Engine Mechanical: Diagnosis Nissan Maxima A35

Precaution for Inspection, Repair and Replacement

1. Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and replace if necessary.

Use the Chart Below to Help You Find the Cause of the Symptom

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. SYMPTOM CHART Location of noise Type of noise Operating condition of engine Source of noise Check item Reference Before warm-up After warm-up When starting When idling When racing While driving Top of engine Rocker cover Cylinder head Ticking or clicking C A - A B - Tappet noise Valve clearance «CAMSHAFT VALVE CLEARANCE»(ref-388044-S36719893842011022800000) Rattle C A - A B C Camshaft bearing noise Camshaft journal clearance Camshaft runout «CAMSHAFT»(ref-388044-S02237047702011022800000) Crankshaft pulley Cylinder block (Side of engine) Oil pan Slap or knock - A - B B - Piston pin noise Piston and piston pin clearance Connecting rod bushing clearance «PISTON AND PISTON PIN CLEARANCE»(ref-388044-S24186376792011022800000) Slap or rap A - - B B A Piston slap noise Piston-to-bore clearance Piston ring side clearance Piston ring end gap Connecting rod bend and torsion «PISTON RING SIDE CLEARANCE»(ref-388044-S05080672972011022800000) Knock A B C B B B Connecting rod bearing noise Connecting rod bushing clearance (Small end) Connecting rod bearing clearance (Big end) «CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)»(ref-388044-S29907242252011022800000) Knock A B - A B C Main bearing noise Main bearing oil clearance Crankshaft runout «MAIN BEARING»(ref-388044-S05354666772011022800000) Front of engine Timing chain cover Tapping or ticking A A - B B B Timing chain and chain tensioner noise Timing chain cracks and wear Timing chain tensioner operation «TIMING CHAIN»(ref-388044-S33959513652011022800000) Front of engine Squeaking or fizzing A B - B - C Drive belts (Sticking or slipping) Drive belts deflection «DRIVE BELTS»(ref-388044-S35163573002011022800000) Creaking A B A B A B Drive belts (Slipping) Idler pulley bearing operation Squall Creak A B - B A B Water pump noise Water pump operation «WATER PUMP»(ref-388046-S27175727742011022800000) A: Closely related B: Related C: Sometimes related -: Not related

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1. Remove the ignition coil. Refer to " «REMOVAL AND INSTALLATION LH»(ref-388044-S05582705652011022800000) " and " «REMOVAL AND INSTALLATION RH»(ref-388044-S27585452232011022800000) ".
2. Remove the spark plug with a suitable spark plug wrench.

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1. Do not use a wire brush for cleaning the spark plugs. Replace as necessary.
2. If plug is covered with carbon, a spark plug cleaner may be used. Cleaner air pressure : less than 588 kPa (6 kg/cm 2 , 85 psi) Cleaning time : less than 20 seconds
3. Checking and adjusting plug gap is not required between change intervals. If the gap is out of specification, replace the spark plug.

INSPECTION AFTER REMOVAL

Surface Distortion

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1. Using straightedge and feeler gauge, inspect the surface distortion of the intake manifold. Inspect the surface distortion of the intake manifold collector. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S24115967902011022800000) ". Standard : 0.1 mm (0.004 in)

INSPECTION AFTER INSTALLATION

Make sure there is no fuel leakage at connections as follows

1. Apply fuel pressure to fuel lines by turning ignition switch ON (with engine stopped). Then check for fuel leaks at connections.
2. Start the engine and rev it up and check for fuel leaks at connections. CAUTION: Do not touch engine immediately after stopping as engine is extremely hot. NOTE: Use mirrors for checking on connections out of the direct line of sight.

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Surface Distortion

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1. Use a reliable straightedge and feeler gauge to check the flatness of the exhaust manifold mating surfaces. Limit : 0.3 mm (0.012 in)

Clean oil strainer if any object is attached.

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1. Apply a continuous bead of sealant to the lower oil pan. Use Genuine Silicone RTV Sealant, or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-388039-S31807235822011022800000) ". Be sure the sealant is 4.5 - 5.5 mm (0.177 - 0.217 in) wide. Installation must be done within 5 minutes after applying sealant.
2. Install the lower oil pan. Tighten the lower oil pan bolts in order as shown in illustration. Wait at least 30 minutes before refilling the engine with oil.

1. Start the engine and check for leaks. Refer to " «INSPECTION»(ref-388050-S42239623232011022800000) ".
2. Inspect the engine oil level. Refer to " «INSPECTION»(ref-388050-S42239623232011022800000) ".

Clean debris from oil strainer.

1. Start the engine and check for leaks. Refer to " «INSPECTION»(ref-388050-S42239623232011022800000) ".
2. Inspect the engine oil level. Refer to " «INSPECTION»(ref-388050-S42239623232011022800000) ".

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1. Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-388039-S31807235822011022800000) ".
2. Use procedure below to check for fuel leakage.
3. Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
4. Start engine. With engine speed increased, check again for fuel leakage at connection points.
5. Run engine to check for unusual noise and vibration.
6. Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including engine oil and engine coolant.
7. Bleed air from passages in lines and hoses, such as in cooling system.
8. After cooling down engine, again check oils/fluids including engine oil and engine coolant. Refill to specified level, if necessary.
9. Summary of the inspection items: INSPECTION ITEMS CHART Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Transmission/transaxle fluid A/T and CVT Models Leakage Level/Leakage Leakage M/T Models Level/Leakage Leakage Level/Leakage Other oils and fluids (1) Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gas - Leakage - (1) Power steering fluid, brake fluid, etc.

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INSPECTION

Check for cracks and any excessive wear of the timing chain. Replace the timing chain as necessary.

INSPECTION OF CAMSHAFT SPROCKET (INT) OIL GROOVE

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1. Check engine oil level. Refer to " «INSPECTION»(ref-388050-S42239623232011022800000) ".
2. Perform the following procedure so as to prevent the engine from being unintentionally started while checking. Release fuel pressure. Refer to " «INSPECTION»(ref-388048-S32388389072011022800000) ". Disconnect ignition coil and injector harness connectors if practical.
3. Remove IVT control solenoid valve.
4. Crank engine, and then make sure that engine oil comes out from IVT control cover oil hole. End cranking after checking. WARNING: Be careful not to touch rotating parts (drive belts, idler pulley, and crankshaft pulley, etc.). CAUTION: Engine oil may squirt from IVT control solenoid valve installation hole during cranking. Use a shop cloth to prevent engine oil from splashing on worker, engine components and vehicle. Do not allow engine oil to get on rubber components such as drive belts or engine mount insulators. Immediately wipe off any splashed engine oil.
5. Clean oil groove between oil strainer and IVT control solenoid valve if engine oil does not come out from IVT control cover oil hole.
6. Remove components between IVT control solenoid valve and camshaft sprocket (INT), and then check each oil groove for clogging. Clean oil groove if necessary.
7. After inspection, installation of the remaining components is in the reverse order of removal.

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1. Turn crankshaft until the cylinder requiring new oil seals is at TDC. This will prevent valve from dropping into cylinder. CAUTION: When rotating crankshaft, be careful to avoid scarring the front cover with the timing chain.
2. Remove camshaft relating to valve oil seal to be removed. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S31826977942011022800000) ".
3. Remove valve lifters. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S31826977942011022800000) ".
4. Remove valve collet, valve spring retainer and valve spring using Tool. CAUTION: When working, take care not to damage valve lifter holes. Tool numbers : KV10116200 (J-26336-A) : KV10115900 (J-26336-20) : KV10109220 (-) Compress valve spring using Tool attachment, adapter. Remove valve collet with magnet hand.
5. 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 under cover. Refer to " «EXPLODED VIEW»(ref-388049-S07537635232011022800000) ". Drive belts. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S22307760252011022800000) ". Radiator fan. Refer to " «REMOVAL AND INSTALLATION»(ref-388046-S01449383982011022800000) ".
2. Remove plate cover.
3. Remove the crankshaft pulley as follows: Lock the drive plate using Tool attached to the starter bolt hole. Tool number : - (J-50288) CAUTION: Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear, when setting the Tool. Loosen crankshaft pulley 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.
4. Remove front oil seal from front cover. Using a suitable tool. CAUTION: Be careful not to damage front cover or crankshaft.

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1. Apply new engine oil to new oil seal and install. Install new oil seal in the direction as shown in illustration. CAUTION: Press fit straight and avoid causing burrs or tilting the oil seal. Press-fit oil seal until it becomes flush with the timing chain case end face, using suitable tool. Make sure the garter spring in the oil seal is in position and seal lip is not inverted.
2. Install crankshaft pulley and tighten the bolt in two steps. Lubricate thread and seat surface of the bolt with new engine oil. For the second step angle tighten using Tool. Step 1 : 44.1 N.m (4.5 kg-m, 33 ft-lb) Step 2 : 84° - 90° degrees clockwise Tool number : KV10112100 (BT-8653-A)
3. Remove the Tool attached to the starter bolt hole. Tool number : KV10117700 (J-44716) CAUTION: Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear, when removing the Tool.
4. Installation of the remaining components is in reverse order of removal.

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1. Remove the upper oil pan. Refer to " «REMOVAL AND INSTALLATION (UPPER OIL PAN)»(ref-388044-S20358380952011022800000) ".
2. Remove drive plate. Refer to " «DOWEL PIN ALIGNMENT»(ref-388044-S14126332862011022800000) ".
3. Remove rear oil seal retainer using Tool. Tool Number : KV10111100 (J-37228) CAUTION: Be careful not to damage mating surface. If rear oil 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 old liquid gasket material from mating surface of cylinder block and oil pan using a suitable scraper.
2. Install the rear oil seal retainer using Tool (A). Tool number : - (J-47128) Loosen the wing nut (B) on the end of the Tool (A). Insert the arbor (D) into the crankshaft pilot hole until the outer lip (C) of the Tool (A) covers the edge of the crankshaft sealing surface. Tighten the wing nut (B) to secure the Tool (A) to the crankshaft. Apply sealant to rear oil seal retainer as shown in illustration. Use Genuine Silicone RTV Sealant, or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-388039-S31807235822011022800000) ". Assembly should be completed within 5 minutes after coating. Lubricate the sealing surface of the new rear main seal with new engine oil. Slide the new rear main seal (1) over the Tool (A) and onto the crankshaft. Loosen the wing nut and push the threaded rod into the handle to remove the Tool (A). Tighten the rear oil seal retainer bolts to specification.
3. Installation of the remaining components is in the reverse order of removal. CAUTION: When replacing an engine or transmission you must make sure the dowels are installed correctly during re-assembly. Improper alignment caused by missing dowels may cause vibration, oil leaks or breakage of drivetrain components.

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1. Remove the engine from the vehicle. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S31213686922011022800000) ".
2. Remove the rear timing chain case. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S28727425442011022800000) ".
3. Remove the intake manifold. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S37412770292011022800000) ".
4. Remove the intake and exhaust camshafts. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S31826977942011022800000) ".
5. Remove the coolant outlet housing. Refer to " «REMOVAL AND INSTALLATION»(ref-388046-S03132073582011022800000) ".
6. Remove the RH and LH cylinder head bolts, with power tool. The bolts should be loosened gradually in three stages. Loosen the bolts in the numerical order as shown in illustration.
7. Remove cylinder heads and gaskets. Discard the cylinder head gaskets and use new gaskets for installation.

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1. 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 in illustration.
2. Install new gaskets on the cylinder heads. CAUTION: Do not rotate crankshaft and camshaft separately or valves will strike piston heads.
3. 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) Lubricate threads and seat surfaces of the bolts with new engine oil.
4. Install the cylinder heads on the cylinder block. Tighten the cylinder head bolts in the five steps in the numerical order as shown in illustration using Tool. Tool Number : KV10112100 (BT-8653-A) Tightening procedure: Cylinder head bolts Step a : 98.1 N.m (10 kg-m, 72 ft-lb) Step b : Loosen in the reverse order of tightening Step c : 39.2 N.m (4.0 kg-m, 29 ft-lb) Step d : 103° degrees rotation clockwise Step e : 103° degrees rotation clockwise
5. Installation of the remaining components is in the reverse order of removal.

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1. Remove spark plug.
2. Remove valve lifter. Identify installation positions, and store them without mixing them up.
3. Remove valve collet. Compress valve spring and remove valve collet with magnet hand using Tool. CAUTION: When working, take care not to damage valve lifter holes. Tool numbers : KV10109220 (-) : KV10116200 (J-26336-A) : KV10115900 (J-26336-20)
4. Remove valve spring retainer, valve spring and valve spring seat.
5. Push valve stem to combustion chamber side, and remove valve. Identify installation positions, and store them without mixing them up.
6. Remove valve oil seals using Tool. Tool number : KV10107902 (J-38959)
7. If valve seat must be replaced, refer to " «INSPECTION AFTER DISASSEMBLY»(ref-388044-S42302101922011022800000) ".
8. If valve guide must be replaced, refer to " «INSPECTION AFTER DISASSEMBLY»(ref-388044-S42302101922011022800000) ".
9. Remove spark plug tube, as necessary. Using pair of pliers, pull spark plug tube out of cylinder head. CAUTION: Take care not to damage cylinder head. Once removed, spark plug tube will be deformed and cannot be reused. Do not remove it unless absolutely necessary.

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1. When valve guide is removed, install it. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-388044-S42302101922011022800000) ".
2. When valve seat is removed, install it. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-388044-S42302101922011022800000) ".
3. Install valve oil seals using Tool. Tool number : - (J-39386) Height "H" (Without valve spring seat installed) Intake and exhaust : 14.3 - 14.9 mm (0.563 - 0.587 in)
4. Install valve spring seat.
5. Install valves. Install it in the original position. NOTE: Larger diameter valves are for intake side.
6. Install valve spring (uneven pitch type) with narrow pitch end (paint mark) to cylinder head side (valve spring seat side).
7. Install valve spring retainer.
8. Install valve collet. Compress valve spring with valve spring compressor, attachment and adapter using Tool. Install valve collet with magnet hand. CAUTION: When working, take care not to damage valve lifter holes. Tap valve stem edge lightly with plastic hammer after installation to check its installed condition. Tool numbers : KV10109220 (-) : KV10116200 (J-26336-A) : KV10115900 (J-26336-20)
9. Install valve lifter. Install it in the original position.
10. Install spark plug tube. Press-fit spark plug tube as follows: Remove old liquid gasket adhering to cylinder head mounting hole. Apply sealant to area within approximately 12 mm (0.47 in) from edge of spark plug tube press-fit side. Use Genuine High Strength Locking Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-388039-S31807235822011022800000) ". Press-fit spark plug tube so that its height "H" is as specified in using suitable drift. Press-fit height "H" : 37.7 - 38.7 mm (1.484 - 1.529 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.
11. Install spark plug.

1. Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-388039-S31807235822011022800000) ".
2. Use procedure below to check for fuel leakage.
3. Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
4. Start engine. With engine speed increased, check again for fuel leakage at connection points.
5. Run engine to check for unusual noise and vibration.
6. Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including engine oil and engine coolant.
7. Bleed air from passages in lines and hoses, such as in cooling system.
8. After cooling down engine, again check oils/fluids including engine oil and engine coolant. Refill to specified level, if necessary.
9. Summary of the inspection items: INSPECTION ITEMS CHART Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Transmission/transaxle fluid A/T and CVT Models Leakage Level/Leakage Leakage M/T Models Level/Leakage Leakage Level/Leakage Other oils and fluids (1) Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gas - Leakage - (1) Power steering fluid, brake fluid, etc.

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1. Remove the engine assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S31213686922011022800000) ".
2. Remove the drive plate. Refer to " «DOWEL PIN ALIGNMENT»(ref-388044-S14126332862011022800000) ".
3. Install the engine on engine stand.
4. Remove the knock sensor. CAUTION: Carefully handle sensor to avoid shocking it.
5. Drain the engine of all coolant and oil.
6. Remove the oil pan. Refer to " «REMOVAL AND INSTALLATION (UPPER OIL PAN)»(ref-388044-S20358380952011022800000) ".
7. Remove the crankshaft pulley. Use a suitable tool to prevent the crankshaft from turning.
8. Remove the timing chain. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S33483831572011022800000) ".
9. Remove the cylinder head. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S30230598572011022800000) ".
10. Remove pilot converter. Tool number : ST16610001 (J-23907)
11. Cut away liquid gasket and remove rear oil seal retainer using Tool. Refer to " «PRECAUTION FOR LIQUID GASKET»(ref-388044-S20989129222011022800000) ". Tool number : KV10111100 (J-37228) 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.
12. Remove the piston and connecting rod assemblies. Position the crankshaft pin corresponding to the connecting rod to be removed onto the bottom dead center. Remove the connecting rod cap. Using a hammer handle or similar tool, push the piston and connecting rod assembly out to the cylinder head side. Before removing the piston and connecting rod assembly, check the connecting rod side clearance. Refer to " «CONNECTING ROD BEARING»(ref-388044-S38311342642011022800000) ".
13. Remove the connecting rod bearings. CAUTION: When removing the connecting rod side bearings, note the installation position. Keep them in the correct order.
14. Remove the piston rings from the piston. Use a piston ring expander. CAUTION: When removing the piston rings, be careful not to damage the piston. Do not expand the rings excessively. Be careful to mark the rings if they are to be reused so they are installed in their original position. Before removing the piston rings, check the piston ring side clearance. Refer to " «INSPECTION»(ref-388044-S12914783432011022800000) ".
15. Remove the piston from the connecting rod as follows. Using a snap ring pliers, remove the snap ring. CAUTION: Do not reuse snap rings, always replace with new ones. Heat the pistons to 60° - 70°C (140° - 158°F). Push out the piston pin with a suitable tool, with an outer diameter approximately 20 mm (0.8 in).
16. Remove the rear oil seal retainer from the cylinder block. Insert a screwdriver or similar tool between the rear end of the crankshaft counter weight and rear oil seal retainer, and separate the liquid gasket to remove. CAUTION: Be careful not to damage the mating surface. NOTE: When replacing the rear oil seal during on-vehicle service, it is necessary to remove the oil pan. Refer to " «REMOVAL AND INSTALLATION (UPPER OIL PAN)»(ref-388044-S20358380952011022800000) ".
17. Remove the baffle plate from the main bearing beam.
18. Loosen the bolts in the numerical order as shown in illustration and remove the main bearing beam, bearing caps and crankshaft. Before loosening the main bearing cap bolts, measure the crankshaft side clearance. Refer to " «INSPECTION»(ref-388044-S12914783432011022800000) ".
19. Remove the oil jets and dowel pins.
20. Remove the main bearings and thrust bearings from the cylinder block and main bearing caps. When removing them, note the direction and position. Keep them in the correct order for installation.

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1. Blow out the coolant and oil passages and cylinder bore to remove any foreign materials. CAUTION: Use goggles to protect your eyes.
2. Apply liquid gasket and install each plug into the cylinder block. Use Genuine Silicone RTV Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-388039-S31807235822011022800000) ".
3. Install the oil jets. Insert the oil jet dowel pin into the cylinder block dowel pin hole, and tighten the bolts.
4. Install the main bearings and the thrust bearings. Remove dust, dirt, and oil on the bearing mating surfaces of the cylinder block and the main bearing cap. Install the thrust bearings to both sides of the No. 3 journal housing on the cylinder block and the main bearing cap. Install the thrust bearings with the oil groove facing the crankshaft arm (outside). Install bearing with a projection on one end on cylinder block and bearing with a projection at center on cap. Align each projection with mating notch.
5. Set the upper main bearings in their proper positions on the cylinder block. Confirm the correct main bearings are used. Refer to " «INSPECTION»(ref-388044-S12914783432011022800000) ".
6. Instructions for the re-use of the main bearing cap bolts. A plastic zone tightening method is used for tightening the main bearing cap bolts. Measure d1 and d2 as shown in illustration. For d2, select the minimum diameter in the measuring area. If the difference between d1 and d2 exceeds the limit, replace the bolts for assembly. Limit (d1 - d2) : 0.11 mm (0.0043 in)
7. After installing the crankshaft, lower main bearings, main bearing caps, main bearing beam, and bearing cap bolts. Tighten the bearing cap bolts in the numerical order as shown in illustration. Make sure that the front marks on the main bearing beam faces the front of the engine. Prior to tightening all the bearing cap bolts, place the bearing beam in its proper position by shifting the crankshaft in the axial position. After tightening the bearing cap bolts, make sure the crankshaft turns smoothly. Lubricate the threads and seat surfaces of the bolts with new engine oil. Tighten the bolts in two stages: CAUTION: Measure the tighten angle in 2 stages using Tool. Do not measure visually. Stage 1 : 32.3 - 38.3 N.m (3.3 - 3.9 kg-m, 24 - 28 ft-lb) Stage 2 : 90° - 95° degrees clockwise Tool number : KV10112100 (BT-8653-A)
8. Measure crankshaft end play. If beyond the limit, replace the bearing with a new one. Standard : 0.10 - 0.25 mm (0.0039 - 0.0098 in) Limit : 0.30 mm (0.0118 in)
9. Install the rear oil seal retainer using Tool (A). Tool number : - (J-47128) Loosen the wing nut (B) on the end of the Tool (A). Insert the arbor (D) into the crankshaft pilot hole until the outer lip (C) of the Tool (A) covers the edge of the crankshaft sealing surface. Tighten the wing nut (B) to secure the Tool (A) to the crankshaft. Apply sealant to rear oil seal retainer as shown in illustration. Use Genuine Silicone RTV Sealant, or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-388039-S31807235822011022800000) ". Assembly should be completed within 5 minutes after coating. Lubricate the sealing surface of the new rear main seal with new engine oil. Slide the new rear main seal (1) over the Tool (A) and onto the crankshaft. Loosen the wing nut and push the threaded rod into the handle to remove the Tool (A). Tighten the rear oil seal retainer bolts to specification.
10. Install the piston to the connecting rod. Using suitable snap ring pliers, install the snap ring fully into the pin-groove of the piston rear side. Piston front mark (A) Oil hole (B) Connecting rod front mark (C) Cylinder No. (D) Install the piston to the connecting rod. Heat the piston until the piston pin can be pushed in by hand without excess force [approx. 60° - 70°C (140° to 158°F)]. From the front to the rear, insert the piston pin into the piston and through the connecting rod. Assemble so that the piston front mark (B) on the crown and the oil hole (C), connecting rod front mark (D) and Cylinder No. (E) on the are positioned as shown in illustration. <=: Front Piston grade number (A) Pin grade number (F) Install the snap ring into the front of the piston pin-groove. After installing, check that the connecting rod pivots smoothly on the pin. CAUTION: Do not reuse snap rings, always replace with new ones.
11. Using a piston ring expander, install the piston rings. CAUTION: Be careful not to damage the piston. When the piston rings are not replaced, remount the rings in their original positions. When replacing the piston rings, those without stamped surface (A) can be mounted either side up. Install the second ring with the stamped surface (B) facing upward. If the ring is not stamped it can face in either direction. Top ring (A) : - Second ring (B) : 2A Position each ring with the gap as shown in illustration, referring to the piston front mark.
12. Install the connecting rod bearings to the connecting rod and the connecting rod cap. When installing the connecting rod bearings, apply engine oil to the bearing surface (crankshaft side). Do not apply oil to the back surface (connecting rod and cap side), but thoroughly clean it. When installing, align the connecting rod bearing protrusion with the notch of the connecting rod to install. Check that the oil holes on the connecting rod and on the corresponding bearing are aligned.
13. Install the piston and connecting rod assembly into the corresponding cylinder. Position the crankshaft pin corresponding to the connecting rod to be installed onto the bottom dead center. Apply engine oil sufficiently to the cylinder bore, piston, and crankshaft pin. Match the cylinder position with the cylinder No. (B) on the connecting rod to install. Install the piston with the piston front mark (A) on the crown facing the front of the engine () using a suitable tool. Oil hole (C) CAUTION: Be careful not to damage the crankshaft pin and cylinder wall, resulting from interference of the connecting rod big end.
14. Install the connecting rod cap. Match the stamped cylinder number marks on the connecting rod with those on the cylinder cap for installation. Install the piston connecting rod assembly and cap so that the front mark on the cap and piston are facing the front of the engine. Lubricate the threads and seat surfaces with new engine oil.
15. Check the connecting rod cap bolts before reusing, then install in their original position in the connecting rod. The bolts should screw in smoothly by hand. Measure the outer diameter of the connecting rod cap bolt as shown in illustration. Outer diameter "d" of the connecting rod bolt Standard : 7.90 - 8.00 mm (0.3110 - 0.3150 in) Limit : 7.75 mm (0.3051 in)
16. Tighten the connecting rod nuts in two stages using Tool: Stage 1 : 19 - 21 N.m (1.9 - 2.1 kg-m, 14 - 15 ft-lb) Stage 2 : 90° - 95° degrees clockwise CAUTION: Always use either an angle wrench or protractor. Avoid tightening based on visual check alone. Tool number : KV10112100 (BT-8653-A) Apply engine oil to the threads and seats of the connecting rod bolts and nuts. After tightening the nuts, make sure that the crankshaft rotates smoothly. Check the connecting rod side clearance. If beyond the limit, replace the connecting rod and/or crankshaft. Connecting rod side clearance: Standard : 0.20 - 0.35 mm (0.0079 - 0.0138 in) Limit : 0.40 mm (0.0157 in)
17. Install the baffle plate to the main bearing beam.
18. Install the knock sensor. Make sure that there is no foreign material on the cylinder block mating surface and the back surface of the knock sensor. Install the knock sensor with the connector facing the rear of the engine. Do not tighten the bolts while holding the connector. Make sure that the knock sensor does not interfere with other parts. CAUTION: If any impact by dropping occurs to the knock sensor, replace it with new one.
19. Install the pilot converter with it's chamfer facing crankshaft as shown in illustration. <=: Crankshaft side
20. Install the drive plate. Refer to " «DOWEL PIN ALIGNMENT»(ref-388044-S14126332862011022800000) ".
21. Install the cylinder head. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S30230598572011022800000) ".
22. Install the timing chain. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S33483831572011022800000) ".
23. Install the oil pan. Refer to " «REMOVAL AND INSTALLATION (UPPER OIL PAN)»(ref-388044-S20358380952011022800000) ".
24. Remove the engine from the stand and install the engine assembly into the vehicle. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S31213686922011022800000) ".
25. Assembly of the remaining parts is in the reverse order of disassembly.
26. Fill the engine with the specified oil and coolant. Refer to " «FOR NORTH AMERICA : FLUIDS AND LUBRICANTS»(ref-388045-S04059756952011022800000) " (United State or Canada) " «FOR MEXICO : FLUIDS AND LUBRICANTS»(ref-388045-S31450118582011022800000) " (Mexico). CAUTION: Wait at least 30 minutes for the sealant to set-up before filling the engine with fluids and running it.

Scheme 82

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 83

Scheme 84

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)
2. <=: Front
3. Piston Grade No. (A)
4. Piston front mark (B)
5. Oil hole (C)
6. Connecting rod front mark (D)
7. Cylinder No. (E)
8. Pin Grade No. (F)

Piston and Piston Pin Interference Fit

Standard Interference Fit = "Dp" - "dp"

Standard : 0.002 - 0.010 mm (0.0001 - 0.0004 in)

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.

Scheme 85

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 : 0.045 - 0.125 mm (0.0018 - 0.0049 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 86

1. Insert piston ring until it is in the middle of the cylinder bore and measure the end gap. Standard Top ring : 0.23 - 0.28 mm (0.0091 - 0.0110 in) 2nd ring : 0.33 - 0.43 mm (0.0130 - 0.0169 in) Oil ring : 0.20 - 0.45 mm (0.0079 - 0.0177 in) Limit: Top ring : 0.50 mm (0.0197 in) 2nd ring : 0.62 mm (0.0244 in) Oil ring : 0.80 mm (0.0315 in)
2. If out of specification, replace piston ring.