reverse order as shown to remove intake manifold. see scheme 18: Identifying Intake Manifold Bolt And Nuts Tightening Sequence
5. Remove gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

Scheme 424

1. Check the surface distortion of the intake manifold mating surface with straightedge and feeler gauge. Limit: 0.1 mm (0.004 in)
2. If it exceeds the limit, replace intake manifold. see scheme 19: Checking Surface Distortion

Intake Manifold

1. If stud bolts were removed from cylinder head, install them and tighten to the specified torque. Intake manifold studs: 11.0 N.m (1.1kg-m, 8 ft-lb)
2. Tighten all nuts and bolts to the specified torque in two or more steps in numerical order as shown. Intake manifold bolt and nuts 1st step: 7.4 N.m (0.75 kg-m, 5 ft-lb) 2nd step and after: 29.0 N.m (3.0 kg-m, 21 ft-lb) see scheme 20: Identifying Intake Manifold Bolt And Nuts Tightening Sequence

Identifying Exhaust Manifold And Three Way Catalyst With Torque Specifications. Scheme 425

Scheme 426

Scheme 427

Scheme 428

1. Remove air cleaner case and air duct. Refer to " «REMOVAL»(ref-272352-S25129190762007111800000) ".
2. Remove engine undercover with power tool.
3. Disconnect harness connector and remove heated oxygen sensor 2 on both banks using Tool. Tool number: KV10114400 (J-38365) CAUTION: Be careful not to damage heated oxygen sensor 2. Discard any heated oxygen sensor 2 which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; replace with a new sensor. see scheme 22: Identifying Heated Oxygen Sensor
4. Remove center exhaust tube, main muffler and left front exhaust tube. Refer to " «REMOVAL»(ref-272344-S31000716222007111800000) ".
5. Remove exhaust manifold cover (left bank).
6. Disconnect harness connector and remove air fuel ratio sensor 1 (left bank) using Tool. Tool number: - (J-44626) CAUTION: Be careful not to damage air fuel ratio sensor 1. Discard any air fuel ratio sensor 1 which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; replace with a new sensor. see scheme 23: Identifying Air Fuel Ratio Sensor (Left Bank)
7. Remove three way catalyst (left bank).
8. Loosen nuts with power tool in reverse order as shown. NOTE: Disregard the numerical order No. 7 and 8 in removal. see scheme 24: Identifying Exhaust Manifold Nuts Loosening Sequence
9. Remove gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

Scheme 429

1. Check the surface distortion of the exhaust manifold mating surface with straightedge and feeler gauge. Limit: 0.3 mm (0.012 in)
2. If it exceeds the limit, replace exhaust manifold. see scheme 25: Identifying Starter Motor And Set Ring Gear Stopper

Exhaust Manifold Gasket

Install in direction as shown.

Scheme 430

Exhaust Manifold

1. If stud bolts were removed, install them and tighten to the specified torque. Exhaust manifold stud torque: 14.7 N.m (1.5 kg-m, 11 ft-lb)
2. Install exhaust manifold and tighten nuts in numerical order as shown. NOTE: Tighten nuts No. 1 and 2 in two steps. The numerical order No. 7 and 8 shown second step. see scheme 27: Identifying Exhaust Manifold Nuts Loosening Sequence

Heated Oxygen Sensor

Install in direction as shown.

1. If stud bolts were removed, install them and tighten to the specified torque. Exhaust manifold stud torque: 14.7 N.m (1.5 kg-m, 11 ft-lb)
2. Install exhaust manifold and tighten nuts in numerical order as shown. NOTE: Tighten nuts No. 1 and 2 in two steps. The numerical order No. 7 and 8 shown second step. see scheme 31: Identifying Exhaust Manifold Nuts Loosening Sequence

Timing Chain

Check for cracks and any excessive wear at link plates and roller links of timing chain. Replace timing chain as necessary.

Scheme 431

CAMSHAFT JOURNAL OIL CLEARANCE

1. (Oil clearance) = (Camshaft bracket inner diameter) - (Camshaft journal diameter). Standard: No. 1: 0.045-0.086 mm (0.0018-0.0034 in) No. 2, 3, 4: 0.035-0.076 mm (0.0014-0.0030 in) Limit: 0.15 mm (0.0059 in)
2. If the calculated value exceeds the limit, replace either or both camshaft and cylinder head. NOTE: Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head. Replace whole cylinder head assembly.

Scheme 432

Scheme 433

1. Install dial indicator in thrust direction on front end of camshaft. Measure the end play of dial indicator when camshaft is moved forward/backward (in direction to axis). Standard: 0.115-0.188 mm (0.0045-0.0074 in) Limit: 0.24 mm (0.0094 in) see scheme 163: Checking Camshaft End Play
2. Measure the following parts if out of the limit. Dimension "A" for camshaft No. 1 journal Standard: 27.500-27.548 mm (1.0827-1.0846 in) Dimension "B" for cylinder head No. 1 journal bearing Standard: 27.360-27.385 mm (1.0772-1.0781 in)
3. Refer to the standards above, and then replace camshaft and/or cylinder head. see scheme 164: Cylinder Head No. 1 Journal Bearing Dimensions

Scheme 434

1. Put V-block on precise flat table, and support No. 2 and 4 journal of camshaft. CAUTION: Do not support journal No. 1 (on the side of camshaft sprocket) because it has a different diameter from the other three locations.
2. Measure the camshaft sprocket runout with dial indicator. (Total indicator reading) Limit: 0.15 mm (0.0059 in) If it exceeds the limit, replace camshaft sprocket. see scheme 165: Checking Camshaft Sprocket Runout

Valve Lifter

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

Scheme 435

1. If anything above is found, replace valve lifter. Refer to " «AVAILABLE VALVE LIFTER»(ref-272352-S00223080852007111800000) ". see scheme 166: Checking Surface Of Valve Lifter

Scheme 436

1. Measure the outer diameter at 1/2 height of valve lifter with micrometer since valve lifter is in barrel shape. Standard (Intake and exhaust): 33.977-33.987 mm (1.3377-1.3381 in) see scheme 167: Checking Outer Diameter Of Valve Lifter

Scheme 437

1. Measure the inner diameter of valve lifter hole of cylinder head with inside micrometer. Standard (Intake and exhaust): 34.000-34.016 mm (1.3386-1.3392 in) see scheme 168: Checking Diameter Of Valve Lifter Bore Of Cylinder Head

VALVE LIFTER CLEARANCE

1. Valve lifter clearance) = (Valve lifter hole diameter) - (Valve lifter outer diameter), Refer to " «VALVE CLEARANCE»(ref-272352-S06202775132007111800000) ". Standard (Intake and exhaust): 0.013-0.039 mm (0.0005-0.0015 in)
2. If the calculated value is out of the standard, referring to each standard of valve lifter outer diameter and valve lifter hole diameter, replace either or both valve lifter and cylinder head.

Scheme 438

Scheme 439

Scheme 440

Scheme 441

Scheme 442

Scheme 443

Scheme 444

1. Install timing chain tensioners (secondary) on both sides of cylinder head. Install timing chain tensioner with its stopper pin attached. Install timing chain tensioner with sliding part facing downward on right-side cylinder head, and with sliding part facing upward on left-side cylinder head. Install new O-rings as shown. see scheme 169: Identifying Timing Chain Tensioner
2. Install valve lifters. Install it in the original position.
3. Install camshafts. Install camshaft with dowel pin attached to its front end face on the exhaust side. see scheme 170: Attaching Dowel Pin To Camshaft Front End Face On Exhaust Side Follow your identification marks made during removal, or follow the identification marks that are present on new camshafts for proper placement and direction. PAINT MARK SPECIFICATIONS Bank INT/EXH Dowel pin Paint marks Identification mark M1 M2 RH INT No Green No RE EXH Yes No White RE LH INT No Green No LH EXH Yes No White LH see scheme 171: Identifying Identification Marks On Cam Shaft Install camshaft so that dowel pin hole and dowel pin on front end face are positioned as shown. (No. 1 cylinder TDC on its compression stroke) NOTE: Large and small pin holes are located on front end face of camshaft (INT), at intervals of 180°. Face small dia. side pin hole upward (in cylinder head upper face direction). Though camshaft does not stop at the portion as shown, for the placement of cam nose, it is generally accepted camshaft is placed for the same direction as shown. (Scheme 432): Identifying Dowel Pin Hole
4. Install camshaft brackets. Remove foreign material completely from camshaft bracket backside and from cylinder head installation face. Install camshaft bracket in original position and direction as shown. (Scheme 433): Identifying Camshaft Brackets Install camshaft brackets (No. 2 to 4) aligning the stamp marks as shown. NOTE: There are no identification marks indicating left and right for camshaft bracket (No. 1). (Scheme 434): Aligning Stamp Marks Apply liquid gasket to mating surface of camshaft bracket (No. 1) as shown on right and left banks. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-272334-S29650495302007111800000) ". (Scheme 435): Applying Liquid Gasket To Mating Surface Of Camshaft Bracket
5. Tighten camshaft bracket bolts in the following steps, in numerical order as shown. Camshaft bracket bolts Step 1 (bolts 7-10): 1.96 N.m (0.2 kg-m, 17 in-lb) Step 2 (bolts 1-6): 1.96 N.m (0.2 kg-m, 17 in-lb) Step 3: 5.88 N.m (0.6 kg-m, 52 in-lb) Step 4: 10.4 N.m (1.1 kg-m, 92 in-lb) (Scheme 436): Identifying Camshaft Bracket Bolts Loosening Sequence
6. Measure the difference in levels between front end faces of camshaft bracket (No. 1) and cylinder head. Standard: -0.14 to 0.14 mm (-0.0055 to 0.0055 in) Measure two positions (both intake and exhaust side) for a single bank. If the measured value is out of the standard, re-install camshaft bracket (No. 1). (Scheme 437): Measuring Between Front End Faces Of No 1 Camshaft Bracket And Cylinder Head
7. Check and adjust the valve clearance. Refer to " «VALVE CLEARANCE»(ref-272352-S06202775132007111800000) ".
8. Installation of the remaining components is in the reverse order of removal.

Cylinder Head Distortion

Note. When performing this inspection, cylinder block distortion should be also checked. Refer to " CYLINDER BLOCK DISTORTION ".

Scheme 445

1. Using suitable tool, wipe off oil, scale, gasket, sealant and carbon deposits from surface of cylinder head. CAUTION: Do not allow gasket fragments to enter engine oil or engine coolant passages.
2. At each of several locations on bottom surface of cylinder head, measure the distortion in six directions. Limit: 0.1 mm (0.004 in) If it exceeds the limit, replace cylinder head. see scheme 206: Checking Bottom Surface Of Cylinder Head

Scheme 446

Scheme 447

Scheme 448

1. Install new cylinder head gasket.
2. Turn crankshaft until No. 1 piston is set at TDC. Crankshaft key should line up with the right bank cylinder center line as shown. see scheme 207: Aligning Crankshaft Key
3. Install cylinder head follow the steps below to tighten cylinder head bolts in numerical order as shown. CAUTION: If cylinder head bolts re-used, check their outer diameters before installation. Refer to " «CYLINDER HEAD BOLTS OUTER DIAMETER»(ref-272352-S11508383462007111800000) ". Step a: 98 N.m (10 kg-m, 72 ft-lb) Step b: Loosen to 0 N.m in the reverse order of tightening. Step c: 39.2 N.m (4.0 kg-m, 29 ft-lb) Step d: 90° clockwise Step e: 90° clockwise see scheme 208: Identifying Cylinder Head Bolts Loosening Sequence see scheme 209: Checking Cylinder Head Bolts Tightening Angle
4. After installing cylinder head, measure distance between front end faces of cylinder block and cylinder head (left and right banks). Standard: 14.1-14.9 mm (0.555-0.587 in) If the measured value is out of the standard, re-install cylinder head. see scheme 210: Checking Distance Between Front End Faces Of Cylinder Block And Cylinder Head (Left And Right Banks)
5. Installation of the remaining parts is in the reverse order of removal.

VALVE DIMENSIONS

1. Check dimensions of each valve. For dimensions, refer to " «VALVE DIMENSIONS»(ref-272352-S04241455652007111800000) ".
2. If dimensions are out of the standard, replace valve and check the valve seat contact. Refer to " «VALVE SEAT CONTACT»(ref-272352-S06966534722007111800000) ".

Valve Stem Diameter

Measure the diameter of valve stem with micrometer.

Standard

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

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

Scheme 449

Valve Guide Inner Diameter

Measure the inner diameter of valve guide with inside micrometer.

Standard

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

Valve Guide Clearance

(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)

1. If the calculated value exceeds the limit, replace valve and/or valve guide. When valve guide must be replaced, refer to " «VALVE GUIDE REPLACEMENT»(ref-272352-S34408636952007111800000) ".

HOW TO SELECT PISTON

When New Cylinder Block is Used

Check the cylinder bore grade ("1", "2", or "3") on rear side of cylinder block, and select piston of the same grade.

Note. Piston is available with piston pin as a set for the service part. (Only "0" grade piston pin is available.)

Scheme 450

When Cylinder Block is Reused

Scheme 451

1. Measure the cylinder bore inner diameter. Refer to " «CYLINDER BORE INNER DIAMETER»(ref-272352-S39680250582007111800000) ".
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner diameter of the "Piston Selection Table". see scheme 268: Identifying Piston And Piston Pin Grade Number
3. Select piston of the same grade.

PISTON SELECTION TABLE

Note. Piston is available together with piston pin as assembly. Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no piston pin grades can be selected. (Only "0" grade is available.) No second grade mark is available on piston.

HOW TO SELECT CONNECTING ROD BEARING

When New Connecting Rod and Crankshaft are Used

Check pin journal grade ("0", "1", or "2") on front of crankshaft, and select connecting rod bearing of the same grade.

Note. There is no grading for connecting rod big end diameter.

Checking Outer Diameter Of Piston Pin. Scheme 452

When Crankshaft and Connecting Rod are Reused

1. Measure the connecting rod big end diameter. Refer to " «CONNECTING ROD BIG END DIAMETER»(ref-272352-S06224623212007111800000) ".
2. Make sure that the connecting rod big end diameter is within the standard value.
3. Measure the crankshaft pin journal diameter. Refer to " «CRANKSHAFT PIN JOURNAL DIAMETER»(ref-272352-S08692022412007111800000) ".
4. Determine the grade of crankshaft pin journal grade by corresponding to the measured dimension in "Crankshaft pin journal diameter" column of "Connecting Rod Bearing Selection Table".
5. Select connecting rod bearing of the same grade.

CONNECTING ROD BEARING SELECTION TABLE

THICKNESS SPECIFICATIONS

Scheme 453

1. When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod bearings, use undersize (US) bearings.
2. When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing installed, and grind crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard. CAUTION: In grinding crankshaft pin to use undersize bearings, keep the fillet R [1.5-1.7 mm (0.059-0.067 in)]. see scheme 270: Identifying Crankshaft Journals

BEARING UNDERSIZE TABLE

HOW TO SELECT MAIN BEARING

When New Cylinder Block and Crankshaft are Used

1. "Main Bearing Selection Table" rows correspond to bearing housing grade on rear left side of cylinder block. see scheme 271: Identifying Bearing Housing Grade
2. "Main Bearing Selection Table" columns correspond to journal diameter grade on front side of crankshaft. see scheme 272: Identifying Journal Diameter Grade
3. Select main bearing grade at the point where selected row and column meet in "Main Bearing Selection Table".

When Cylinder Block and Crankshaft are Reused

1. Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter. Refer to " «MAIN BEARING HOUSING INNER DIAMETER»(ref-272352-S09090331062007111800000) " and " «CRANKSHAFT MAIN JOURNAL DIAMETER»(ref-272352-S00496592362007111800000) ".
2. Correspond the measured dimension in "Cylinder block main bearing housing inner diameter" row of "Main Bearing Selection Table".
3. Correspond the measured dimension in "Crankshaft main journal diameter" column of "Main Bearing Selection Table".
4. Select main bearing grade at the point where selected row and column meet in following selection table.

Main Bearing Selection Table

Scheme 454

Main Bearing Grade Table (All Journals)

MAIN BEARING GRADE REFERENCE CHART

Undersize Bearing Usage Guide

1. When the specified main bearing oil clearance is not obtained with standard size main bearings, use underside (US) bearing.
2. When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and grind main journal so that the main bearing oil clearance satisfies the standard. CAUTION: In grinding crankshaft main journal to use undersize bearings, keep the fillet R [1.5-1.7 mm (0.059-0.067 in)]. see scheme 274: Identifying Crankshaft Journals

Bearing undersize table

BEARING UNDERSIZE REFERENCE

Scheme 455

1. Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with dial indicator. Standard: 0.10-0.25 mm (0.0039-0.0098 in) Limit: 0.30 mm (0.0118 in)
2. If the measured value exceeds the limit, replace thrust bearings, and measure again. If it still exceeds the limit, replace crankshaft also. see scheme 275: Checking Crankshaft End Play

Scheme 456

1. Measure the side clearance between connecting rod and crankshaft arm with feeler gauge. Standard: 0.20-0.35 mm (0.0079-0.0138 in) Limit: 0.40 mm (0.0157 in)
2. If the measured value exceeds the limit, replace connecting rod, and measure again. If it still exceeds the limit, replace crankshaft also. (Scheme 450): Checking Connecting Rod Side Clearance

Piston Pin Hole Diameter

Measure the inner diameter of piston pin hole with inside micrometer.

Standard: 21.993-22.005 mm (0.8659-0.8663 in)

Scheme 457

Piston to Piston Pin Oil Clearance

(Piston to piston pin oil clearance) = (Piston pin hole diameter) - (Piston pin outer diameter)

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

1. If the calculated value is out of the standard, replace piston and piston pin assembly.
2. When replacing piston and piston pin assembly, refer to " «HOW TO SELECT PISTON»(ref-272352-S40429933312007111800000) ". NOTE: Piston is available together with piston pin as assembly. Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no piston pin grades can be selected. (Only "0" grade is available.)

Scheme 458

1. Measure side clearance of piston ring and piston ring groove with feeler gauge. Standard: Top ring: 0.045-0.080 mm (0.0018-0.0031 in) 2nd ring: 0.030-0.070 mm (0.0012-0.0028 in) Oil ring: 0.065-0.135 mm (0.0026-0.0053 in) Limit: Top ring: 0.11 mm (0.0043 in) 2nd ring: 0.10 mm (0.0039 in) (Scheme 453): Checking Piston Ring Side Clearance
2. If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, replace piston also.

Scheme 459

1. Make sure that the cylinder bore inner diameter is within the specification. Refer to " «CYLINDER BORE INNER DIAMETER»(ref-272352-S39680250582007111800000) ".
2. Lubricate with new engine oil to piston and piston ring, and then insert piston ring until middle of cylinder with piston, and measure the piston ring end gap with feeler gauge. Standard: Top ring: 0.23-0.33 mm (0.0091-0.0130 in) 2nd ring: 0.33-0.48 mm (0.0130-0.0189 in) Oil ring: 0.20-0.50 mm (0.0079-0.0197 in) Limit: Top ring: 0.56 mm (0.0220 in) 2nd ring: 0.68 mm (0.0268 in) Oil ring: 0.85 mm (0.0335 in) see scheme 280: Checking Diameter Of Cylinder Bore
3. If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, re-bore cylinder and use oversize piston and piston rings.

Scheme 460

1. Check with connecting rod aligner. Bend: Limit: 0.15 mm (0.0059 in) per 100 mm (3.94 in) length Torsion: Limit: 0.30 mm (0.0118 in) per 100 mm (3.94 in) length
2. If it exceeds the limit, replace connecting rod assembly. see scheme 281: Checking Connecting Rod Bend And Torsion

Scheme 461

1. Install connecting rod bearing cap without installing connecting rod bearing, and tightening connecting rod bolts to the specified torque. Refer to " «ASSEMBLY»(ref-272352-S31697505562007111800000) " for the tightening procedure.
2. Measure the inner diameter of connecting rod big end with inside micrometer. Standard: 57.000-57.013 mm (2.2441-2.2446 in)
3. If out of the standard, replace connecting rod assembly. (Scheme 454): Checking Connecting Rod Bearing (Big End)

Connecting Rod Bushing Inner Diameter

Measure the inner diameter of connecting rod bushing with inside micrometer.

Standard: 22.000-22.012 mm (0.8661-0.8666 in)

Scheme 462

Connecting Rod Bushing Oil Clearance

(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) - (Piston pin outer diameter)

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

Limit: 0.030 mm (0.0012 in)

1. If the calculated value exceeds the limit, replace connecting rod assembly and/or piston and piston pin assembly.
2. If replacing piston and piston pin assembly, refer to " «HOW TO SELECT PISTON»(ref-272352-S40429933312007111800000) ".
3. If replacing connecting rod assembly, refer to " «CONNECTING ROD BEARING OIL CLEARANCE»(ref-272352-S03628769262007111800000) " to select the connecting rod bearing. (Scheme 456): Identifying Connecting Rod Sample Codes

Factory installed parts grading

1. Service parts apply only to grade "0". GRADE REFERENCE Unit: mm (in) Grade 0 1 Connecting rod bushing inner diameter (1) 22.000-22.006 (0.8661-0.8664) 22.006-22.012 (0.8664-0.8666) Piston pin hole diameter 21.993-21.999 (0.8659-0.8661) 21.999-22. 005 (0.8661-0.8663) Piston pin outer diameter 21.989-21.995 (0.8657-0.8659) 21.995-22.001 (0.8659-0.8662) (1) After installing in connecting rod (Scheme 457): Identifying Piston And Piston Pin Grade Number

Scheme 463

1. Using scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or other contamination. CAUTION: Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.
2. Measure the distortion on the cylinder block upper face at some different points in six directions with straightedge and feeler gauge. Limit: 0.1 mm (0.004 in)
3. If it exceeds the limit, replace cylinder block. see scheme 287: Checking Distortion Of Cylinder Block Upper Face

Scheme 464

1. Install lower cylinder block without installing main bearings, and tighten lower cylinder block bolts to the specified torque. Refer to " «ASSEMBLY»(ref-272352-S31697505562007111800000) " for the tightening procedure.
2. Measure the inner diameter of main bearing housing with bore gauge. Standard: 74.993-75.017 mm (2.9525-2.9534 in)
3. If out of the standard, replace cylinder block and lower cylinder block as assembly. NOTE: Cylinder block cannot be replaced as a single part, because it is machined together with lower cylinder block. (Scheme 458): Identifying Inner Diameter Of Main Bearing Housing

Scheme 465

Scheme 466

1. Using bore gauge, measure 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") ("X" is in longitudinal direction of engine) Standard inner diameter: 95.500-95.530 mm (3.7598-3.7610 in) Out-of-round (Difference between "X" and "Y"): 0.015 mm (0.0006 in) Taper limit (Difference between "A" and "C"): 0.01 mm (0.0004 in) (Scheme 459): Identifying Cylinder Bore Inner Diameter Measuring Points
2. If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, hone or re-bore the inner wall.
3. Oversize piston is provided. When using oversize piston, rebore cylinder so that the clearance of the piston-to-cylinder bore satisfies the standard. CAUTION: When using oversize piston, use oversize pistons for all cylinders with oversize piston rings. Oversize (OS): 0.2 mm (0.008 in) (Scheme 460): Checking Clearance Of Piston-To-Cylinder Bore

Piston Skirt Diameter

Measure the outer diameter of piston skirt with micrometer.

Measure point: Distance from the top 43.03 mm (1.6941 in)

Standard: 95.480-95.510 mm (3.7590-3.7602 in)

Scheme 467

Piston to Cylinder Bore Clearance

Calculate by piston skirt diameter and cylinder bore inner diameter (direction "X", position "B").

(Clearance) = (Cylinder bore inner diameter) - (Piston skirt diameter).

Standard: 0.010-0.030 mm (0.0004-0.0012 in)

Limit: 0.08 mm (0.0031 in)

1. If the calculated value exceeds the limit, replace piston and piston pin assembly. Refer to " «HOW TO SELECT PISTON»(ref-272352-S40429933312007111800000) ".

Re-boring Cylinder Bore

1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter. Re-bored size calculation: D = A + B - C where, D: Bored diameter A: Piston skirt diameter as measured B: Piston to cylinder 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. NOTE: 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 the specified piston to cylinder bore clearance.
5. Measure finished the cylinder bore for out-of-round and taper. NOTE: Measurement should be done after cylinder bore cools down.

CRANKSHAFT MAIN JOURNAL DIAMETER

1. Measure the outer diameter of crankshaft main journals with micrometer. Standard: 69.951-69.975 mm (2.7540-2.7549 in) dia.
2. If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to " «MAIN BEARING OIL CLEARANCE»(ref-272352-S06989960872007111800000) ".

Scheme 468

1. Measure the outer diameter of crankshaft pin journal with micrometer. Standard: 53.956-53.974 mm (2.1242-2.1250 in) dia.
2. If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer to " «CONNECTING ROD BEARING OIL CLEARANCE»(ref-272352-S03628769262007111800000) ". (Scheme 462): Checking Outer Diameter Of Crankshaft Pin Journal With Micrometer

Scheme 469

1. Measure the dimensions at four different points as shown in the figure on each main journal and pin journal with micrometer.
2. Out-of-round is indicated by the difference in the dimensions between "X" and "Y" at "A" and "B".
3. Taper is indicated by the difference in the dimensions 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) see scheme 293: Identifying Crank Shaft Taper And Out Of Round Dimensions
4. If the measured value exceeds the limit, correct or replace crankshaft.
5. If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select the main bearing and/or connecting rod bearing. Refer to " «MAIN BEARING OIL CLEARANCE»(ref-272352-S06989960872007111800000) " and/or " «CONNECTING ROD BEARING OIL CLEARANCE»(ref-272352-S03628769262007111800000) ".

Scheme 470

1. Place V-block on precise flat table, and support the journals on the both end of crankshaft.
2. Place dial indicator straight up on the No. 3 journal.
3. While rotating crankshaft, read the movement of the pointer on dial indicator. (Total indicator reading) Standard: Less than 0.05 mm (0.002 in) Limit: 0.10 mm (0.0039 in)
4. If it exceeds the limit, replace crankshaft. see scheme 294: Checking Crankshaft Runout

Scheme 471

1. Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified torque. Refer to " «ASSEMBLY»(ref-272352-S31697505562007111800000) " for the tightening procedure.
2. Measure the inner diameter of connecting rod bearing with inside micrometer. (Bearing oil clearance) = (Connecting rod bearing inner diameter) - (Crankshaft pin journal diameter) Standard: 0.034-0.059 mm (0.0013-0.0023 in) (actual clearance) Limit: 0.070 mm (0.0028 in) see scheme 295: Checking Connecting Rod Bearing Oil Clearance
3. If the calculated value exceeds the limit, select proper connecting rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer to " «HOW TO SELECT CONNECTING ROD BEARING»(ref-272352-S31939162472007111800000) ".

Scheme 472

1. Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely.
2. Cut plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
3. Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified torque. Refer to " «ASSEMBLY»(ref-272352-S31697505562007111800000) " for the tightening procedure. CAUTION: Do not rotate crankshaft.
4. Remove connecting rod bearing cap and bearing, and using scale on 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»(ref-272352-S12306433432007111800000) ". (Scheme 463): Measuring Plastigage Width

Scheme 473

1. Install main bearings to cylinder block and lower cylinder block, and tighten lower cylinder block bolts to the specified torque. Refer to " «ASSEMBLY»(ref-272352-S31697505562007111800000) " for the tightening procedure.
2. Measure the inner diameter of main bearing with bore gauge. (Bearing clearance) = (Main bearing inner diameter) - (Crankshaft main journal diameter) Standard: 0.035-0.045 mm (0.0014-0.0018 in) (actual clearance) Limit: 0.065 mm (0.0026 in) (Scheme 464): Identifying Inner Diameter Of Main Bearing
3. If the calculated value exceeds the limit, select proper main bearing according to main bearing inner diameter and crankshaft main journal diameter to obtain specified bearing oil clearance. Refer to " «HOW TO SELECT MAIN BEARING»(ref-272352-S01633891252007111800000) ".

Method of Using Plastigage

1. Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.
2. Cut plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
3. Install main bearings to cylinder block and lower cylinder block, and tighten lower cylinder block bolts to the specified torque. Refer to " «ASSEMBLY»(ref-272352-S31697505562007111800000) " for the tightening procedure. CAUTION: Do not rotate crankshaft.
4. Remove lower cylinder block and bearings, and using scale on 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»(ref-272352-S09571009132007111800000) ". (Scheme 465): Measuring Plastigage Width

Scheme 474

1. When lower cylinder block is removed after being tightened to the specified torque with main bearings installed, the tip end of bearing must protrude. Refer to " «ASSEMBLY»(ref-272352-S31697505562007111800000) " for the tightening procedure. Standard: There must be crush height.
2. If the standard is not met, replace main bearings. (Scheme 466): Checking Crush Height Of Main Bearing

Scheme 475

1. When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings installed, the tip end of bearing must protrude. Refer to " «ASSEMBLY»(ref-272352-S31697505562007111800000) " for the tightening procedure. Standard: There must be crush height.
2. If the standard is not met, replace connecting rod bearings. (Scheme 467): Identifying Crush Height Of Connecting Rod Bearing

Scheme 476

1. Measure the outer diameters ("d1 ", "d2 ") at two positions as shown.
2. If reduction appears in "A" range, regard it as "d2 ". Limit ("d1" - "d2 "): 0.11 mm (0.0051 in)
3. If it exceeds the limit (large difference in dimensions), replace lower cylinder block bolt with new one. (Scheme 468): Identifying Lower Cylinder Block Bolt Outer Diameter

Scheme 477

1. Measure the outer diameter "d" at position shown.
2. If the reduction appears in a position other than "d", regard it as "d". Limit: 7.75 mm (0.3051 in)
3. When "d" exceeds the limit (when it becomes thinner), replace connecting rod bolt with new one. (Scheme 469): Identifying Connecting Rod Bolt Outer Diameter

FLYWHEEL RUNOUT (M/T)

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

Scheme 478

1. Measure the deflection of the flywheel contact surface to the clutch with a dial gauge.
2. Measure the runout at 210 mm (8.27 in) diameter. Limit: 0.45 mm (0.0177 in) or less
3. When measured value exceeds the limit, replace the flywheel with a new one. (Scheme 470): Checking Flywheel Deflection (M/T Models)

MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS)

Movement Amount of Thrust (fore and aft) Direction

1. Measure the movement amount of thrust (fore and aft) direction when 100 N (10.2 kg, 22lb) force is added at the position of 125mm (4.92) radius from the center of the flywheel. Limit: 1.3mm (.051 in) or less
2. If measured value is out of specification, replace flywheel.

Movement Around in Rotation Direction

Check the movement amount with the following procedure

Scheme 479

1. Install a bolt to clutch cover mounting hole and place a torque wrench on the extended line of the flywheel center line. Tighten the bolt at a force of 9.8 N.m (1 kg-m, 87 in-lb) to keep it from loosening.
2. Put a mating mark on the circumference of the two flywheel masses without applying any load (measurement standard points).
3. Apply a force of 9.8 N.m (1 kg-m, 87 in-lb) in each direction, and mark the movement amount on the mass on the transaxle side.
4. Measure dimensions of movement amounts A and B on the circumference of the flywheel on the transaxle side. Flywheel movement in rotation direction: 24 mm (0.94 in) or less When the measured value is out if standard, replace the flywheel. (Scheme 471): Checking Movement Amount Of Radial (Rotation) Direction

DRIVE PLATE

1. Check drive plate and signal plate for deformation or cracks. CAUTION: Do not disassemble drive plate. Do not place drive plate with signal plate facing down. When handling signal plate, take care not to damage or scratch it. Handle signal plate in a manner that prevents it from becoming magnetized.
2. If anything is found, replace drive plate. (Scheme 472): Checking Drive Plate

OIL JET

1. Check nozzle for deformation and damage.
2. Blow compressed air from nozzle, and check for clogs.
3. If it is not satisfied, clean or replace oil jet.

Scheme 480

1. Using clean plastic stick, press check valve in oil jet relief valve. Make sure that valve moves smoothly with proper reaction force.
2. If it is not satisfied, replace oil jet relief valve. (Scheme 473): Checking Oil Jet Relief Valve

DRIVE BELT

DRIVE BELT SPECIFICATIONS

INTAKE MANIFOLD COLLECTOR, INTAKE MANIFOLD AND EXHAUST MANIFOLD

INTAKE MANIFOLD COLLECTOR, INTAKE MANIFOLD AND EXHAUST MANIFOLD SPECIFICATIONS

SPARK PLUG

SPARK PLUG REFERENCE CHART

CAMSHAFT AND CAMSHAFT BEARING

CAMSHAFT AND CAMSHAFT BEARING REFERENCE Unit: mm (in) Items Standard Limit Camshaft journal oil clearance No. 1 0.045-0.086 (0.0018-0.0034) 0.15 (0.0059) No. 2, 3, 4 0.035-0.076 (0.0014-0.0030) Camshaft bracket inner diameter No. 1 26.000-26.021 (1.0236-1.0244) - No. 2, 3, 4 23.500-23.521 (0.9252-0.9260) - Camshaft journal diameter No. 1 25.935-25.955 (1.0211-1.0218) - No. 2, 3, 4 23.445-23.465 (0.9230-0.9238) - Camshaft end play 0.115-0.188 (0.0045-0.0074) 0.24 (0.0094) Camshaft cam height "A" Intake 45.465-45.655 (1.7900-1.7921) 45.265 (1.7821) Exhaust 45.075-45.265 (1.7746-1.7821) 44.875 (1.7667) Camshaft runout [TIR (1) ] Less than 0.02 mm (0.001) 0.05 (0.002) Camshaft sprocket runout [TIR*2 ] - 0.15 (0.0059) (1) Total indicator reading

VALVE LIFTER SPECIFICATIONS

Valve Clearance

VALVE CLEARANCE SPECIFICATIONS

VQ40DE

THICKNESS REFERENCE CHART Unit: mm (in) Identification (stamped) mark Thickness Intake Exhaust 788U N788 7.88 (0.3102) 790U N790 7.90 (0.3110) 792U N792 7.92 (0.3118) 794U N794 7.94 (0.3126) 796U N796 7.96 (0.3134) 798U N798 7.98 (0.3142) 800U N800 8.00 (0.3150) 802U N802 8.02 (0.3157) 804U N804 8.04 (0.3165) 806U N806 8.06 (0.3173) 808U N808 8.08 (0.3181) 810U N810 8.10 (0.3189) 812U N812 8.12 (0.3197) 814U N814 8.14 (0.3205) 816U N816 8.16 (0.3213) 818U N818 8.18 (0.3220) 820U N820 8.20 (0.3228) 822U N822 8.22 (0.3236) 824U N824 8.24 (0.3244) 826U N826 8.26 (0.3252) 828U N828 8.28 (0.3260) 830U N830 8.30 (0.3268) 832U N832 8.32 (0.3276) 834U N834 8.34 (0.3283) 836U N836 8.36 (0.3291) 838U - 8.38 (0.3299) 840U - 8.40 (0.3307)

CYLINDER HEAD

CYLINDER HEAD SPECIFICATIONS Unit: mm (in) Items Standard Limit Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004) Normal cylinder head height "H" 126.3-126.5 (4.972-4.980)

VALVE DIMENSIONS REFERENCE Unit: mm (in) Valve head diameter "D" Intake 37.0-37.3 (1.4567-1.4685) Exhaust 31.2-31.5 (1.228-1.240) Valve length "L" Intake 96.46 (3.7976) Exhaust 93.99 (3.7004) 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) Exhaust 1.3 (0.051)

Scheme 481

Valve Guide

VALVE GUIDE REFERENCE Unit: mm (in) Items Standard 0.2 (0.008) oversize (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) Items Standard Limit Valve guide clearance Intake 0.020-0.053 (0.0008-0.0021) 0.08 (0.003) Exhaust 0.030-0.063 (0.0012-0.0025) 0.09 (0.004) Projection length "L" 12.6-12.8 (0.496-0.504)

Valve Seat

VALVE SEAT SPECIFICATIONS Unit: mm (in) Items Standard Oversize [0.5 (0.02)] (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 outer 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) Valve seat interference fit Intake 0.081-0.113 (0.0032-0.0044) Exhaust 0.064-0.096 (0.0025-0.0038) Diameter "d1" (1) Intake 35 (1.38) Exhaust 28.7 (1.130) Diameter "d2" (2) Intake 36.3-36.8 (1.429-1.449) Exhaust 30.3-30.8 (1.193-1.213) Angle "α1" Intake 60° Exhaust 60° Angle "α2" Intake 88°45' - 90°15' Exhaust 88°45' - 90°15' Angle "α3" Intake 120° Exhaust 120° Contacting width "W" (3) Intake 1.0-1.4 (0.039-0.055) Exhaust 1.2-1.6 (0.047-0.063) Height "h" Intake 5.9-6.0 (0.232-0.236) 5.05-5.15 (0.1988-0.2028) Exhaust 5.9-6.0 (0.232-0.236) 4.95-5.05 (0.1949-0.1988) Depth "H" 6.0 (0.236) (1) Diameter made by intersection point of conic angles "α1" and "α2" (2) Diameter made by intersection point of conic angles "α2" and "α3" (3) Machining data

Valve Spring

VALVE SPRING SPECIFICATIONS

CYLINDER BLOCK

CYLINDER BLOCK SPECIFICATIONS Unit: mm (in) Surface flatness Standard Less than 0.03 (0.0012) Limit 0.1 (0.004) Main bearing housing inner diameter Standard 74.993-75.017 (2.9525-2.9534) Cylinder bore Inner diameter Standard Grade No. 1 95.500-95.510 (3.7598-3.7602) Grade No. 2 95.510-95.520 (3.7602-3.7606) Grade No. 3 95.520-95.530 (3.7606-3.7610) Out-of-round (Difference between "X" and "Y") Limit 0.015 (0.0006) Taper (Difference between "A" and "C") 0.01 (0.0004) Main bearing housing inner diameter (Without bearing) Grade No. A 74.993-74.994 (2.9525-2.9525) Grade No. B 74.994-74.995 (2.9525-2.9526) Grade No. C 74.995-74.996 (2.9526-2.9526) Grade No. D 74.996-74.997 (2.9526-2.9526) Grade No. E 74.997-74.998 (2.9526-2.9527) Grade No. F 74.998-74.999 (2.9527-2.9527) Grade No. G 74.999-75.000 (2.9527-2.9528) Grade No. H 75.000-75.001 (2.9528-2.9528) Grade No. J 75.001-75.002 (2.9528-2.9528) Grade No. K 75.002-75.003 (2.9528-2.9529) Grade No. L 75.003-75.004 (2.9529-2.9529) Grade No. M 75.004-75.005 (2.9529-2.9529) Grade No. N 75.005-75.006 (2.9529-2.9530) Grade No. P 75.006-75.007 (2.9530-2.9530) Grade No. R 75.007-75.008 (2.9530-2.9531) Grade No. S 75.008-75.009 (2.9530-2.9531) Grade No. T 75.009-75.010 (2.9531-2.9531) Grade No. U 75.010-75.011 (2.9531-2.9532) Grade No. V 75.011-75.012 (2.9532-2.9532) Grade No. W 75.012-75.013 (2.9532-2.9533) Grade No. X 75.013-75.014 (2.9533-2.9533) Grade No. Y 75.014-75.015 (2.9533-2.9533) Grade No. 4 75.015-75.016 (2.9533-2.9534) Grade No. 7 75.016-75.017 (2.9534-2.9534) Difference in inner diameter between cylinders Standard Less than 0.03 (0.0012)

Available Piston

AVAILABLE PISTON SPECIFICATIONS Unit: mm (in) Items Standard 0.20 (0.0079) oversize Piston skirt diameter "A" Grade No. 1 95.480-95.490 (3.7590-3.7594) - Grade No. 2 95.490-95.500 (3.7594-3.7598) - Grade No. 3 95.500-95.510 (3.7598-3.7602) - Service - 95.680-95.710 (3.7669-3.7681) Items Standard Limit "a" dimension 43.03 (1.6941) - Piston pin hole diameter Grade No. 0 21.993-21.999 (0.8659-0.8661) - Grade No. 1 21.999-22.005 (0.8661-0.8663) - Piston to cylinder bore clearance 0.010-0.030 (0.0004-0.0012) 0.08 (0.0031)

Scheme 482

Piston Ring

PISTON RING SPECIFICATIONS

Piston Pin

PISTON PIN SPECIFICATIONS

CONNECTING ROD

CONNECTING ROD SPECIFICATIONS

CRANKSHAFT

CRANKSHAFT SPECIFICATIONS Unit: mm (in) Main journal diameter. "DM" grade Standard Grade No. A 69.975-69.974 (2.7549-2.7549) Grade No. B 69.974-69.973 (2.7549-2.7548) Grade No. C 69.973-69.972 (2.7548-2.7548) Grade No. D 69.972-69.971 (2.7548-2.7548) Grade No. E 69.971-69.970 (2.7548-2.7547) Grade No. F 69.970-69.969 (2.7547-2.7547) Grade No. G 69.969-69.968 (2.7547-2.7546) Grade No. H 69.968-69.967 (2.7546-2.7546) Grade No. J 69.967-69.966 (2.7546-2.7546) Grade No. K 69.966-69.965 (2.7546-2.7545) Grade No. L 69.965-69.964 (2.7545-2.7545) Grade No. M 69.964-69.963 (2.7545-2.7544) Grade No. N 69.963-69.962 (2.7544-2.7544) Grade No. P 69.962-69.961 (2.7544-2.7544) Grade No. R 69.961-69.960 (2.7544-2.7543) Grade No. S 69.960-69.959 (2.7543-2.7543) Grade No. T 69.959-69.958 (2.7543-2.7542) Grade No. U 69.958-69.957 (2.7542-2.7542) Grade No. V 69.957-69.956 (2.7542-2.7542) Grade No. W 69.956-69.955 (2.7542-2.7541) Grade No. X 69.955-69.954 (2.7541-2.7541) Grade No. Y 69.954-69.953 (2.7541-2.7540) Grade No. 4 69.953-69.952 (2.7540-2.7540) Grade No. 7 69.952-69.951 (2.7540-2.7540) Pin journal diameter. "DP" grade 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 (2.1242-2.1245) Center distance "r" 45.96-46.04 (1.8094-1.8126) Taper (Difference between "A" and "B") Limit 0.002 (0.0001) Out-of-round (Difference between "X" and "Y") 0.002 (0.0001) Crankshaft runout [TIR (1) ] Standard Less than 0.05 (0.002) Limit 0.10 (0.0039) Crankshaft end play Standard 0.10-0.25 (0.0039-0.0098) Limit 0.30 (0.0118) (1) Total indicator reading

MAIN BEARING

MAIN BEARING SPECIFICATIONS Grade number UPR/LWR Thickness mm (in) Width mm (in) Identification color Remarks 0 - 2.500-2.503 (0.0984-0.0985) 19.9-20.1 (0.783-0.791) Black Grade is the same for upper and lower bearings. 1 - 2.503-2.506 (0.0985-0.0987) Brown 2 - 2.506-2.509 (0.0987-0.0988) Green 3 - 2.509-2.512 (0.0988-0.0989) Yellow 4 - 2.512-2.515 (0.0989-0.0990) Blue 5 - 2.515-2.518 (0.0990-0.0991) Pink 6 - 2.518-2.521 (0.0991-0.0993) Purple 7 - 2.521-2.524 (0.0993-0.0994) White 01 UPR 2.503-2.506 (0.0985-0.0987) Brown Grade is different for upper and lower bearings. LWR 2.500-2.503 (0.0984-0.0985) Black 12 UPR 2.506-2.509 (0.0987-0.0988) Green LWR 2.503-2.506 (0.0985-0.0987) Brown 23 UPR 2.509-2.512 (0.0988-0.0989) Yellow LWR 2.506-2.509 (0.0987-0.0988) Green 34 UPR 2.512-2.515 (0.0989-0.0990) Blue LWR 2.509-2.512 (0.0988-0.0989) Yellow 45 UPR 2.515-2.518 (0.0990-0.0991) Pink LWR 2.512-2.515 (0.0989-0.0990) Blue 56 UPR 2.518-2.521 (0.0991-0.0993) Purple LWR 2.515-2.518 (0.0990-0.0991) Pink 67 UPR 2.521-2.524 (0.0993-0.0994) White LWR 2.518-2.521 (0.0991-0.0993) Purple

Undersize

THICKNESS CHART

Main Bearing Oil Clearance

MAIN BEARING OIL CLEARANCE REFERENCE

CONNECTING ROD BEARING

THICKNESS CHART

THICKNESS CHART

Connecting Rod Bearing Oil Clearance

THICKNESS CHART