Engine Mechanical: Other Nissan Maxima A34

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 (SRS) and SEAT BELTS .

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 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.

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1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source. Repair or replace the identified part as necessary.

Checking Drive Belts

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1. Inspect belt for cracks, fraying, wear or oil adhesion. If necessary, replace with a new one.
2. Inspect drive belt deflections by applying 98 N (10 kg, 22 lb) on the belt midway between pulleys as shown.
3. Measure the belt tension using Tool at the locations shown. Tool number: BT3373-F NOTE: Inspect drive belt deflection or tension when engine is cold. Adjust if belt deflections exceed the limit or if belt tension is not within specifications. CAUTION: When checking belt deflection or tension immediately after installation, first adjust it to the specification value. Then, after turning the crankshaft two turns or more, readjust to the specified value to avoid variation in deflection between pulleys. Tighten idler pulley lock nut by hand and measure deflection or tension without looseness.

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CHANGING AIR CLEANER FILTER

1. Disconnect the tube clamp at the electric throttle control actuator and mass air flow sensor.
2. Separate the mass air flow sensor from the air cleaner to electric throttle control actuator tube.
3. Unhook the air cleaner case side clips and remove the air cleaner case (upper).
4. Remove the air cleaner filter.
5. Install a new air cleaner filter.
6. Installation is in the reverse order of removal.

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Surface Distortion

Using straightedge and feeler gauge, inspect the surface distortion of both the intake manifold and the intake manifold collector.

Limit: 0.1 mm (0.004 in)

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Camshaft Visual Check

Check camshaft for scratches, seizure and wear. Replace if necessary.

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1. Put V-block on precise flat bed and support No. 2 and No. 4 journal of camshaft as shown.
2. Set dial gauges vertically to No. 3 journal as shown.
3. Turn camshaft in one direction slowly by hand, measure the camshaft runout on the dial gauges. Runout is the largest indicator reading after one full revolution. Camshaft Runout Standard: Less than 0.02 mm (0.0008 in) Limit: 0.05 mm (0.0020 in)
4. If actual runout exceeds the limit, replace the camshaft.

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1. Measure camshaft cam lobe height as shown. Refer to «CAMSHAFT AND CAMSHAFT BEARING»(ref-233643-S02711110092006052600000) .
2. If wear has reduced the lobe height below specifications, replace the camshaft.

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1. Measure outer diameter of camshaft journal as shown. Standard outer diameter, No. 1: 25.935 - 25.955 mm (1.0211 - 1.0218 in) Standard outer diameter, No. 2, 3, 4: 23.445 - 23.465 mm (0.9230 - 0.9238 in)

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1. Tighten camshaft bracket bolts to specified torque. Refer to «INSTALLATION»(ref-233643-S27771599142006052600000) .
2. Using inside micrometer, measure inner diameter "A" of camshaft bearing. Standard inner diameter No. 1: 26.000 - 26.021 mm (1.0236 - 1.0244 in) Standard inner diameter No. 2, 3, 4: 23.500 - 23.521 mm (0.9252 - 0.9260 in)

Calculation of Camshaft Journal Clearance

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

Standard No. 1: 0.045 - 0.086 mm (0.0018 - 0.0034 in)

Standard No. 2, 3, 4: 0.035 - 0.076 mm (0.0014 - 0.0030 in)

Limit: 0.15 mm (0.0059 in)

1. When out of the specified range, replace either or both camshaft and cylinder head. NOTE: Inner diameter of camshaft bracket is manufactured together with cylinder head. Replace the whole cylinder head assembly.

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1. Install the camshaft in the cylinder head. Refer to «INSTALLATION»(ref-233643-S27771599142006052600000) .
2. Install dial gauge in thrust direction on front end of camshaft. Measure end play when camshaft is moved forward/backward (in direction to axis) as shown. Standard: 0.115 - 0.188 mm (0.0045 - 0.0074 in) Limit: 0.24 mm (0.0094 in) If out of the specified range, replace with new camshaft and measure again. If out of the specified range again, replace with new cylinder head.

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1. Put V-block on precise flat bed and support No. 2 and No. 4 journal of camshaft as shown.
2. Install camshaft sprocket on camshaft.
3. Measure camshaft sprocket runout. Limit: 0.15 mm (0.0059 in)
4. If sprocket runout exceeds the limit, replace camshaft sprocket.

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

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1. Measure the outer diameter of the valve lifter. Refer to «VALVE LIFTER»(ref-233643-S29366332332006052600000) .
2. If out of the specified range, replace the valve lifter.

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1. Using inside micrometer, measure diameter of valve lifter bore of cylinder head. Refer to «VALVE LIFTER»(ref-233643-S29366332332006052600000) .
2. If out of the specified range, replace the cylinder head assembly.

Calculation of Valve Lifter Clearance

1. (Valve lifter clearance) = (hole diameter for valve lifter) - (outer diameter of valve lifter). Refer to «VALVE LIFTER»(ref-233643-S29366332332006052600000) .
2. If out of specified range, replace either or both valve lifter and cylinder head assembly.

CHECKING

Perform inspection as follows after removal, installation or replacement of camshaft or valve related parts, or if there is unusual engine conditions regarding valve clearance.

Note. Check valve clearance while engine is cold and not running.

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1. Remove the intake manifold collectors. Refer to «REMOVAL»(ref-233643-S31143878602006052600000) .
2. Remove the ignition coils. Refer to «REMOVAL»(ref-233643-S19080929522006052600000) .
3. Remove the spark plugs. Refer to «REMOVAL»(ref-233643-S32769181582006052600000) .
4. Remove the rocker covers. «REMOVAL»(ref-233643-S17687580702006052600000) .
5. Set No. 1 cylinder at TDC on its compression stroke. Align pointer with TDC mark on crankshaft pulley. Check that the valve lifters on No. 1 cylinder are loose and valve lifters on No. 4 are tight. If not, turn the crankshaft one full revolution (360°) and align as shown.
6. Check only the valves as shown. CRANK POSITION AND VALVE REFERENCE Crank Position Valve No. 1 Valve No. 2 Valve No. 3 Valve No. 6 No. 1 TDC Intake Exhaust Exhaust Intake Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Record any valve clearance measurements which are out of specification. They will be used later to determine the required replacement lifter size. Valve Clearance for Checking (cold) Intake: 0.26 - 0.34 mm (0.010 - 0.013 in) Exhaust: 0.29 - 0.37 mm (0.011 - 0.015 in)
7. Turn crankshaft 240°.
8. Set No. 3 cylinder at TDC on its compression stroke.
9. Check only those valves as shown. CRANK POSITION AND VALVE REFERENCE Crank Position Valve No. 2 Valve No. 3 Valve No. 4 Valve No. 5 No. 3 TDC Intake Intake Exhaust Exhaust
10. Turn the crankshaft 240° and align as above.
11. Set No. 5 cylinder at TDC on its compression stroke.
12. Check only those valves as shown. CRANK POSITION AND VALVE REFERENCE Crank Position Valve No. 1 Valve No. 4 Valve No. 5 Valve No. 6 No. 5 TDC Exhaust Intake Intake Exhaust
13. If all valve clearances are within specification, install the following components. If the valve clearances are out of specification, adjust the valve clearances. Rocker covers. Refer to «INSTALLATION»(ref-233643-S05090165792006052600000) . All spark plugs. Refer to «INSTALLATION»(ref-233643-S18084656102006052600000) . All ignition coils. Refer to «INSTALLATION»(ref-233643-S19080929522006052600000) . Intake manifold collectors. Refer to «INSTALLATION»(ref-233643-S03049164792006052600000) .

VALVE ADJUSTING

Note. Perform adjustment by selecting the correct head thickness of the valve lifter (adjusting shims are not used). The specified valve lifter thickness is the dimension at normal temperatures. Ignore dimensional differences caused by temperature. Use specifications for hot engine condition to confirm valve clearances.

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1. Remove the camshaft. Refer to «REMOVAL»(ref-233643-S02124541202006052600000) .
2. Remove the valve lifter that was measured as being outside the standard specifications.
3. Measure the center thickness of the removed lifter with a micrometer as shown.
4. Use the equation below to calculate the replacement valve lifter thickness. Valve lifter thickness calculation equation: t = t1 + (C1 - C2) t = thickness of the replacement lifter t1 = thickness of the removed lifter C1 = measured valve clearance C2 = standard valve clearance The thickness of the new valve lifter can be identified by the stamp mark on the reverse side (inside the lifter). Available thickness of the valve lifter (factory setting): 7.88 - 8.40 mm (0.3102 - 0.3307 in), in 0.02 mm (0.0008 in) increments, in 27 sizes (intake/exhaust). Refer to «VALVE LIFTER»(ref-233643-S29366332332006052600000) . NOTE: Two types of stamp marks are used for parallel setting and for manufacturer identification. Value lifter thickness Intake: 0.30 mm (0.012 in) Exhaust: 0.33 mm (0.013 in)
5. Install the selected replacement valve lifter.
6. Install the camshaft. Refer to «INSTALLATION»(ref-233643-S27771599142006052600000) .
7. Rotate the crankshaft a few turns by hand.
8. Confirm that the valve clearances are within specification.
9. After the engine has been run to full operating temperature, confirm that the valve clearances are within specification. VALVE CLEARANCE SPECIFICATION Valve Clearance Cold Hot (1) (reference data) Intake 0.26 - 0.34 mm (0.010 - 0.013 in) 0.304 - 0.416 mm (0.012 - 0.016 in) Exhaust 0.29 - 0.37 mm (0.011 - 0.015 in) 0.308 - 0.432 mm (0.012 - 0.017 in) (1) Approximately 80°C (176°F)

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1. Remove camshaft and valve lifter relating to valve oil seal to be removed. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S26029749282006052600000) .
2. Rotate crankshaft, and set piston whose oil seal is to removed to top dead center. This prevents valve from dropping inside cylinder. CAUTION: When rotating crankshaft, be careful to avoid scarring the front cover with the timing chain.
3. Remove valve collet, valve spring retainer and valve spring using Tool. Tool numbers: KV10116200 (J-26336-A) : KV10115900 (J-26336-20)
4. Remove valve oil seal using Tool. Tool number: KV10107902 (J-38959)

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1. Apply new engine oil to new valve oil seal joint surface and seal lip.
2. Press in valve oil seal to height "H" using Tool to specified height. Tool number: (J-39386) NOTE: Dimension "H": height measured before valve spring seat installation. Intake and exhaust: 14.3 - 14.9 mm (0.563 - 0.587 in)
3. Installation of the remaining components is in the reverse order of removal.

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1. Remove the following parts: Engine undercover. Drive belts. Refer to «DRIVE BELTS»(ref-233643-S31230987292006052600000) . Radiator fan. Refer to «REMOVAL»(ref-233648-S27412106882006052600000) .
2. Remove the crankshaft pulley as follows: Remove the starter motor. Refer to «M/T MODELS»(ref-233654-S38046219772006052600000) or «5-SPEED A/T MODELS»(ref-233654-S33075291472006052600000) . Lock the ring gear using Tool attached to the mounting bolt hole. Tool number: KV10117700 (J44716) CAUTION: Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear when setting the stopper. Loosen crankshaft pulley bolt using pulley holder and locate bolt seating surface at 10 mm (0.39 in) from its original position. Position a pulley puller at recess hole of crankshaft pulley to remove crankshaft pulley. CAUTION: Do not use a puller claw on crankshaft pulley periphery.
3. Remove front oil seal from front timing chain case. CAUTION: Be careful not to damage front timing chain case or crankshaft.

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1. Apply new engine oil to new oil seal and install it flush with front of mounting surface using a suitable tool. Install new oil seal in the direction shown. Suitable drift Outer diameter: 59 mm (2.32 in) Inner diameter: 49 mm (1.93 in) CAUTION: Press fit straight and avoid causing burrs or tilting the oil seal.
2. Install crankshaft pulley and tighten the bolt in two steps. Lubricate thread and seat surface of the bolt with new engine oil. Apply a paint mark for the second step of angle tightening. Step 1: 39 - 49 N.m (4.0 - 5.0 kg-m, 29 - 36 ft-lb) Step 2: 60° - 65° degrees clockwise
3. Remove Tool attached to the bolt hole. Tool number : KV10117700 (J44716)
4. Installation of the remaining components is in reverse order of removal.

Scheme 229

1. Remove oil pan (upper). Refer to «REMOVAL AND INSTALLATION»(ref-233643-S42259334642006052600000) .
2. Remove the transaxle. Refer to «REMOVAL AND INSTALLATION»(ref-233657-S31594742162006052600000) (M/T), «REMOVAL»(ref-233658-S00131922652006052600000) (5 A/T).
3. Remove flywheel (M/T) or drive plate (A/T).
4. Cut away liquid gasket using Tool and remove rear oil seal retainer. Refer to «PRECAUTIONS FOR LIQUID GASKET»(ref-233643-S19359353082006052600000) . Tool number: KV10111100 (J37228) CAUTION: Be careful not to damage mounting surface. If rear oil seal retainer is removed, replace it with a new one. NOTE: Rear oil seal and retainer form a single part and are replaced as an assembly.

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1. Remove oil liquid gasket on mating surface of cylinder block and oil pan using a scraper.
2. Apply liquid gasket to rear oil seal retainer using Tool as shown. Tool number: WS39930000 (-) Use Genuine Silicone RTV Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233642-S07555866002006052600000) . Assembly should be completed within 5 minutes after coating.
3. Install rear oil seal retainer to cylinder block. Rear oil seal retainer bolts: 8.2 - 9.3 N.m (0.83 - 0.95 kg-m, 72 - 82 in-lb)
4. Install the flywheel (M/T), if equipped. When installing flywheel to crankshaft, be sure to correctly align crankshaft side dowel pin and flywheel side dowel pin hole. Flywheel bolts: 83 - 93 N.m (8.5 - 9.5 kg-m, 61 - 69 ft-lb)
5. Install the drive plate (A/T), if equipped. Install the drive plate and reinforce plate in the direction shown. Align dowel pins of crankshaft rear and drive plate with pin holes of each part. Secure the crankshaft using Tool. Tool number: KV10117700 (J44716) Tighten the drive plate bolts in one or two steps. Drive plate bolts: 83 - 93 N.m (8.5 - 95 kg-m, 61 - 69 ft-lb)
6. Installation of the remaining components is in reverse order of removal.

Scheme 233

1. Run the engine until it reaches normal operating temperature.
2. Turn the ignition switch to OFF.
3. Release fuel pressure and leave the fuel pump electrically disconnected. Refer to «FUEL PRESSURE RELEASE»(ref-233647-S14261418062006052600000) .
4. Remove all six spark plugs. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S32769181582006052600000) .
5. Attach a compression tester to No. 1 cylinder.
6. Depress accelerator pedal fully to keep the electric throttle control actuator butterfly-valve wide open to maximize air intake flow.
7. Crank the engine and record the highest gauge indication.
8. Repeat the measurement on each cylinder (steps 5 - 7 ). NOTE: Always use a fully-charged battery to obtain specified engine speed. Unit: kPa (kg/cm 2 , psi)/300 RPM DIFFERENCE LIMIT BETWEEN CYLINDERS Standard Minimum Difference limit between cylinders 1,275 (13.0,185) 981 (10.0, 142) 98 (1.0, 14)
9. If compression in one or more cylinders is low: Pour a small amount of engine oil into cylinders through the spark plug holes. Retest compression (steps 5 - 8 ). If adding oil helps raise compression pressure, then the piston rings may be worn or damaged. If so, replace piston rings after checking piston. If the pressure stays low, a valve may be sticking or is seating improperly. Inspect and repair the valve and/or valve seat. Refer to «VALVE»(ref-233643-S27642505732006052600000) . If the valve and/or valve seat is damaged excessively, replace as necessary. If compression stays low in two or more cylinders that are next to each other: The cylinder head gasket may be leaking. Both cylinders may have valve component damage. Inspect and repair as necessary.
10. After inspection is complete, install removed components.
11. Start engine and confirm that engine runs smoothly.
12. Perform trouble diagnosis. If DTC appears, erase it. Refer to «TROUBLE DIAGNOSIS»(ref-233647-S23433934712006052600000) .

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1. Remove the intake manifold. Refer to «REMOVAL»(ref-233643-S13203608332006052600000) .
2. Remove the timing chains. Refer to «REMOVAL»(ref-233643-S13804956682006052600000) .
3. Remove the three way catalysts (manifolds), exhaust manifold heat shields and RH exhaust manifold. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S08026371932006052600000) .
4. Remove the intake and exhaust camshafts and the camshaft brackets. Mark the camshaft brackets so they are placed in the same position and direction for installation. Equally loosen the camshaft bracket bolts in several steps in the order shown.
5. Remove the water outlet. Refer to «REMOVAL»(ref-233648-S37765410472006052600000) .
6. Remove the RH and LH cylinder head bolts, using power tool. The bolts should be loosened gradually in three steps in the order shown.
7. Remove cylinder heads and gaskets. Discard the cylinder head gaskets and use new gaskets for installation.
8. If necessary, remove the exhaust manifolds. Loosen the exhaust manifold nuts in the order shown.

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1. Inspect the cylinder head bolts before installing the cylinder heads. CAUTION: Cylinder head bolts are tightened by degree rotation tightening method. Whenever the size difference between d1 and d2 exceeds the limit, replace the bolts with new ones. Limit (d1 - d2): 0.11 mm (0.0043 in)
2. If a reduction in outer diameter appears in a position other than d2, use it as the d2 measuring point.
3. Lubricate threads and seat surfaces of the bolts with new engine oil for installation.

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1. Before installing the rear timing chain case, remove the old Silicone RTV Sealant from mating surface using a scraper. Also remove old sealant from mating surface of cylinder block. Remove the old Silicone RTV Sealant from the bolt hole and thread.
2. Before installing the No. 1 camshaft bracket, remove the old Silicone RTV Sealant from the mating surface using a scraper. Do not scratch the mating surface.
3. Turn the crankshaft until No. 1 piston is set at TDC on the compression stroke. The crankshaft key should line up with the right bank cylinder center line as shown.
4. Install new gaskets on the cylinder heads. CAUTION: Do not rotate crankshaft and camshaft separately or valves will strike piston heads.
5. If necessary, install the exhaust manifolds. Tighten the exhaust manifold nuts in the order shown. Exhaust manifold nuts: 28.4 - 33.3 N.m (2.9 - 3.3 kg-m, 21 - 24 ft - lb)
6. Install the cylinder heads on the cylinder block. Tighten the cylinder head bolts in five steps in the order shown. Step a: 98 N.m (10 kg-m, 72 ft-lb) Step b: 0 N.m Loosen in the reverse order of tightening. Step c: 32.9 N.m (4.0 kg-m, 29 ft-lb) Step d: 90° degrees clockwise Step e: 90° degrees clockwise
7. Install the water outlet. Refer to «INSTALLATION»(ref-233648-S37765410472006052600000) .
8. Install camshaft chain tensioners on both sides of cylinder head. Camshaft chain tensioner bolts: 7 - 10 N.m (0.8 - 1.0 kg-m, 62 - 88 in-lb)
9. Install exhaust and intake camshafts and camshaft brackets. Intake camshaft has a drill mark on camshaft sprocket mounting flange. Follow your identification marks made during removal, or follow the identification marks that are present on the new camshaft components for proper placement. Position the camshafts: RH exhaust camshaft dowel pin at about 10 o'clock LH exhaust camshaft dowel pin at about 2 o'clock.
10. Before installing No. 1 camshaft bracket, apply sealant to mating surface. Use Genuine Silicone RTV Sealant, or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233642-S07555866002006052600000) . Before installation, wipe off any protruding sealant. Refer to «LIQUID GASKET APPLICATION PROCEDURE»(ref-233648-S30774711842006052600000) . Install camshaft brackets in their original positions and directions. Align the stamp marks as shown. If any part of the valve assembly or camshaft is replaced, check and adjust the valve clearance. Refer to «VALVE CLEARANCE»(ref-233643-S23371903282006052600000) .
11. Tighten the camshaft bracket bolts in five steps in the order shown. NOTE: Lubricate the threads and seat surfaces of the camshaft bracket bolts with new engine oil before installation. 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: (bolts 1 - 6) 10.4 N.m (1.1 kg-m, 92 in-lb)
12. Install the IVT control solenoid valves with new gaskets. IVT control solenoid valve bolts: 10 - 12 N.m (1.0 - 1.3 kg-m, 87 - 112 in-lb)
13. Install the new O-rings on the cylinder block.
14. Install the new O-rings on the cylinder head.
15. Install the RH exhaust manifold, three way catalysts (manifolds) and exhaust manifold heat shields. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S08026371932006052600000) .
16. Install timing chain. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S13804956682006052600000) .
17. Install the intake manifold. Refer to «INSTALLATION»(ref-233643-S03821170862006052600000) .

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1. Remove valve lifter. Mark position for installation.
2. Remove valve collet. Compress valve spring using Tool. Remove valve collet with magnet driver. Tool numbers: KV10116200 (J26336-B) : KV10115900 (J26336-20) : KV10109230 (-)
3. Remove valve spring retainer, valve spring, and valve spring seat.
4. Push valve stem to combustion chamber side, and remove valve, mark for assembly. Inspect valve guide clearance before removal. Refer to «VALVE GUIDE CLEARANCE»(ref-233643-S05169910052006052600000) . Confirm installation point.
5. Remove the valve oil seals using Tool. Tool number: KV10107902 (J38959)
6. If valve seat must be replaced, refer to «VALVE SEAT REPLACEMENT»(ref-233643-S08916106272006052600000) .
7. If valve guide must be replaced, refer to «VALVE GUIDE REPLACEMENT»(ref-233643-S26559658682006052600000) .
8. Remove spark plug with spark plug wrench.
9. Remove spark plug tube, as necessary. Using a pair of pliers, pull spark plug tube out of cylinder head. CAUTION: Be careful not to damage cylinder head. Once removed, a spark plug tube will be deformed and cannot be reused. Do not remove it unless absolutely necessary.

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1. Clean the surface of the cylinder head. Use a reliable straightedge and feeler gauge to check the flatness of cylinder head surface.
2. Check along six positions as shown. Head surface distortion Limit: 0.1 mm (0.004 in)
3. If beyond the specified limit, resurface or replace it.
4. The limit for cylinder head resurfacing is determined by the cylinder block resurfacing. Resurfacing Limit Amount of cylinder head resurfacing is "A". Amount of cylinder block resurfacing is "B". The maximum limit : A + B = 0.2 mm (0.008 in)
5. After resurfacing cylinder head, check that camshaft rotates freely by hand. If resistance is felt, cylinder head must be replaced. Nominal cylinder: 126.3 - 126.5 mm Head height "H" (4.972 - 4.980 in)

VALVE DIMENSIONS

Check dimensions of each valve, refer to VALVE DIMENSIONS .

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1. Measure valve deflection as shown in the figure. (Valve and valve guide mostly wear in this direction.) Valve deflection limit (dial gauge reading) Intake: 0.24 mm (0.0094 in) Exhaust: 0.28 mm (0.0110 in)
2. If it exceeds the limit, check valve to valve guide clearance. Measure valve stem diameter and valve guide inner diameter. Check that clearance is within specification. Valve to valve guide clearance standard Intake: 0.020 - 0.053 mm (0.0008 - 0.0021 in) Exhaust: 0.030 - 0.063 mm (0.0012 - 0.0025 in) Valve to valve guide clearance limit Intake: 0.08 mm (0.0031 in) Exhaust: 0.09 mm (0.004 in) If it exceeds the limit, replace valve or valve guide.

VALVE SPRING SQUARENESS

Set try square along the side of valve spring and rotate the spring. Measure the maximum clearance between the top face of spring and try square.

Out-of-square limit: Less than 2.0 mm (0.079 in)

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VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD

Check valve spring pressure at specified spring height.

Standard: 166 - 188 N (16.9 - 19.2 kg, 37.3 - 42.3 lb) at height 37.0 mm (1.457 in)

Limit: 378 - 426 N (38.6 - 43.5 kg, 85.0 - 95.8 lb) at height 27.8 mm (1.094 in)

If it is not within specifications, replace the spring.

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1. Install valve guide. Refer to «VALVE GUIDE REPLACEMENT»(ref-233643-S26559658682006052600000) .
2. Install valve seat. Refer to «VALVE SEAT REPLACEMENT»(ref-233643-S08916106272006052600000) .
3. Install new valve spring seats and new valve oil seals using Tool. Tool number: (J39386) Install with valve oil seal drift to match dimension in illustration. NOTE: Dimension "H": Height measured before valve spring seat installation. Height "H" Intake and exhaust: 14.3 - 14.9 mm (0.563 - 0.587 in)
4. Install the valves in their original position, as marked during disassembly.
5. Install valve spring (uneven pitch type). Install smaller pitch end (paint mark) to cylinder head side (valve spring seat side).
6. Install valve spring retainer.
7. Install valve collet. Tool numbers: KV10116200 (J26336-B) : KV10115900 (J26336-20) : KV10109230 (-) Compress valve spring using Tool and install valve collet. Tap stem edge lightly with plastic hammer after installation to check its installed condition.
8. Install valve lifter.
9. Install spark plug tube as follows: Remove old liquid gasket from cylinder head mounting hole. Apply liquid gasket to area within approximately 12 mm (0.47 in) from edge of spark plug tube press fit side. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233642-S07555866002006052600000) . Using a drift, press fit the spark plug tube so that it height "H" is as specified. Standard press fit height: 38.55 - 38.65 mm "H" (1.5177 - 1.5217 in) CAUTION: When press fitting, take care not to deform spark plug tube. After press fitting, wipe off liquid gasket protruding onto cylinder head upper face.
10. Install spark plug with spark plug wrench. Spark plug: 20 - 29 N.m (2.0 - 3.0 kg-m, 14 - 22 ft-lb)

Scheme 280

Scheme 281

Scheme 282

1. Drain coolant. Refer to «DRAINING ENGINE COOLANT»(ref-233644-S13037486022006052600000) .
2. Remove the front cowl grille. Refer to «REMOVAL AND INSTALLATION»(ref-233645-S31308520782006052600000) .
3. Remove the windshield wiper assembly. Refer to «REMOVAL AND INSTALLATION OF WIPER MOTOR AND LINKAGE»(ref-233646-S28715745702006052600000) .
4. Disconnect engine room harness from the engine side and position it aside. Disconnect engine harness ground connections. Access the connector through the glove box opening. Refer to «INSTRUMENT PANEL ASSEMBLY»(ref-233659-S33210817362006052600000) .
5. Remove the hood. Refer to «REMOVAL AND INSTALLATION OF HOOD ASSEMBLY»(ref-233660-S33059485352006052600000) .
6. Remove the battery and battery tray. Refer to «REMOVAL AND INSTALLATION»(ref-233654-S08818943502006052600000) .
7. Remove the engine cover using power tool. Remove side engine covers.
8. Disconnect the mass air flow sensor electrical connector.
9. Remove the fresh air intake tube and air cleaner to electric throttle control actuator tube attached to air cleaner lid. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S23956234542006052600000) .
10. Disconnect two connectors below mass air flow sensor attached to the shock tower.
11. Release fuel pressure. Refer to «FUEL PRESSURE RELEASE»(ref-233647-S14261418062006052600000) .
12. Disconnect fuel hose quick connection at vehicle piping side. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S24437408532006052600000) .
13. Remove and position aside the IPDM E/R and bracket and position aside. Refer to «REMOVAL AND INSTALLATION OF IPDM E/R»(ref-233661-S42132645482006052600000) .
14. Remove the radiator assembly, coolant reservoir, and system hoses. Refer to «REMOVAL»(ref-233648-S29776269262006052600000) .
15. Disconnect the power brake booster vacuum hose from the back of the intake manifold collector.
16. Disconnect heater hoses at the cowl.
17. Disconnect the two fusible link connectors at the battery positive terminal.
18. Disconnect the harness retainers and position the engine harness aside.
19. Remove the ground cable.
20. Remove the clutch operating cylinder with lines attached and position aside. Refer to «REMOVAL AND INSTALLATION»(ref-233662-S07131253332006052600000) .
21. Drain engine oil. Refer to «CHANGING ENGINE OIL»(ref-233644-S09752316582006052600000) .
22. Drain A/T oil. Refer to «CHANGING A/T FLUID»(ref-233644-S09092123082006052600000) .
23. Drain M/T oil. Refer to «CHANGING M/T OIL»(ref-233644-S38577389542006052600000) .
24. Disconnect the transaxle shift controls. Refer to «SHIFT CONTROL SYSTEM»(ref-233658-S26732994072006052600000) (5 A/T).
25. Remove RH splash shield.
26. Remove the front wheel and tires.
27. Remove the drive belts. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S17836745932006052600000) .
28. Remove the front exhaust tube and hanger using power tools. Refer to «REMOVAL AND INSTALLATION»(ref-233649-S22833986492006052600000) .
29. Remove engine oil cooler pipe bolts.
30. Remove the idler pulley and idler bracket.
31. Remove the engine undercover.
32. Remove the A/C compressor using power tools. Discharge and recover the R134a refrigerant. Refer to «HFC-134A (R-134A) SERVICE PROCEDURE»(ref-233653-S16640295362006052600000) .
33. Remove the front drive shafts. Refer to «REMOVAL AND INSTALLATION»(ref-233652-S33721208742006052600000) .
34. Remove the front suspension member. Refer to «REMOVAL AND INSTALLATION»(ref-233650-S01688699322006052600000) . CAUTION: Make sure to disconnect electrically controlled engine mounting insulator harness clips and power steering line mounts from the front suspension member prior to removal.
35. Disconnect the power steering pressure switch.
36. Remove the power steering pump, without disconnecting the piping, from the engine and position and secure it aside. Refer to «REMOVAL»(ref-233655-S36405366352006052600000) .
37. Install engine slingers into front of left bank cylinder head and rear of right bank cylinder head. Engine slinger bolts: 24.5 - 31.4 N.m (2.5 - 3.2 kg-m, 18 - 23 ft-lb)
38. Secure a hoist to the engine slingers.
39. Remove the LH transaxle mount through bolt.
40. Remove the RH engine mounting insulator nuts and bolt.
41. Carefully lower the engine and transaxle assembly with the hoist avoiding interference with the vehicle body. CAUTION: Before and during this procedure, always check if any harnesses are left connected. Avoid any damage to, or any oil/grease smearing or spills onto the engine mounting insulators.
42. Remove the crankshaft position sensor (POS).
43. Remove the starter motor. Refer to «M/T MODELS»(ref-233654-S38046219772006052600000) and «5-SPEED A/T MODELS»(ref-233654-S33075291472006052600000) .
44. Disconnect the transmission electrical connectors, harness retainers and position harness aside.
45. Separate the engine and transaxle and mount the engine on a suitable engine stand.

Manual Transaxle

Scheme 283

Scheme 284

1. When installing the transaxle to the engine, use the specified tightening torque in the order shown.

5 A/T

Scheme 285

Scheme 286

1. When installing the transaxle to the engine, use the specified tightening torque in the numerical sequence as shown.
2. After installation, check the transaxle oil level, and check for any leaks and any loose mechanisms.
3. Install crankshaft position sensor (POS). Crankshaft position sensor (POS) bolt: 8.4 - 10.8 N.m (0.86 - 0.98 kg-m, 74.6 - 95.5 in-lb)
4. Install idler pulley. Idler pulley bolts: 25 - 31 N.m (2.5 - 3.2 kg-m, 18 - 23 ft-lb)

Piston Selection Table

Unit: mm (in)

PISTON SELECTION CHART

Note. The piston is available together with piston pin as an assembly. The piston pin (piston pin bore) grade is provided only for the parts installed at the plant. For service parts, no piston pin grades can be selected. (Only 0 grade is available.) No grade mark is indicated on 2 grade piston.

When New Connecting Rod and Crankshaft are Used

Check pin diameter grade number (0, 1 or 2) stamped in front of crankshaft and select connecting rod bearing of same grade number.

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

Scheme 287

When Crankshaft and Connecting Rod are Reused

1. Measure dimensions of the big end inner diameter of connecting rod and outer diameter of crankshaft pin individually.
2. Confirm the big end inner diameter of connecting rod is within the standard value.
3. Apply the measured dimension to the «CONNECTING ROD BEARING SELECTION TABLE»(ref-233643-S09620629482006052600000) .
4. Determine the grade of crankshaft pin diameter grade by comparing the measurement with the values under the crankshaft pin outer diameter of the «CONNECTING ROD BEARING SELECTION TABLE»(ref-233643-S09620629482006052600000) .

Scheme 288

Undersize Bearings Usage Guide

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

Bearing Undersize Table

Unit: mm (in)

BEARING UNDERSIZE CHART

Scheme 289

Scheme 290

Scheme 291

1. «MAIN BEARING SELECTION TABLE»(ref-233643-S28940336932006052600000) rows correspond to bearing housing grade on rear left side of cylinder block.
2. Apply journal diameter grade stamped on crankshaft front side to column in «MAIN BEARING SELECTION TABLE»(ref-233643-S28940336932006052600000) .
3. Find sign (main bearing grade) at crossing of row and column in «MAIN BEARING SELECTION TABLE»(ref-233643-S28940336932006052600000) .

When Cylinder Block and Crankshaft are Reused

1. Measure inner diameter of cylinder block main bearing housing and outer diameter of crankshaft journal.
2. Find measured dimension in "Cylinder block bearing housing inner diameter" row of «MAIN BEARING SELECTION TABLE»(ref-233643-S28940336932006052600000) .
3. Find the measured dimension in "Crankshaft main journal diameter" column in «MAIN BEARING SELECTION TABLE»(ref-233643-S28940336932006052600000) .
4. Select main bearing grade at the point where selected row and column intersect.

Scheme 292

Scheme 293

Scheme 294

1. Use undersize bearing when oil clearance with standard size main bearing is not within specification. CAUTION: Keep fillet R when grinding crankshaft journal in order to use undersize bearing (all journals).
2. When using undersize bearing, measure the bearing inner diameter with bearing installed, and grind journal until oil clearance falls within specification.

Unit: mm (in)

BEARING UNDERSIZE CHART

Scheme 295

1. Using a dial indicator, measure the clearance between the thrust bearings and the connecting rods when the crankshaft is moved from front to rear. Standard: 0.10 - 0.25 mm (0.0039 - 0.0098 in) Limit: 0.30 mm (0.0118 in)
2. If beyond the limit, replace the thrust bearings and measure again. If still beyond the limit, replace the crankshaft.

Scheme 296

1. Measure the side clearance between the connecting rod and crankshaft with a feeler gauge. Standard: 0.20 - 0.35 mm (0.0079 - 0.0138 in) Limit: 0.40 mm (0.016 in)
2. If beyond the limit, replace the connecting rod and measure again. If still beyond the limit, replace the crankshaft.

Scheme 297

1. Measure the inner diameter of piston pin hole "dp". Standard diameter "dp" Grade No. 0: 21.993 - 21.999 mm (0.8659 - 0.8661 in) Grade No. 1: 21.999 - 22.005 mm (0.8661 - 0.8663 in)

Scheme 298

1. Measure outer diameter of piston pin "Dp". Standard diameter "Dp" Grade No. 0 : 21.989 - 21.995 mm (0.8657 - 0.8659 in) Grade No. 1 : 21.995 - 22.001 mm (0.8659 - 0.8662 in)

Piston and Piston Pin Interference Fit

Standard Interference Fit = "Dp" - "dp"

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

Scheme 299

1. If clearance is exceeds specification, replace either or both of piston/piston pin assembly and connecting rod assembly with reference to specification of each part.
2. When replacing piston/piston pin assembly, refer to «PISTON-TO-CYLINDER BORE CLEARANCE»(ref-233643-S20968336152006052600000) .

Scheme 300

1. Measure side clearance of piston ring and piston ring groove with feeler gauge. Standard Side Clearance 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) Maximum Limit Top ring: 0.11 mm (0.0043 in) 2nd ring: 0.1 mm (0.004 in) Oil ring
2. If out of specification, replace piston ring assembly. If clearance exceeds maximum limit with new rings, replace piston

Scheme 301

1. Check if inner diameter of cylinder bore is within specification. Refer to «PISTON-TO-CYLINDER BORE CLEARANCE»(ref-233643-S20968336152006052600000) .
2. Insert piston ring until it is in the middle of the cylinder bore and measure the end gap. 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: 0.54 mm (0.0213 in) 2nd ring: 0.80 mm (0.0315 in) Oil ring: 0.95 mm (0.0374 in)
3. If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylinder and use oversized piston and piston ring.

CONNECTING ROD BEND AND TORSION

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

Scheme 302

Scheme 303

1. If it exceeds the limit, replace connecting rod assembly.

Scheme 304

1. Install the connecting rod cap without the connecting rod bearing installed. After tightening the connecting rod nut to the specified torque, measure the connecting rod bearing housing big end inner diameter using an inside micrometer. Standard : 55.000 - 55.013 mm (2.1654 - 2.1659 in)

Scheme 305

1. Measure inner diameter of piston pin bushing. Standard Grade No. 0: 22.000 - 22.006 mm (0.8661 - 0.8664 in) Grade No. 1: 22.006 - 22.012 mm (0.8664 - 0.8666 in)

Scheme 306

1. Measure outer diameter of piston pin. Standard Grade No. 0: 21.989 - 21.995 mm (0.8657 - 0.8659 in) Grade No. 1: 21.995 - 22.001 mm (0.8659 -0.8662 in)

Connecting Rod Bushing Oil Clearance (Small End)

(Connecting rod small end oil clearance) = (Inner diameter of connecting rod small end) - (Outer diameter of piston pin)

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

Limit: 0.030 mm (0.0012 in)

Scheme 307

1. If the measured value exceeds the standard, replace the connecting rod assembly and/or piston and piston pin assembly.
2. If replacing the piston and piston pin assembly, refer to the Table for Selective Fitting for Piston to select the piston corresponding to the applicable bore grade of the cylinder block to be used. Refer to «PISTON-TO-CYLINDER BORE CLEARANCE»(ref-233643-S20968336152006052600000) .
3. If replacing the connecting rod assembly, refer to «CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)»(ref-233643-S03035712962006052600000) .

Factory installed parts grading

1. Service parts apply only to grade 0.

Unit: mm (in)

PISTON PIN BUSHING INNER DIAMETER AND PISTON PIN OUTER DIAMETER SPECIFICATION

Scheme 308

Scheme 309

1. Using a scraper, remove any old gasket material on the cylinder block surface, and remove any oil, scale, carbon, or other contamination. CAUTION: Be careful not to allow gasket flakes to enter the oil or coolant passages.
2. Measure the distortion on the block upper face at different points in six directions. Distortion limit: 0.10 mm (0.0039 in)
3. If out of specification, resurface the cylinder block. The allowable amount of resurfacing is dependent on the amount of any cylinder head resurfacing. The resurfacing limit is [amount of cylinder head resurfacing] + [amount of cylinder head resurfacing] = 0.2 mm (0.008 in). Cylinder block height: 214.95 - 215.05 mm (8.4626 - 8.4665 in)

Scheme 310

1. Install the main bearing caps with the main bearings removed, and tighten the mounting bolts to the specified torque.
2. Using a bore gauge, measure the inner diameter of the main bearing housing. Standard: 63.993 - 64.017 mm (2.5194 - 2.5203 in)
3. If out of the standard, replace the cylinder block and main bearing caps as an assembly. NOTE: These components cannot be replaced individually, since they were processed together.

Scheme 311

Scheme 312

Scheme 313

Scheme 314

Scheme 315

Scheme 316

1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper. The X axis is in the longitudinal direction of the engine. Cylinder bore inner diameter If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary. Out-of-round (Difference between, X - Y) : less than 0.015 mm (0.0006 in) Taper (Difference between, C - A) : less than 0.015 mm (0.0006 in)
2. Check for scratches and seizure. If seizure is found, hone it. If both cylinder block and piston are replaced with new ones, select piston of the same grade number punched on cylinder block rear position. These numbers are punched in either Arabic or Roman numerals.
3. Measure piston skirt diameter. Piston diameter "A" : Refer to «PISTON, PISTON RING AND PISTON PIN»(ref-233643-S33223815572006052600000) . Measuring point "a" (distance from the top): 41.0 mm (1.614 in)
4. Check that piston-to-bore clearance is within specification. Piston-to-bore clearance at "B": 0.010 - 0.030 mm (0.0004 - 0.0012 in) The piston-to-bore clearance is measured at the "B" level in the cylinder as shown.
5. Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. If oversize piston is used, use it for all cylinders with oversize piston ring. Refer to «PISTON, PISTON RING AND PISTON PIN»(ref-233643-S33223815572006052600000) .
6. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter "A". Rebored size calculation where, : D = A + B - C D: Bored diameter A: Piston diameter as measured B: Piston-to-bore clearance C: Honing allowance 0.02 mm (0.0008 in)
7. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted after boring.
8. Cut cylinder bores. When any cylinder needs boring, all other cylinders must also be bored. Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a time.
9. Hone cylinders to obtain specified piston-to-bore clearance.
10. Measure finished cylinder bore for out-of-round and taper. Measurement should be done after cylinder bore cools down.

OUTER DIAMETER OF CRANKSHAFT JOURNAL

Measure outer diameter of crankshaft journals. Refer to OUT-OF-ROUND AND TAPER OF CRANKSHAFT .

Scheme 317

OUTER DIAMETER OF CRANKSHAFT PIN

Measure outer diameter of crankshaft pin. Refer to OUT-OF-ROUND AND TAPER OF CRANKSHAFT .

Scheme 318

1. Check the crankshaft main and pin journals for scoring, wear, or cracks.
2. Measure the journals for taper and out-of-round. Standard Out-of-round (difference between, X - Y): 0.002 mm (0.0001 in) Taper (difference between, A - B): 0.002 mm (0.0001 in)

Scheme 319

1. Place a V-block on a precise flat table to support the journals on the both ends of the crankshaft.
2. Place a dial gauge straight up on the No. 3 journal.
3. While rotating the crankshaft, read the movement of the pointer on the dial gauge. Runout limit (total indicator reading): less than 0.10 mm (0.0039 in)

Scheme 320

Scheme 321

1. Install the connecting rod bearing to the connecting rod and cap.
2. Install the connecting rod cap to the connecting rod. Tighten to specification. Refer to «ASSEMBLY»(ref-233643-S20515040022006052600000) .
3. Measure the inner diameter "C" of each connecting rod (big end) as shown.
4. Measure the outer diameter "Dp" of each crankshaft pin journal.
5. Calculate the connecting rod bearing clearance. Connecting rod bearing clearance = C - Dp Standard : 0.034 - 0.059 mm (0.0013 - 0.0023 in) Limit : 0.070 mm (0.0028 in)
6. If the clearance cannot be adjusted within the standard of any bearing, grind the crankshaft journal and use undersized bearings. Refer to «HOW TO SELECT CONNECTING ROD BEARINGS»(ref-233643-S34059798132006052600000) .

Scheme 322

1. Remove oil and dust on the 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 the connecting rod bearings to the connecting rod cap, and tighten the connecting rod nuts to the specified torque. CAUTION: Never rotate the crankshaft.
4. Remove the connecting rod cap and bearings, and using the scale on the Plastigage bag, measure the Plastigage width. NOTE: The procedure when the measured value exceeds the repair limit is same as that described in «METHOD BY CALCULATION»(ref-233643-S04296186682006052600000) .

Scheme 323

1. Install the main bearings to the cylinder block and bearing cap. Refer to «ASSEMBLY»(ref-233643-S20515040022006052600000) .
2. Calculate the main bearing clearance. (Oil clearance) = (Inner diameter of main bearing) - (Outer diameter of crankshaft journal) Standard: 0.035 - 0.045 mm (0.0014 - 0.0018 in) Limit: 0.065 mm (0.0026 in)
3. If the calculated clearance exceeds the specified limit, replace the bearings. Refer to «HOW TO SELECT MAIN BEARINGS»(ref-233643-S37477052592006052600000) .

Scheme 324

1. Remove oil and dust on the 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 the main bearings and main bearing caps. Refer to «ASSEMBLY»(ref-233643-S20515040022006052600000) . CAUTION: Never rotate the crankshaft.
4. Remove the main bearing caps and bearings, and using the scale on the Plastigage bag, measure the Plastigage width. NOTE: The procedure when the measured value exceeds the repair limit is same as that described in «METHOD BY CALCULATION»(ref-233643-S39864005612006052600000) .

Scheme 325

1. When the bearing cap is removed after being tightened to the specified torque with main bearings installed, the tip end of the bearing must protrude. Refer to «ASSEMBLY»(ref-233643-S20515040022006052600000) for tightening procedure. Standard: There must be a crush height.
2. If the standard is not met, replace main bearings.

Scheme 326

1. When the connecting rod bearing cap is removed after being tightened to the specified torque with main bearings installed, the tip end of the bearing must protrude. Refer to «ASSEMBLY»(ref-233643-S20515040022006052600000) for tightening procedure. Standard: There must be a crush height.
2. If the standard is not met, replace connecting rod bearings.

Scheme 327

1. Measure outer diameters (d1, d2) at two positions as shown.
2. Measure d2 at a point with A. Limit : 0.11 mm (0.0051 in)
3. When the value of d1 - d2 exceeds the limit (a large difference in dimensions) replace the bolt with a new one.

Scheme 328

1. Measure outer diameter d as shown. Standard: 7.90 - 8.00 mm (0.3110 - 0.3150 in) Limit: 7.75 mm (0.3051 in)
2. When the value of d exceeds the limit (when it becomes thinner) replace the bolt with a new one.

DRIVE PLATE RUNOUT (A/T)

Runout (Total Indicator Reading)

Drive plate (A/T): less than 0.15 mm (0.0059 in)

Scheme 329

Scheme 330

FLYWHEEL RUNOUT (M/T)

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

Scheme 331

1. Measure the deflection of the flywheel contact surface to the clutch with a dial gauge.
2. Measure the deflection at 210 mm (8.27 in) diameter. Standard: 0.45 mm (0.0177 in) or less Limit: 1.3 mm (0.051 in) or less
3. When measured value exceeds the limit, replace the flywheel with a new one.

Movement Around in Rotation Direction

Check the movement amount with the following procedure

Scheme 332

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 exceeds the standard, replace the flywheel.

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, replace oil jet.

Scheme 333

1. Using a 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.

SPARK PLUG

SPARK PLUG SPECIFICATION

Scheme 334

Scheme 335

Valve Clearance

Unit: mm (in)

VALVE CLEARANCE SPECIFICATION

Scheme 336

Valve Lifter

Unit: mm (in)

VALVE LIFTER SPECIFICATION

Scheme 337

Scheme 338

Scheme 339

Scheme 340

Scheme 341

Scheme 342

Scheme 343

Scheme 344

Scheme 345

Scheme 346

Scheme 347

Scheme 348

Scheme 349

Scheme 350

Undersize

Unit: mm (in)

UNDERSIZE MAIN BEARING SPECIFICATION

CONNECTING ROD BEARING

CONNECTING ROD BEARING SPECIFICATION

Unit: mm (in)

UNDERSIZE CONNECTING ROD BEARING SPECIFICATION

MISCELLANEOUS COMPONENTS

Unit: mm (in)

MISCELLANEOUS COMPONENTS SPECIFICATION

Scheme 351