Engine Mechanical: Other Nissan Juke I

Precaution for Procedure without Cowl Top Cover

When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. to prevent damage to windshield.

Scheme 181

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 " and " SEAT BELTS " of this Service Information.

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

Special Cautions to Ensure the Safe Disposal of Sodium-filled Exhaust Valves

Handling and disposal of sodium-filled exhaust valves requires special care and consideration. Under conditions such as breakage with subsequent contact with water, metal sodium which lines the inner portion of exhaust valve will react violently, forming sodium hydroxide and hydrogen which may result in an explosion. Sodium-filled exhaust valve is identified on the top of its stem as shown in illustration.

Scheme 182

DEALER DISPOSAL INSTRUCTIONS

Scheme 183

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Scheme 186

1. Clamp valve stem in a vice.
2. The valve has a specially-hardened surface. To cut through it, first remove a half-round section, approximately 30 mm (1.18 in) long using air-powered grinder until black color is removed and silver color appears.
3. Use hacksaw to cut through approximately half the diameter of valve stem. Make the serration at a point 40 mm (1.57 in) from the end of valve stem.
4. Cover the serrated end of the valve with a large shop towel (A). Strike the valve face end with a hammer, separating it into two pieces.
5. Fill a bucket (such as a 20 l oil can) with at least 10 l (2-5/8 US gal, 2-1/4 lmp gal) of water. Carefully place the already cut (serrated) valves into the water one-at-a-time using a set of large tweezers and quickly move away at least 2.7 m (9 ft).
6. The valves should be placed in a standing position as shown in the illustration to allow complete reaction. After the bubbling action has subsided, additional valves can be placed into the bucket allowing each subsequent chemical reaction to subside. However, no more than 8 valves should be placed in the same 10 l (2-5/8 US gal, 2-1/4 lmp gal) amount of water. The complete chemical reaction may take as long as 4 to 5 hours. Remove the valves using a set of large tweezers after the chemical reaction has stopped. Afterwards, valves can be disposed as ordinary scrap.

Disconnecting Fuel Piping

1. Before starting work, check 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.

Precaution for Handling High Pressure Fuel System

1. High pressure fuel system components are between high pressure fuel pump and fuel injector.
2. Always release fuel pressure and never start the engine when performing removal and installation.
3. When removing or installing parts without releasing fuel pressure, fuel may be splashed and, if fuel contacts skin or eyes, it may cause inflammation.

Special Service Tools

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

Tool number (Kent-Moore No.) Tool name Description KV10111100 (J-37228) Seal cutter Removing oil pan (upper and lower) etc. KV10114400 (J-38365) Heated oxygen sensor wrench Loosening or tightening heated oxygen sensor 2 (AWD models) For 22 mm (0.87 in) width hexagon nut KV10116200 (J-26336-A) Valve spring compressor KV10115900 (J-26336-20) Attachment KV10109220 (-) Adapter Disassembling and assembling valve mechanism Part (1) is a component of KV10116200 (J-26336-A), but Part (2) is not so. KV10112100 (BT8653-A) Angle wrench Tightening bolts for main bearing cap, cylinder head, etc. KV10117100 (J-3647-A) Heated oxygen sensor wrench Loosening or tightening air fuel ratio sensor 1 For 22 mm (0.87 in) width hexagon nut 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 (G). 20 (0.79) dia. 13 (0.51) dia. 10.3 (0.406) dia. 8 (0.31) dia. 10.7 (0.421) 5 (0.20) H: Side B Unit: mm (in) EM03470000 (J-8037) Piston ring compressor Installing piston assembly into cylinder bore ST16610001 (J-23907) Pilot bushing puller Removing pilot converter KV11103000 (-) Pulley puller Removing crankshaft pulley KV11105210 (J-44716) Stopper plate Fixing drive plate KV10119600 (-) Injector remover Removing fuel injector KV101197S0 (-) Injector seal drift set Installing fuel injector seal ring

Scheme 187

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Scheme 196

Commercial Service Tools

(Kent-Moore No.) Tool name Description (-) Spark plug wrench Removing and installing spark plug 14 mm (0.55 in) (-) Pulley holder Crankshaft pulley removing and installing (-) Valve seat cutter set Finishing valve seat dimensions (-) Piston ring expander Removing and installing piston ring (-) Valve guide drift Removing and installing valve guide (-) Valve guide reamer Reaming valve guide inner hole Reaming hole for oversize valve guide (J-43897-18) (J-43897-12) Oxygen sensor thread cleaner Reconditioning the exhaust system threads before installing a new air fuel ratio sensor (Use with anti-seize lubricant shown below.) J-43897-18 [18 mm (0.71 in) dia.] for zirconia heated oxygen sensor J-43897-12 [12 mm (0.47 in) dia.] for titania heated oxygen sensor Mating surface shave cylinder Flutes (-) Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907) Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads (-) Manual lift table caddy Removing and installing engine (-) Tube presser Pressing the tube of liquid gasket

Scheme 197

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Scheme 200

Scheme 201

Electric Throttle Control Actuator

1. Tighten bolts of electric throttle control actuator equally and diagonally in several steps.
2. Perform "Throttle Valve Closed Position Learning" after repair when removing harness connector of the electric throttle control actuator. Refer to " «WORK PROCEDURE»(ref-516395-S34891707702012120600000) ".
3. Perform "Throttle Valve Closed Position Learning" and "Idle Air Volume Learning" after repair when replacing electric throttle control actuator. Refer to " «WORK PROCEDURE»(ref-516395-S34891707702012120600000) " and " «WORK PROCEDURE»(ref-516395-S36108739382012120600000) ".

Vacuum hose (with check valve)

Check that the check valve. Refer to " INSPECTION ".

Scheme 202

Air inlet hose 1, Air inlet tube 1 and Recirculation valve

1. Remove engine cover. Refer to " «EXPLODED VIEW»(ref-516394-S32227874482012120600000) ".
2. Make matching marks on each connecting part for reference at installation.
3. Remove recirculation hose and vacuum hose to recirculation valve.
4. Loosen clamp, and then remove air inlet hose 1.
5. Remove recirculation valve and turbocharger boost sensor from air inlet tube 1, if necessary.
6. loosen clamp, and then remove air inlet hose 1.

Air inlet tube 3

1. Remove engine cover. Refer to " «EXPLODED VIEW»(ref-516394-S32227874482012120600000) ".
2. Make matching marks on each connecting part for reference at installation.
3. Loosen clamp, and then remove air inlet tube 3.

Scheme 203

1. Remove front bumper. Refer to " «EXPLODED VIEW»(ref-516396-S35683358922012120600000) ".
2. Remove radiator core support upper. Refer to " «EXPLODED VIEW»(ref-516400-S22744293852012120600000) "(With intelligent key system) or " «EXPLODED VIEW»(ref-516414-S17462178782012120600000) "(Without intelligent key system).
3. Make matching marks on each connecting part for reference at installation.
4. Remove air inlet hose 2.
5. Loosen air inlet tube 2 clamp, and then remove charge air cooler (1). CAUTION: Avoid interference between the charge air cooler and radiator. When removing charge air cooler, close opening on turbo charger and intake manifold with shop cloth or other suitable material.
6. Remove air inlet tube 2, if necessary.

Exploded View

Scheme 204

Check for Fuel Leakage

1. Turn ignition switch "ON" (with the engine stopped). With fuel pressure applied to fuel piping, check that there is no fuel leakage at connection points. NOTE: Use mirrors for checking at points out of clear sight.
2. Start the engine. With engine speed increased, check again that there is no fuel leakage at connection points. CAUTION: Never touch the engine immediately after it is stopped because the engine is extremely hot.

Scheme 205

Check on Fuel Leakage

1. Turn ignition switch "ON" (with the engine stopped). With fuel pressure applied to fuel piping, check there are no fuel leakage at connection points. NOTE: Use mirrors for checking at points out of clear sight.
2. Start the engine. With engine speed increased, check again that there are no fuel leakage at connection points. CAUTION: Never touch the engine immediately after stopped, as the engine becomes extremely hot.

Scheme 206

Scheme 207

1. Drain engine coolant. Refer to " «DRAINING»(ref-516398-S08374559152012120600000) ".
2. Remove engine cover. Refer to " «EXPLODED VIEW»(ref-516394-S32227874482012120600000) ".
3. Remove air inlet tube assembly. Refer to " «EXPLODED VIEW»(ref-516394-S42591055892012120600000) ".
4. Remove PCV hose.
5. Remove rocker cover protector.
6. Disconnect ignition coil harness connector, and them remove ignition coil. CAUTION: Never drop or shock ignition coil. Never disassemble ignition coil.
7. Move ignition harness.
8. Remove rocker cover. Loosen bolts in reverse order shown in the figure.
9. Remove PCV valve and PCV hose, if necessary.
10. Remove rocker cover gasket from rocker cover.

Setting

Note. Explained here is how to disassemble with engine stand supporting transaxle surface. When using different type of engine stand, note with difference in steps and etc.

Scheme 208

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Scheme 210

Scheme 211

1. Remove the engine and the transaxle assembly from the vehicle, and separate the transaxle from the engine. Refer to " «2WD: REMOVAL AND INSTALLATION»(ref-516394-S36690152752012120600000) " (2WD models) or " «4WD (AWD): REMOVAL AND INSTALLATION»(ref-516394-S30689725612012120600000) " (4WD models).
2. Install engine to engine stand with the following procedure: Remove flywheel (M/T models) or drive plate (CVT models). Secure flywheel (M/T models) or drive plate (CVT models) (1) with a stopper plate [SST: KV11105210 (J-44716)] (A), and remove mounting bolts. NOTE: This figure shows CVT models as an example. Remove pilot converter (1) (CVT models) or pilot bush (M/T models) using pilot bushing puller [SST: ST16610001 (J-23907)] (A) or suitable tool. NOTE: This figure shows CVT models as an example. Lift the engine with a hoist to install it onto widely use engine stand. CAUTION: Use the engine stand that has a load capacity [approximately 135 kg (298 lb) or more] large enough for supporting the engine weight. If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the potential risk of overturning stand. Intake manifold: Refer to " «EXPLODED VIEW»(ref-516394-S40399315512012120600000) ". Catalyst converter: Refer to " «2WD: EXPLODED VIEW»(ref-516394-S26730609962012120600000) " (2WD models) or " «AWD: EXPLODED VIEW»(ref-516394-S30349499242012120600000) " (AWD models). Rocker cover: Refer to " «EXPLODED VIEW»(ref-516394-S05809942372012120600000) ". NOTE: The figure shows an example of widely used engine stand (A) that can support mating surface of transaxle with flywheel (M/T models) or drive plate (CVT models) removed. CAUTION: Before removing the hanging chains, check the engine stand is stable and there is no risk of overturning.
3. Drain engine oil. Refer to " «DRAINING»(ref-516404-S29020311892012120600000) ". CAUTION: Be sure to clean drain plug and install with new drain plug washer.
4. Drain engine coolant by removing water drain plug (1) from inside of the engine. Tightening torque: Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-516394-S26369057342012120600000) ". Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-516389-S27688368402012120600000) ".

Timing Chain

Check for cracks (A) and any excessive wear (B) at link plates and roller links of timing chain. Replace timing chain if necessary.

Scheme 212

Camshaft Journal Oil Clearance

CAMSHAFT JOURNAL OUTER DIAMETER

Measure the outer diameter of camshaft journal with a micrometer (A).

Standard: Refer to " CAMSHAFT ".

Scheme 213

CAMSHAFT BRACKET INNER DIAMETER

Scheme 214

1. Tighten camshaft bracket bolts with specified torque. Refer to " «REMOVAL AND INSTALLATION»(ref-516394-S15609777012012120600000) ".
2. Measure the inner diameter of camshaft bracket with a bore gauge (A).

Standard: Refer to " CAMSHAFT ".

CAMSHAFT JOURNAL OIL CLEARANCE

1. (Oil clearance) = (Camshaft bracket inner diameter) - (Camshaft journal diameter) Standard and Limit: Refer to " «CAMSHAFT»(ref-516394-S39024377212012120600000) ".
2. If it exceeds the limit, replace camshaft or cylinder head, or both. NOTE: Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head. Replace whole cylinder head assembly.

Scheme 215

Scheme 216

1. Install camshaft in cylinder head. Refer to " «REMOVAL AND INSTALLATION»(ref-516394-S15609777012012120600000) ".
2. Install dial indicator in thrust direction on front end of camshaft. Read the end play of dial indicator (A) when camshaft is moved forward/backward (in direction to axis). Standard and Limit: Refer to " «CAMSHAFT»(ref-516394-S39024377212012120600000) ". Measure the following parts if out of the standard. Dimension (A) for groove of cylinder head No. 1 journal Standard: 4.000 - 4.030 mm (0.1575 - 0.1587 in) Dimension (B) for camshaft flange Standard: 3.877 - 3.925 mm (0.1526 - 0.1545 in) Refer to the standards above, and then replace camshaft and/or cylinder head.

Scheme 217

1. Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft. CAUTION: Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations.
2. Measure the camshaft sprocket runout with a dial indicator (A). (Total indicator reading) Limit: Refer to " «CAMSHAFT»(ref-516394-S39024377212012120600000) ". If it exceeds the limit, replace camshaft sprocket.

Valve Lifter

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

Scheme 218

1. If anything above is found, replace valve lifter. Refer to " «CAMSHAFT»(ref-516394-S39024377212012120600000) ".

Valve Lifter Clearance

VALVE LIFTER OUTER DIAMETER

Scheme 219

1. Measure the outer diameter of valve lifter with a micrometer (A). Standard: Refer to " «CAMSHAFT»(ref-516394-S39024377212012120600000) ".

VALVE LIFTER HOLE DIAMETER

Measure the inner diameter of valve lifter hole of cylinder head with an inside micrometer (A).

Standard: Refer to " CAMSHAFT ".

VALVE LIFTER CLEARANCE

Scheme 220

1. (Valve lifter clearance) = (Valve lifter hole diameter) - (Valve lifter outer diameter) Standard: Refer to " «CAMSHAFT»(ref-516394-S39024377212012120600000) ".
2. If out of the standard, referring to the each standard of valve lifter outer diameter and valve lifter hole diameter, replace either or both valve lifter and cylinder head.

Scheme 221

Scheme 222

Cylinder Head Distortion

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

Scheme 223

1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper. CAUTION: Never allow gasket debris to enter passages for engine oil or water.
2. At each of several locations on bottom surface of cylinder head, measure the distortion in six directions using straightedge (A) and feeler gauge (B). Limit: Refer to " «CYLINDER HEAD»(ref-516394-S22659529612012120600000) ". If it exceeds the limit, replace cylinder head.

VALVE DIMENSIONS

1. Check the dimensions of each valve. For the dimensions, refer to " «CYLINDER HEAD»(ref-516394-S22659529612012120600000) ".
2. If dimensions are out of the standard, replace valve and check valve seat contact. Refer to " «VALVE SEAT CONTACT»(ref-516394-S16833248912012120600000) ".

VALVE GUIDE CLEARANCE

Valve Stem Diameter

1. Measure the diameter of valve stem with micrometer (A). Standard: Refer to " «CYLINDER HEAD»(ref-516394-S22659529612012120600000) ".

Valve Guide Inner Diameter

1. Measure the inner diameter of valve guide with bore gauge. Standard: Refer to " «CYLINDER HEAD»(ref-516394-S22659529612012120600000) ".

Valve Guide Clearance

Scheme 224

1. (Valve guide clearance) = (Valve guide inner diameter) - (Valve stem diameter) Standard and Limit: Refer to " «CYLINDER HEAD»(ref-516394-S22659529612012120600000) ".
2. If the calculated value exceeds the limit, replace valve and/or valve guide. When valve guide must be replaced. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-516394-S16292594622012120600000) ".

Scheme 225

1. After confirming that the dimensions of valve guides and valves are within the specifications, perform this procedure.
2. Apply Prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve contact on the surface.
3. Check if the contact area band is continuous all around the circumference.
4. If not, grind to adjust valve fitting and check again. If the contacting surface still has "NG" conditions (B) even after the recheck, replace valve seat. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-516394-S16292594622012120600000) ".

Scheme 226

1. Set a try square (A) along the side of valve spring and rotate spring. Measure the maximum clearance between the top of spring and try square. Limit: Refer to " «CYLINDER HEAD»(ref-516394-S22659529612012120600000) ".
2. If it exceeds the limit, replace valve spring.

Scheme 227

1. Check valve spring pressure with valve spring seat installed at the specified spring height. CAUTION: Never remove valve spring seat from valve spring. Standard: Refer to " «CYLINDER HEAD»(ref-516394-S22659529612012120600000) ".
2. If the installation load or load with valve open is out of the standard, replace valve spring (with valve spring seat).

CRANKSHAFT END PLAY

1. Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with a dial indicator (A). Standard and Limit: Refer to " «CYLINDER BLOCK»(ref-516394-S33770760562012120600000) ".
2. If the measured value exceeds the limit, replace thrust bearings, and measure again. If it still exceeds the limit, replace crankshaft also.

Scheme 228

1. Measure the side clearance between connecting rod and crankshaft arm with a feeler gauge (A). Standard and Limit: Refer to " «CYLINDER BLOCK»(ref-516394-S33770760562012120600000) ".
2. If the measured value exceeds the limit, replace connecting rod, and measure again. If it still exceeds the limit, replace crankshaft also.

Piston Pin Hole Diameter

Measure the inner diameter of piston pin hole with an inside micrometer (A).

Standard: Refer to " CYLINDER BLOCK ".

Scheme 229

Piston to Piston Pin Oil Clearance

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

Standard: Refer to " CYLINDER BLOCK ".

1. If oil clearance is out of the standard, replace piston and piston pin assembly.
2. When replacing piston and piston pin assembly. Refer to " «DESCRIPTION»(ref-516394-S13956406822012120600000) ". 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 grades can be selected. (Only grade "0" is available.)

Scheme 230

1. Measure the side clearance of piston ring and piston ring groove with a feeler gauge (A). Standard and Limit: Refer to " «CYLINDER BLOCK»(ref-516394-S33770760562012120600000) ".
2. If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, replace piston also.

Scheme 231

1. Check that cylinder bore inner diameter is within specification. Refer to " «PISTON TO CYLINDER BORE CLEARANCE»(ref-516394-S00264421412012120600000) ".
2. Lubricate with new engine oil to piston (1) and piston ring (2), and then insert (A) piston ring until middle of cylinder (B) with piston, and measure piston ring end gap with a feeler gauge (C). Standard and Limit: Refer to " «CYLINDER BLOCK»(ref-516394-S33770760562012120600000) ".
3. If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, rebore cylinder and use oversized piston and piston rings.

Scheme 232

1. Check with a connecting rod aligner. Limit: Refer to " «CYLINDER BLOCK»(ref-516394-S33770760562012120600000) ".
2. If it exceeds the limit, replace connecting rod assembly.

Scheme 233

1. Install connecting rod cap (1) without connecting rod bearing installed, and tightening connecting rod cap bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-516394-S26369057342012120600000) ".
2. Measure the inner diameter of connecting rod big end with an inside micrometer. Standard: Refer to " «CYLINDER BLOCK»(ref-516394-S33770760562012120600000) ".
3. If out of the standard, replace connecting rod assembly.

Connecting Rod Bushing Inner Diameter

Measure the inner diameter of connecting rod bushing with an inside micrometer (A).

Standard: Refer to " CYLINDER BLOCK ".

Scheme 234

Connecting Rod Bushing Oil Clearance

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

Standard and Limit: Refer to " CYLINDER BLOCK ".

1. If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin assembly.
2. If replacing piston and piston pin assembly. Refer to " «PISTON»(ref-516394-S32496736992012120600000) ".
3. If replacing connecting rod assembly. Refer to " «CONNECTING ROD BEARING»(ref-516394-S03668963202012120600000) ".

Scheme 235

1. Using a 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 a straight edge (A) and feeler gauge (B). Limit: Refer to " «CYLINDER BLOCK»(ref-516394-S33770760562012120600000) ".
3. If it exceeds the limit, replace cylinder block.

Scheme 236

1. Install main bearing cap without main bearings installed, and tighten main bearing cap mounting bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-516394-S26369057342012120600000) ".
2. Measure the inner diameter of main bearing housing with a bore gauge.
3. Measure the position shown in the figure [5 mm (0.20 in)] backward from main bearing housing front side in the 2 directions as shown in the figure. The smaller one is the measured value. Standard: Refer to " «CYLINDER BLOCK»(ref-516394-S33770760562012120600000) ".
4. If out of the standard, replace cylinder block and main bearing caps assembly. NOTE: Main bearing caps cannot be replaced as a single, because it is machined together with cylinder block.

Scheme 237

1. Using a bore gauge, measure the cylinder bore for wear, out-of-round and taper at six different points on each cylinder. [(A) and (B) directions at (C), (D), and (E)] [(A) is in longitudinal direction of engine] NOTE: When determining cylinder bore grade, measure the cylinder bore (B) direction at (D) position. Standard: Cylinder bore inner diameter : Refer to " «CYLINDER BLOCK»(ref-516394-S33770760562012120600000) ". Limit: Out-of-round [Difference between (A) and (B)] Taper [Difference between (C) and (D)] : Refer to " «CYLINDER BLOCK»(ref-516394-S33770760562012120600000) ".
2. If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, replace cylinder block. NOTE: Oversize piston is not provided.

Piston Skirt Diameter

Measure the outer diameter of piston skirt with a micrometer (A).

Standard: Refer to " CYLINDER BLOCK ".

Scheme 238

Piston to Cylinder Bore Clearance

Calculate by piston skirt diameter and cylinder bore inner diameter [direction (B), position (D)].

Scheme 239

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

Standard and Limit: Refer to " CYLINDER BLOCK ".

1. If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block. Refer to " «PISTON»(ref-516394-S32496736992012120600000) ".

Scheme 240

1. Measure the outer diameter of crankshaft main journals with a micrometer (A). Standard: Refer to " «CYLINDER BLOCK»(ref-516394-S33770760562012120600000) ".
2. If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to " «MAIN BEARING»(ref-516394-S12822908342012120600000) ".

CRANKSHAFT PIN JOURNAL DIAMETER

1. Measure the outer diameter of crankshaft pin journal with a micrometer. Standard: Refer to " «CYLINDER BLOCK»(ref-516394-S33770760562012120600000) ".
2. If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer to " «CONNECTING ROD BEARING»(ref-516394-S34332405452012120600000) ".

Scheme 241

1. Measure the dimensions at four different points as shown in the figure on each main journal and pin journal with a micrometer.
2. Out-of-round is indicated by the difference in dimensions between (X) and (Y) at (A) and (B).
3. Taper is indicated by the difference in dimension between (A) and (B) at (X) and (Y). Limit: Out-of-round [Difference between (X) and (Y)] Taper [Difference between (A) and (B)] : Refer to " «CYLINDER BLOCK»(ref-516394-S33770760562012120600000) ".
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 main bearing and/or connecting rod bearing. Refer to " «CONNECTING ROD BEARING»(ref-516394-S03668963202012120600000) " and/or " «MAIN BEARING»(ref-516394-S34752395502012120600000) ".

Scheme 242

1. Place a V-block on a precise flat table to support the journals on the both end of the crankshaft.
2. Place a dial indicator (A) straight up on the No. 3 journal.
3. While rotating crankshaft, read the movement of the pointer on the dial indicator. (Total indicator reading) Standard and Limit: Refer to " «CYLINDER BLOCK»(ref-516394-S33770760562012120600000) ".
4. If it exceeds the limit, replace crankshaft.

Scheme 243

1. Install connecting rod bearings (2) to connecting rod (3) and connecting rod bearing cap (1), and tighten connecting rod cap bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-516394-S26369057342012120600000) ".
2. Measure the inner diameter of connecting rod bearing with an inside micrometer. (Bearing oil clearance) = (Connecting rod bearing inner diameter) - (Crankshaft pin journal diameter) Standard and Limit: Refer to " «CONNECTING ROD BEARING»(ref-516394-S34332405452012120600000) ".
3. If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to " «CONNECTING ROD BEARING»(ref-516394-S03668963202012120600000) ".

Scheme 244

1. Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.
2. Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
3. Install connecting rod bearings to connecting rod and cap, and tighten connecting rod cap bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-516394-S26369057342012120600000) ". CAUTION: Never rotate crankshaft.
4. Remove connecting rod cap and bearing, and using the scale (A) on the plastigage bag, measure the plastigage width. NOTE: The procedure when the measured value exceeds the limit is same as that described in the "Method by Calculation".

Scheme 245

1. Install main bearings (3) to cylinder block (1) and main bearing cap (2), and tighten main bearing cap mounting bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-516394-S26369057342012120600000) ".
2. Measure the inner diameter of main bearing with a bore gauge. (Bearing oil clearance) = (Main bearing inner diameter) - (Crankshaft main journal diameter) Standard and Limit: Refer to " «MAIN BEARING»(ref-516394-S12822908342012120600000) ".
3. If clearance 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 " «MAIN BEARING»(ref-516394-S34752395502012120600000) ".

Scheme 246

1. Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.
2. Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
3. Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap mounting bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-516394-S26369057342012120600000) ". CAUTION: Never rotate crankshaft.
4. Remove main bearing cap and bearings, and using the scale (A) on the plastigage bag, measure the plastigage width. NOTE: The procedure when the measured value exceeds the limit is same as that described in the "Method by Calculation".

Scheme 247

1. When main bearing cap is removed after being tightened to the specified torque with main bearings (1) installed, the tip end of bearing must protrude (B). Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-516394-S26369057342012120600000) ". Standard: There must be crush height.
2. If the standard is not met, replace main bearings.

Scheme 248

1. When connecting rod cap is removed after being tightened to the specified torque with connecting rod bearings (1) installed, the tip end of bearing must protrude (B). Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-516394-S26369057342012120600000) ". Standard: There must be crush height.
2. If the standard is not met, replace connecting rod bearings.

Scheme 249

1. Measure the outer diameters (d1) and (d2) at two positions as shown in the figure.
2. If reduction appears in places other than (B) range, regard it as (d2). Limit [(d1) - (d2)]: 0.15 mm (0.0059 in)
3. If it exceeds the limit (a large difference in dimensions), replace main bearing cap mounting bolt with a new one.

Scheme 250

1. Measure the outer diameter (d) at position as shown in the figure.
2. If 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 cap bolt with a new one.

Scheme 251

1. Measure the deflection of flywheel contact surface to torque with a dial indicator (A).
2. Measure the deflection at 210 mm (8.27 in) diameter. Limit: 0.45 mm (0.0177 in) or less.
3. If measured value is out of the standard, replace flywheel.
4. If a trace of burn or discoloration is found on the surface, repair it with sandpaper. CAUTION: When measuring, keep magnetic fields (such as dial indicator stand) away from signal plate of the rear end of crankshaft.

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, 22 lb) force is added at the portion of 125 mm (4.92 in) radius from the center of flywheel. Standard: 1.8 mm (0.071 in) or less
2. If measured value is out of the standard, replace flywheel.

Movement Amount in Radial (Rotation) Direction

Check the movement amount of radial (rotation) direction with the following procedure

Scheme 252

1. Install clutch cover mounting bolt (1) to clutch cover mounting hole, and place a torque wrench (A) on the extended line of the flywheel (2) center line. Tighten bolt at a force of 9.8 N.m (1.0 kg-m, 87 in-lb) to keep it from loosening.
2. Put a mating mark on circumferences of the two flywheel masses without applying any load (Measurement standard points).
3. Apply a force of 9.8 N.m (1.0 kg-m, 87 in-lb) in each direction, and mark the movement amount on the mass on the transaxle side.
4. Measure the dimensions of movement amounts "A" and "B" on circumference of the flywheel on the transaxle side. Limit: 33.2 mm (1.307 in) or less. If measured value is out of the standard, replace flywheel.

Scheme 253

1. Measure the deflection of drive plate contact surface to torque converter with a dial indicator (A).
2. Measure the deflection at the area limited between 12.4 mm (0.488 in) dia and 20.0 mm (0.787 in) dia around hole (B). Limit: 0.35 mm (0.0138 in) or less.
3. If measured value is out of the standard, replace drive plate.

PISTON SELECTION TABLE

Note. Piston is available together with piston pin as an assembly.

Scheme 254

Scheme 255

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

WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED

1. Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter individually. Refer to " «INSPECTION»(ref-516394-S05015785222012120600000) ".
2. Apply the measured dimension to the "Connecting Rod Bearing Selection Table".
3. Read the symbol at the cross point of selected row and column in the "Connecting Rod Bearing Selection Table".
4. Apply the symbol obtained to the "Connecting Rod Bearing Grade Table" to select connecting rod bearing.

Scheme 256

CONNECTING ROD BEARING GRADE TABLE

Connecting rod bearing grade table: Refer to " CONNECTING ROD BEARING ".

Scheme 257

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 the 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)] (A). Bearing undersize table : Refer to " «CONNECTING ROD BEARING»(ref-516394-S34332405452012120600000) ".

Scheme 258

Scheme 259

1. "Main Bearing Selection Table" rows correspond to main bearing housing grade on rear left side of cylinder block (L). If there is a correction stamp mark on cylinder block, use it as a correct reference.
2. Apply main journal diameter grade stamped on crankshaft front side to column in the "Main Bearing Selection Table".
3. Read the symbol at the cross point of selected row and column in the "Main Bearing Selection Table". CAUTION: There are two main bearing selection tables. One is for No. 1, 4, and 5 journals and the other is for No. 2 and 3 journals. Make certain to use the appropriate table. This is due to differences in the specified clearances.
4. Apply the symbol obtained to the "Main Bearing Grade Table" to select main bearing. NOTE: Service part is available as a set of both upper and lower.

WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED

1. Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main journal diameter individually. Refer to " «INSPECTION»(ref-516394-S05015785222012120600000) ".
2. Apply the measured dimension to the "Main Bearing Selection Table".
3. Read the symbol at the cross point of selected row and column in the "Main Bearing Selection Table". CAUTION: There are two main bearing selection tables. One is for No. 1, 4, and 5 journals and the other is for No. 2 and 3 journals. Make certain to use the appropriate table. This is due to differences in the specified clearances.
4. Apply the symbol obtained to the "Main Bearing Grade Table" to select main bearing. NOTE: Service part is available as a set of both upper and lower.

Scheme 260

Scheme 261

MAIN BEARING GRADE TABLE (ALL JOURNALS)

Main bearing grade table (All journals): Refer to " MAIN BEARING ".

UNDERSIZE BEARING USAGE GUIDE

1. When the specified main bearing oil clearance is not obtained with standard size main bearings, use undersize (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)] (A). Bearing undersize table: Refer to " «MAIN BEARING»(ref-516394-S12822908342012120600000) ".

DRIVE BELT

SPARK PLUG

EXHAUST MANIFOLD

TURBOCHARGER ACTUATOR

CAMSHAFT

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, 5 0.030 - 0.071 (0.0012 - 0.0028) Camshaft bracket inner diameter No. 1 28.000 - 28.021 (1.1024 - 1.1032) - No. 2, 3, 4, 5 25.000 - 25.021 (0.9843 - 0.9851) - Camshaft journal diameter No. 1 27.935 - 27.955 (1.0998 - 1.1006) - No. 2, 3, 4, 5 24.950 - 24.970 (0.9823 - 0.9831) - Camshaft end play 0.075 - 0.153 (0.0030 - 0.0060) 0.24 (0.0094) Camshaft cam height "A" Intake 44.605 - 44.795 (1.7561 - 1.7636) 44.66 (1.75827) Exhaust 43.175 - 43.365 (1.6998 - 1.7073) 44.20 (1.74016) Camshaft runout [TIR (1) ] Less than 0.02 (0.0008) 0.05 (0.0020) Camshaft sprocket runout [TIR (1) ] - 0.15 (0.0059) (1) Total indicator reading

VALVE CLEARANCE

AVAILABLE VALVE LIFTER

Unit: mm (in) Identification mark Thickness 300 3.00 (0.1181) 302 3.02 (0.1189) 304 3.04 (0.1197) 306 3.06 (0.1205) 308 3.08 (0.1213) 310 3.10 (0.1220) 312 3.12 (0.1228) 314 3.14 (0.1236) 316 3.16 (0.1244) 318 3.18 (0.1252) 320 3.20 (0.1260) 322 3.22 (0.1268) 324 3.24 (0.1276) 326 3.26 (0.1283) 328 3.28 (0.1291) 330 3.30 (0.1299) 332 3.32 (0.1307) 334 3.34 (0.1315) 336 3.36 (0.1323) 338 3.38 (0.1331) 340 3.40 (0.1339) 342 3.42 (0.1346) 344 3.44 (0.1354) 346 3.46 (0.1362) 348 3.48 (0.1370) 350 3.50 (0.1378)

CYLINDER HEAD

Unit: mm (in) Items Standard Limit Head surface distortion - 0.1 (0.004) Normal cylinder head height "H" 130.9 (5.15)

Unit: mm (in) Valve head diameter "D" Intake 31.2 - 31.5 (1.228 - 1.240) Exhaust 25.6 - 25.9 (1.008 - 1.020) Valve length "L" Intake 107.08 (4.22) Exhaust 106.06 (4.18) Valve stem diameter "d" Intake 5.465 - 5.480 (0.2152 - 0.2157) Exhaust 5.455 - 5.470 (0.2148 - 0.2154) Valve seat angle "α" 45°15' - 45°45' Valve margin "T" Intake 1.4 (0.055) Exhaust 1.4 (0.055)

VALVE GUIDE

Unit: mm (in) Items Standard Oversize (service) [0.2 (0.008)] Valve guide Outer diameter 9.523 - 9.534 (0.3749 - 0.3754) 9.723 - 9.734 (0.3828 - 0.3832) Inner diameter (Finished size) 5.500 - 5.518 (0.2165 - 0.2172) Cylinder head valve guide hole diameter 9.475 - 9.496 (0.3730 - 0.3739) 9.675 - 9.696 (0.3809 - 0.3817) 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) 0.1 (0.004) Exhaust 0.030 - 0.063 (0.0012 - 0.0025) Projection length "H" 13.35 - 13.65 (0.5256 - 0.5374)

VALVE SEAT

Unit: mm (in) Items Standard Oversize (service) [0.5 (0.020)] Cylinder head seat recess diameter "D" Intake 31.900 - 31.927 (1.2559 - 1.2570) 35.200 - 35.227 (1.3858 - 1.3869) Exhaust 26.300 - 26.327 (1.0354 - 1.0365) 29.200 - 29.227 (1.1496 - 1.1507) Valve seat outer diameter "d" Intake 31.997 - 32.013 (1.2597 - 1.2604) 32.497 - 32.513 (1.2794 - 1.2800) Exhaust 26.408 - 26.424 (1.0397 - 1.0403) Valve seat interference fit 0.07 - 0.113 (0.0028 - 0.0044) Diameter "d1" (1) Intake 29.2 (1.150) Exhaust 23.3 (0.917) Diameter "d2" (2) Intake 30.5 - 31.0 (1.201 - 1.220) Exhaust 24.9 - 25.4 (0.980 - 1.0) Angle "α1" Intake 70° Exhaust 45° Angle "α2" 88°45' - 90°15' Angle "α3" 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) 5.09 - 5.10 (0.2004 - 0.2008) Exhaust Depth "H" Intake 6.01 (0.2366) Exhaust 6.07 (0.2390) (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

CYLINDER BLOCK

Unit: mm (in) Cylinder block top surface distortion Limit 0.1 (0.004) Cylinder bore inner diameter Standard Grade No. 1 79.700 - 79.710 (3.1378 - 3.1382) Grade No. 2 79.710 - 79.720 (3.1382 - 3.1386) Out-of-round Limit 0.015 (0.0006) Taper 0.010 (0.0004) Main bearing housing inner diameter grade Grade No. A 55.997 - 55.998 (2.2046 - 2.2046) Grade No. B 55.998 - 55.999 (2.2046 - 2.2047) Grade No. C 55.999 - 56.000 (2.2047 - 2.2047) Grade No. D 56.000 - 56.001 (2.2047 - 2.2048) Grade No. E 56.001 - 56.002 (2.2048 - 2.2048) Grade No. F 56.002 - 56.003 (2.2048 - 2.2048) Grade No. G 56.003 - 56.004 (2.2048 - 2.2049) Grade No. H 56.004 - 56.005 (2.2049 - 2.2049) Grade No. J 56.005 - 56.006 (2.2049 - 2.2050) Grade No. K 56.006 - 56.007 (2.2050 - 2.2050) Grade No. L 56.007 - 56.008 (2.2050 - 2.2050) Grade No. M 56.008 - 56.009 (2.2050 - 2.2051) Grade No. N 56.009 - 56.010 (2.2051 - 2.2051) Grade No. P 56.010 - 56.011 (2.2051 - 2.2052) Grade No. R 56.011 - 56.012 (2.2052 - 2.2052) Grade No. S 56.012 - 56.013 (2.2052 - 2.2052) Grade No. T 56.013 - 56.014 (2.2052 - 2.2053) Grade No. U 56.014 - 56.015 (2.2053 - 2.2053) Grade No. V 56.015 - 56.016 (2.2053 - 2.2053) Grade No. W 56.016 - 56.017 (2.2053 - 2.2054)

Scheme 262

AVAILABLE PISTON

Unit: mm (in) Piston skirt diameter "A" Standard Grade No. 1 79.670 - 79.680 (3.1366 - 3.1370) Grade No. 2 79.680 - 79.690 (3.1370 - 3.1374) Measure point "H" 43.4 (1.7087) Piston pin hole diameter 21.993 - 21.999 (0.8658 - 0.8661) Piston to cylinder bore clearance Standard 0.020 - 0.040 (0.0008 - 0.0016) Limit 0.08 (0.0031)

PISTON RING

PISTON PIN

CONNECTING ROD

CRANKSHAFT

Unit: mm (in) Center distance "r" 40.41 - 40.49 (1.5909 - 1.5940) Out-of-round Limit 0.0035 (0.0001) Taper Limit Runout [TIR (1) ] Standard 0.05 (0.0020) Limit 0.10 (0.0039) Crankshaft end play Standard 0.10 - 0.26 (0.0039 - 0.0102) Limit 0.30 (0.0118) Crankshaft pin journal diameter "Dp" grade. Grade No. A 43.970 - 43.971 (1.7311 - 1.7311) Grade No. B 43.969 - 43.970 (1.7311 - 1.7311) Grade No. C 43.968 - 43.969 (1.7310 - 1.7311) Grade No. D 43.967 - 43.968 (1.7310 - 1.7310) Grade No. E 43.966 - 43.967 (1.7309 - 1.7310) Grade No. F 43.965 - 43.966 (1.7309 - 1.7309) Grade No. G 43.964 - 43.965 (1.7309 - 1.7309) Grade No. H 43.963 - 43.964 (1.7308 - 1.7309) Grade No. J 43.962 - 43.963 (1.7308 - 1.7308) Grade No. K 43.961 - 43.962 (1.7307 - 1.7308) Grade No. L 43.960 - 43.961 (1.7307 - 1.7307) Grade No. M 43.959 - 43.960 (1.7307 - 1.7307) Grade No. N 43.958 - 43.959 (1.7306 - 1.7307) Grade No. P 43.957 - 43.958 (1.7306 - 1.7306) Grade No. R 43.956 - 43.957 (1.7305 - 1.7306) Grade No. S 43.955 - 43.956 (1.7305 - 1.7305) Grade No. T 43.954 - 43.955 (1.7305 - 1.7305) Grade No. U 43.953 - 43.954 (1.7304 - 1.7305) Crankshaft main journal diameter "Dm" grade. Grade No. A 51.978 - 51.979 (2.0464 - 2.0464) Grade No. B 51.977 - 51.978 (2.0463 - 2.0464) Grade No. C 51.976 - 51.977 (2.0463 - 2.0463) Grade No. D 51.975 - 51.976 (2.0463 - 2.0463) Grade No. E 51.974 - 51.975 (2.0462 - 2.0463) Grade No. F 51.973 - 51.974 (2.0462 - 2.0462) Grade No. G 51.972 - 51.973 (2.0461 - 2.0462) Grade No. H 51.971 - 51.972 (2.0461 - 2.0461) Grade No. J 51.970 - 51.971 (2.0461 - 2.0461) Grade No. K 51.969 - 51.970 (2.0460 - 2.0461) Grade No. L 51.968 - 51.969 (2.0460 - 2.0460) Grade No. M 51.967 - 51.968 (2.0459 - 2.0460) Grade No. N 51.966 - 51.967 (2.0459 - 2.0459) Grade No. P 51.965 - 51.966 (2.0459 - 2.0459) Grade No. R 51.964 - 51.965 (2.0458 - 2.0459) Grade No. S 51.963 - 51.964 (2.0458 - 2.0458) Grade No. T 51.962 - 51.963 (2.0457 - 2.0458) Grade No. U 51.961 - 51.962 (2.0457 - 2.0457) Grade No. V 51.960 - 51.961 (2.0457 - 2.0457) Grade No. W 51.959 - 51.960 (2.0456 - 2.0457) (1) Total indicator reading

UNDERSIZE TABLE

CONNECTING ROD BEARING OIL CLEARANCE

MAIN BEARING OIL CLEARANCE