Engine Mechanical: Other Nissan Maxima A35

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 Safety Restraint and Seat Belt section of this Service article.

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

Precaution 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 Tool

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

SPECIAL SERVICE TOOL CHART Tool number (Kent-Moore No.) Tool name Description ST0501S000 (-) Engine stand assembly ST05011000 (-) Engine stand ST05012000 (-) Base Disassembling and assembling KV101J0010 (J-47242) Engine support table Removal engine and transmission assembly KV10116200 (J-26336-A) Valve spring compressor KV10115900 (J-26336-20) Attachment KV10109220 (-) Adapter Disassembling valve mechanism Part (1) is a component of KV10116200 (J-26336-A), but part (2) is not. KV10107902 (J-38959) Valve oil seal puller Removing valve oil seal - (J-39386) Valve oil seal drift Installing valve oil seal ST16610001 (J-23907) Pilot bushing puller Removing crankshaft pilot bushing KV10111100 (J-37228) Seal cutter Removing steel oil pan and rear timing chain case WS39930000 (-) Tube presser Pressing the tube of liquid gasket 16441 6N210 (J-45488) Quick connector release Removing fuel tube quick connectors in engine room (Available in SEC. 164 of PARTS CATALOG: Part No. 16441 6N210) KV10112100 (BT-8653-A) Angle wrench Tightening bolts for bearing cap, cylinder head, etc. KV991J0050 (J-44626) Air fuel sensor Socket Loosening or tightening air fuel ratio A/F sensor 22 mm (0.87 in) KV10114400 (J-38365) Heated oxygen sensor wrench Loosening or tightening rear heated oxygen sensor 22 mm (0.87 in) - (J-50288) Ring gear stopper Removing and installing crankshaft pulley - (J-47128) Seal installer Installing rear main seal

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Commercial Service Tool

COMMERCIAL SERVICE TOOL CHART (Kent-Moore No.) Tool name Description Power tool Loosening bolts and nuts Spark plug wrench Removing and installing spark plug Valve seat cutter set Finishing valve seat dimensions Piston ring expander Removing and installing piston ring Valve guide drift Removing and installing valve guide Intake & Exhaust: 9.5 mm (0.374 in) dia. 5.5 mm (0.217 in) dia. Valve guide reamer Reaming valve guide 1 or hole for oversize valve guide 2 Intake & Exhaust: d1: 6.0 mm (0.236 in) dia. d2: 10.2 mm (0.402 in) dia. (J-43897-18) (J-43897-12) Oxygen sensor thread cleaner Reconditioning the exhaust system threads before installing a new oxygen sensor (Use with anti-seize lubricant shown in illustration below.) J-43897-18 (18 mm dia.) for zirconia oxygen sensor J-43897-12 (12 mm dia.) for titania oxygen sensor Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907) Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads

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CHANGING THE AIR CLEANER FILTER

1. Unhook the air cleaner case side clips.
2. Remove the air cleaner filter.
3. Install a new air cleaner filter.
4. Lock the air cleaner case side clips.

CHECKING

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

Check valve clearance while engine is cold and not running.

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1. Remove the air duct with air cleaner case, collectors, hoses, wires, harnesses, and connectors. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S37478427172011022800000) ".
2. Remove the intake manifold collectors. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S24115967902011022800000) ".
3. Remove the ignition coils and spark plugs. Refer to " «EXPLODED VIEW»(ref-388044-S24503572912011022800000) ".
4. Remove the rocker covers. Refer to " «EXPLODED VIEW»(ref-388044-S18248949352011022800000) ".
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 in illustration.
6. Check only the valves as shown in illustration. INTAKE AND EXHAUST VALVES POSITION CHART 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 in illustration. INTAKE AND EXHAUST VALVES POSITION CHART 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 in illustration. INTAKE AND EXHAUST VALVES POSITION CHART 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. Intake manifold collectors Rocker covers All spark plugs All ignition coils

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.

Scheme 249

Scheme 250

1. Remove the camshaft.
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 in illustration.
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 " «CAMSHAFT»(ref-388044-S36597921902011022800000) ".
5. Install the selected replacement valve lifter.
6. Install the camshaft.
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. STANDARD VALVE CLEARANCE CHART Standard 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)

Scheme 251

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 " «INSPECTION»(ref-388048-S32388389072011022800000) ".
4. Remove all six spark plugs. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S21400944562011022800000) ".
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 ). Always use a fully-charged battery to obtain specified engine speed. CYLINDERS HEAD CHART Unit: kPa (kg/cm 2 , psi)/RPM Standard Minimum Difference limit between cylinders 1,275 (13.0, 185)/300 981 (10.0, 142)/300 98 (1.0, 14)/300
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 " «INSPECTION AFTER DISASSEMBLY»(ref-388044-S42302101922011022800000) ". 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.

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.

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1. Remove the engine room cover. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S09328238872011022800000) ".
2. Remove front air duct. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S37478427172011022800000) ".
3. Remove blow by hose from rocker cover.
4. Remove camshaft position sensors. CAUTION: Handle carefully to avoid dropping and shocks. Do not disassemble. Do not allow metal powder to adhere to magnetic part at sensor tip (A). Do not place sensors in a location where they are exposed to magnetism.
5. Disconnect the ignition coil connectors.
6. Remove the ignition coils. Refer to " «REMOVAL AND INSTALLATION LH»(ref-388044-S05582705652011022800000) ". CAUTION: Never shock ignition coils.
7. Remove LH rocker cover bolts from cylinder head as shown in illustration.

Camshaft Visual Check

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

Scheme 255

1. Put V-block on precise flat bed and support No. 2 and No. 4 journal of camshaft as shown in illustration.
2. Set dial gauges vertically to No. 3 journal as shown in illustration.
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.

Scheme 256

1. Measure camshaft cam lobe height as shown in illustration. Refer to " «CAMSHAFT»(ref-388044-S36597921902011022800000) ".
2. If wear has reduced the lobe height below specifications, replace the camshaft.

Camshaft Journal Clearance

Outer Diameter of Camshaft Journal

Scheme 257

1. Measure outer diameter of camshaft journal as shown in illustration. 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)

Inner Diameter of Camshaft Bracket

Scheme 258

1. Tighten camshaft bracket bolt with specified torque.
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.

Scheme 259

1. Install the camshaft in the cylinder head.
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 in illustration. 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.

Scheme 260

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

Scheme 261

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

Valve Lifter Clearance

Outer Diameter of Valve Lifter

Scheme 262

1. Measure the outer diameter of the valve lifter. Refer to " «CAMSHAFT»(ref-388044-S36597921902011022800000) ".
2. If out of the specified range, replace the valve lifter.

Valve Lifter Bore Diameter

Scheme 263

1. Using inside micrometer, measure diameter of valve lifter bore of cylinder head. Refer to " «CAMSHAFT»(ref-388044-S36597921902011022800000) ".
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 " «CAMSHAFT»(ref-388044-S36597921902011022800000) ".
2. If out of specified range, replace either or both valve lifter and cylinder head assembly.

CYLINDER HEAD DISTORTION

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

Check along six positions as shown in illustration.

Head surface distortion

Limit : 0.1 mm (0.004 in)

Standard : Less than 0.03 mm (0.0012 in)

If beyond the specified limit, resurface or replace it.

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

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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)

After resurfacing cylinder head, check that camshaft rotates freely by hand. If resistance is felt, cylinder head must be replaced.

Nominal cylinder head height : 126.3 - 126.5 mm (4.972 - 4.980 in)

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1. Measure valve deflection as shown in illustration. (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. Refer to " «CYLINDER HEAD»(ref-388044-S38525453412011022800000) ". Check that clearance is within specification. (Valve guide clearance) = (Valve guide inner diameter) - (Valve stem diameter) Valve to valve guide clearance standard Intake : 0.020 - 0.053 mm (0.0008 - 0.0021 in) Exhaust : 0.040 - 0.073 mm (0.0016 - 0.0029 in) Valve to valve guide clearance limit Intake : 0.08 mm (0.0031 in) Exhaust : 0.1 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 : 373 - 421 N (38.0 - 42.9 kg, 84 - 95 lb) at height 27.2 mm (1.071 in)

If it is not within specifications, replace the spring.

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1. Release fuel pressure. Refer to " «INSPECTION»(ref-388048-S32388389072011022800000) ".
2. Drain coolant. Refer to " «CHANGING ENGINE COOLANT»(ref-388046-S32332017542011022800000) ".
3. Drain power steering fluid. Refer to " «DRAINING»(ref-388052-S32771720742011022800000) ".
4. Drain transaxle fluid. Refer to " «CHANGING»(ref-388054-S30601461722011022800000) ".
5. Remove the engine under cover. Refer to " «EXPLODED VIEW»(ref-388049-S07537635232011022800000) ".
6. Remove the engine room cover. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S09328238872011022800000) ".
7. Remove front air duct, air duct hose and resonator assembly and air cleaner case assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S37478427172011022800000) ".
8. Remove battery. Refer to " «REMOVAL AND INSTALLATION (BATTERY)»(ref-388040-S08852523192011022800000) ".
9. Remove ECM.
10. Remove transmission control module. Refer to " «REMOVAL AND INSTALLATION»(ref-388054-S20238056362011022800000) ".
11. Remove battery ground cable with current sensor.
12. Remove battery tray and bracket. Refer to " «REMOVAL AND INSTALLATION (BATTERY TRAY)»(ref-388040-S08029399692011022800000) ".
13. Remove cowl top extension. Refer to " «REMOVAL AND INSTALLATION»(ref-388049-S31424973292011022800000) ".
14. Remove lower cowl top extension brace. Refer to " «EXPLODED VIEW»(ref-388049-S02200598192011022800000) ".
15. Remove IPDM E/R. Refer to " «REMOVAL AND INSTALLATION»(ref-388055-S00476911162011022800000) ".
16. Remove upper radiator hose. NOTE: Cap or plug opening(s) to prevent fluid from spilling.
17. Disconnect CVT cooler hoses. NOTE: Cap or plug opening(s) to prevent fluid from spilling.
18. Disconnect fuel hose quick connection at vehicle piping side. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S28770987952011022800000) ". NOTE: Cap or plug opening(s) to prevent fluid from spilling.
19. Disconnect EVAP vacuum hose.
20. Disconnect heater hoses (engine side). NOTE: Cap or plug opening(s) to prevent fluid from spilling.
21. Remove coolant reservoir tank.
22. Disconnect transaxle shift control cables.
23. Remove lower radiator hose. NOTE: Cap or plug opening(s) to prevent fluid from spilling.
24. Disconnect brake booster vacuum hose.
25. Remove power steering reservoir.
26. Remove torque rod.
27. Remove RH engine mount.
28. Remove the cooling fan assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-388046-S01449383982011022800000) ".
29. Discharge and recover the R134a refrigerant. Refer to " «COLLECTION AND CHARGE»(ref-388042-S13764361162011022800000) ".
30. Remove the front drive shafts. Refer to " «REMOVAL AND INSTALLATION (LEFT SIDE)»(ref-388056-S12243327802011022800000) " and " «REMOVAL AND INSTALLATION (RIGHT SIDE)»(ref-388056-S24874846812011022800000) ".
31. Remove the rear lower insulator and torque rod.
32. Remove the front exhaust tube. Refer to " «REMOVAL AND INSTALLATION»(ref-388057-S11279870772011022800000) ".
33. Disconnect the A/C high side and low side hoses from the A/C compressor. Refer to " «HIGH-PRESSURE FLEXIBLE HOSE : REMOVAL AND INSTALLATION FOR HIGH-PRESSURE FLEXIBLE HOSE»(ref-388042-S11178982192011022800000) ", " «LOW-PRESSURE FLEXIBLE HOSE : REMOVAL AND INSTALLATION FOR LOW-PRESSURE FLEXIBLE HOSE»(ref-388042-S11246801052011022800000) ".
34. Install engine slingers into front of LH cylinder head and rear of RH cylinder head. (A): RH cylinder head (B): LH cylinder head
35. Remove rear cover plate.
36. Remove the torque converter bolts.
37. Disconnect engine mount vacuum hoses.
38. Position a suitable support table under suspension member and engine assembly.
39. For additional safety, secure the engine in position with suitable tool.
40. Remove suspension member bolts. Refer to " «REMOVAL AND INSTALLATION»(ref-388058-S35089205882011022800000) ".
41. Carefully lower the engine, transaxle assembly and suspension member using Tool, avoiding interference with the vehicle body. Tool number : KV101J0010 (J-47242) 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 mount insulators.
42. Remove the starter motor. Refer to " «REMOVAL AND INSTALLATION»(ref-388059-S20201299772011022800000) ".
43. Remove the crankshaft position sensor (POS). Refer to " «EXPLODED VIEW»(ref-388044-S04031738122011022800000) ".
44. Disconnect CVT speed sensor and CVT unit connector. Refer to " «EXPLODED VIEW»(ref-388054-S15390710832011022800000) ".
45. Separate the engine from the transaxle assembly.
46. Lift the engine from the suspension member.

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

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

Scheme 274

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 275

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 276

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 277

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, use the Table for Selective Fitting for Piston to select the piston corresponding to the applicable bore grade of the cylinder block to be used. Follow the "PISTON-TO-CYLINDER BORE CLEARANCE" procedure.

Factory installed parts grading

Scheme 278

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

Service parts apply only to grade 0.

SERVICE PARTS GRADE SPECIFICATION

Scheme 279

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 280

1. Install the main bearing caps with the main bearings removed, and tighten the bolts to the specified torque.
2. Using a bore gauge, measure the inner diameter of the main bearing housing "A". 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 as a single unit, because they were processed together.

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1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper at (A), (B) and (C). The X axis is in the longitudinal direction of the engine. Cylinder bore inner diameter CYLINDER BORE INNER DIAMETER SPECIFICATION Grade No. Standard inner diameter Wear limit No. 1 95.500 - 95.510 mm (3.7598 - 3.7602 in) 0.20 mm (0.0079 in) No. 2 95.510 - 95.520 mm (3.7602 - 3.7606 in) No. 3 95.520 - 95.530 mm (3.7606 - 3.7610 in) If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary. Out-of-round (Difference between X and Y) : limit 0.015 mm (0.0006 in) Taper (Difference between A and C) : limit 0.010 mm (0.0004 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 " «CYLINDER BLOCK»(ref-388044-S28968475992011022800000) ". Measuring point "a" (Distance from the top) : 38.0 mm (1.496 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 in illustration.
5. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter "A". Rebored size calculation : D = A + B - C where, D : Bored diameter A : Piston diameter as measured B : Piston-to-bore clearance C : Honing allowance 0.02 mm (0.0008 in)
6. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted after boring.
7. 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.
8. Hone cylinders to obtain specified piston-to-bore clearance.
9. Measure finished cylinder bore for out-of-round and taper. Measurement should be done after cylinder bore cools down.

Scheme 286

Scheme 287

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 (X - Y) : 0.002 mm (0.0001 in) Taper (A - B) : 0.002 mm (0.0001 in)
3. Measure crankshaft runout. Place a V-block on a precise flat table to support the journals on the both ends of the crankshaft. Place a dial gauge straight up on the No. 3 journal. While rotating the crankshaft, read the movement of the pointer on the dial gauge. Runout limit (total indicator reading) : 0.10 mm (0.0039 in)

BEARING CLEARANCE

1. Use either of the following two methods, however method "A" gives more reliable results and so is the preferred method.

Method A (Using Bore Gauge and Micrometer)

Main Bearing

Scheme 288

Scheme 289

Scheme 290

Scheme 291

Scheme 292

Scheme 293

Scheme 294

1. Set the main bearings in their proper positions on the cylinder block and the main bearing cap.
2. Install the main bearing caps and bearing beam to the cylinder block. Tighten all bolts in the numerical order as specified. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-388044-S39693684222011022800000) ".
3. Measure the inner diameters "A" of each main bearing as shown in illustration.
4. Measure the outer diameters "Dm" of each crankshaft main journal as shown in illustration.
5. Calculate the main bearing clearance. Main bearing clearance = "A" - "Dm" Standard : 0.035 - 0.045 mm (0.0014 - 0.0018 in) Limit : 0.065 mm (0.0026 in) If it exceeds the limit, replace the bearing. If clearance cannot be adjusted using any standard bearing grade, grind crankshaft journal and use an undersized bearing. When grinding the crankshaft journal, confirm that the "L" dimension in the fillet role is more than the specified limit. "L" : 0.10 mm (0.0039 in)
6. If the crankshaft or the cylinder block is replaced with a new one, select thickness of the main bearings as follows: The grade number of each cylinder block main journal is punched on the respective cylinder block. These numbers are punched in either Arabic or Roman numerals. If measured diameter is out of the grade punched, decide suitable grade from available main bearings. The grade number of each crankshaft main journal is punched on the crankshaft end. These numbers are punched in either Arabic or Roman numerals. If measured diameter is out of grade punched, decide the suitable grade from available main bearings. Select the main bearing suitable thickness according to the following table

Scheme 295

Scheme 296

Scheme 297

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 " «DISASSEMBLY AND ASSEMBLY»(ref-388044-S39693684222011022800000) ".
3. Measure the inner diameter "C" of each connecting rod (big end) as shown in illustration.
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 : 0.020 - 0.045 mm (0.0008 - 0.0018 in) Limit : 0.070 mm (0.0028 in)
6. If the calculated clearance exceeds the specified limit, replace the bearings.
7. If the clearance cannot be adjusted within the standard of any bearing, grind the crankshaft journal and use undersized bearings.
8. If the crankshaft is replaced with a new one, select the connecting rod bearings according to the following table: Connecting Rod Bearing Grade Number (Identification Color) CONNECTING ROD BEARING GRADE NUMBER IDENTIFICATION COLOR CHART Crankshaft pin journal grade number Connecting rod bearing grade number 0 0 (black) 1 1 (brown) 2 2 (green) These numbers are punched in either Arabic or Roman numerals.

Method B (Using Plastigage)

Scheme 298

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 A (Using Bore Gauge and Micrometer)".

DRIVE PLATE RUNOUT

Runout (Total Indicator Reading)

Drive plate torque converter surface : less than 0.35 mm (.0138 in)

Ring gear : less than 0.5 mm (.0197 in)

Scheme 299

Scheme 300

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 301

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.

Scheme 302

Scheme 303

1. Use suitable tool to lock the drive plate and match mark (A) the drive plate before removing the bolts. CAUTION: Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear.
2. Remove drive plate. Loosen the drive plate in a diagonal order. CAUTION: Never place drive plate with signal plate facing down. When handling the signal plate, take care not to damage or scratch it. Handle the signal plate in a manner that prevents it from becoming magnetized.

DRIVE BELT

DRIVE BELT SPECIFICATIONS SERVICE DATA

SPARK PLUG

SPARK PLUG SPECIFICATIONS SERVICE DATA

INTAKE MANIFOLD

INTAKE MANIFOLD SPECIFICATIONS SERVICE DATA

EXHAUST MANIFOLD

EXHAUST MANIFOLD SPECIFICATIONS SERVICE DATA

CAMSHAFT

CAMSHAFT SPECIFICATIONS SERVICE DATA Unit: mm (in) Items Standard Limit Camshaft journal oil clearance No. 1 0.045 - 0.086 (0.0018 - 0.0034) 0.15 (0.0059) No. 2, 3, 4 0.035 - 0.076 (0.0014 - 0.0030) Camshaft bracket inner diameter No. 1 26.000 - 26.021 (1.0236 - 1.0244) - No. 2, 3, 4 23.500 - 23.521 (0.9252 - 0.9260) - Camshaft journal diameter No. 1 25.935 - 25.955 (1.0211 - 1.0218) - No. 2, 3, 4 23.445 - 23.465 (0.9230 - 0.9238) - Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) 0.24 (0.0094) Camshaft cam height "A" Intake 45.475 - 45.665 (1.7904 - 1.7978) 0.2 (0.008) (1) Exhaust 45.485 - 45.675 (1.7907 - 1.7982) 0.2 (0.008) (1) Camshaft runout [TIR (2) ] Less than 0.02 (0.0008) 0.05 (0.0020) Camshaft sprocket runout [TIR (2) ] Less than 0.15 (0.0059) - Difference in level between front end faces of No. 1 camshaft bracket and cylinder head -0.14 (-0.0055) - (1) Cam wear limit (2) Total indicator reading

Scheme 304

VALVE LIFTER

VALVE LIFTER SPECIFICATIONS SERVICE DATA

VALVE CLEARANCE

VALVE CLEARANCE SPECIFICATIONS SERVICE DATA

AVAILABLE VALVE LIFTER

AVAILABLE VALVE LIFTER SPECIFICATIONS SERVICE DATA Unit: mm (in) Identification (stamped) mark (1) Thickness 788U 7.88 (0.3102) 790U 7.90 (0.3110) 792U 7.92 (0.3118) 794U 7.94 (0.3126) 796U 7.96 (0.3134) 798U 7.98 (0.3142) 800U 8.00 (0.3150) 802U 8.02 (0.3157) 804U 8.04 (0.3165) 806U 8.06 (0.3173) 808U 8.08 (0.3181) 810U 8.10 (0.3189) 812U 8.12 (0.3197) 814U 8.14 (0.3205) 816U 8.16 (0.3213) 818U 8.18 (0.3220) 820U 8.20 (0.3228) 822U 8.22 (0.3236) 824U 8.24 (0.3244) 826U 8.26 (0.3252) 828U 8.28 (0.3260) 830U 8.30 (0.3268) 832U 8.32 (0.3276) 834U 8.34 (0.3283) 836U 8.36 (0.3291) 838U 8.38 (0.3299) 840U 8.40 (0.3307) (1) Always check with the Parts Department for the latest parts information

Scheme 305

CYLINDER HEAD

CYLINDER HEAD SPECIFICATIONS SERVICE DATA Unit: mm (in) Items Standard Limit Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004) Normal cylinder head height "H" 126.3 - 126.5 (4.97 - 4.98) - Spark plug tube installation height 37.7 - 38.7 (1.484 - 1.529)

Scheme 306

VALVE DIMENSIONS

VALVE DIMENSIONS SPECIFICATIONS SERVICE DATA Unit: mm (in) Valve head diameter "D" Intake 36.6 - 36.9 (1.441 - 1.453) Exhaust 30.2 - 30.5 (1.189 - 1.201) Valve length "L" Intake 97.13 (3.8240) Exhaust 94.67 (3.7272) Valve stem diameter "d" Intake 5.965 - 5.980 (0.2348 - 0.2354) Exhaust 5.955 - 5.970 (0.2344 - 0.2350) Valve seat angle "α" Intake 45°15' - 45°45' Exhaust Valve margin "T" Intake 1.15 - 1.45 (0.0453 - 0.0571) Exhaust 1.45 - 1.75 (0.0571 - 0.0689) Valve margin "T" limit More than 0.5 (0.020) Valve stem end surface grinding limit Less than 0.2 (0.008)

Scheme 307

VALVE OIL SEAL

VALVE OIL SEAL SPECIFICATIONS SERVICE DATA

VALVE GUIDE

VALVE GUIDE SPECIFICATIONS SERVICE DATA Unit: mm (in) Items Standard Oversize (Service) [0.2 (0.008)] Valve guide Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029) Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369) Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014) Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023) Items Standard Limit Valve guide clearance Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031) Exhaust 0.040 - 0.073 (0.0016 - 0.0029) 0.01 (0.004) Valve deflection Intake - 0.24 (0.0094) Exhaust - 0.28 (0.0110) Projection length "L" 12.6 - 12.8 (0.496 - 0.504)

Scheme 308

VALVE SEAT

VALVE SEAT SPECIFICATIONS SERVICE DATA Unit: mm (in) Items Standard Oversize (Service) [0.5 (0.02)] Cylinder head seat recess diameter "D" Intake (A) 38.000 - 38.016 (1.4961 - 1.4967) 38.500 - 38.516 (1.5157 - 1.5164) Exhaust (B) 31.600 - 31.616 (1.2441 - 1.2447) 32.100 - 32.116 (1.2638 - 1.2644) Valve seat outer diameter Intake 38.097 - 38.113 (1.4999 - 1.5005) 38.597 - 38.613 (1.5196 - 1.5202) Exhaust 31.680 - 31.696 (1.2472 - 1.2479) 32.180 - 32.196 (1.2669 - 1.2676) Valve seat interference fit Intake 0.081 - 0.113 (0.0032 - 0.0044) Exhaust 0.064 - 0.096 (0.0025 - 0.0038) Height "h" Intake (A) 5.9 - 6.0 (0.232 - 0.236) 5.0 - 5.1 (0.197 - 0.201) Exhaust (B) 5.9 - 6.0 (0.232 - 0.236) 4.9 - 5.0 (0.193 - 0.197) Contacting width "W" (1) Intake (A) 1.18 - 1.22 (0.0465 - 0.0480) Exhaust (B) 1.38 - 1.42 (0.0543 - 0.0559) Cylinder head seat recess depth (H) 6.0 (0.236) Depth "L" Intake (A) 41.16 - 41.76 (1.6205 - 1.6441) Exhaust (B) 41.09 - 41.69 (1.6177 - 1.6413) (1) Machining data

Scheme 309

Scheme 310

VALVE SPRING

VALVE SPRING SPECIFICATIONS SERVICE DATA

VALVE SPRING SPECIFICATIONS SERVICE DATA

CYLINDER BLOCK

CYLINDER BLOCK SPECIFICATIONS SERVICE DATA Unit: mm (in) Surface distortion Standard Less than 0.03 (0.0012) Limit 0.10 (0.0039) Main bearing housing inner diameter Standard 63.993 - 64.017 (2.5194 - 2.5203) Cylinder bore Inner diameter Standard Grade No. 1 95.500 - 95.510 (3.7598 - 3.7602) Grade No. 2 95.510 - 95.520 (3.7602 - 3.7606) Grade No. 3 95.520 - 95.530 (3.7606 - 3.7610) Wear limit 0.20 (0.0079) Out-of-round Limit 0.015 (0.0006) Taper (Difference between A and C) 0.015 (0.0006) Main bearing housing inner diameter grade (Without bearing) Grade No. A 63.993 - 63.994 (2.5194 - 2.5194) Grade No. B 63.994 - 63.995 (2.5194 - 2.5195) Grade No. C 63.995 - 63.996 (2.5195 - 2.5195) Grade No. D 63.996 - 63.997 (2.5195 - 2.5196) Grade No. E 63.997 - 63.998 (2.5196 - 2.5196) Grade No. F 63.998 - 63.999 (2.5196 - 2.5196) Grade No. G 63.999 - 64.000 (2.5196 - 2.5197) Grade No. H 64.000 - 64.001 (2.5197 - 2.5197) Grade No. J 64.001 - 64.002 (2.5197 - 2.5198) Grade No. K 64.002 - 64.003 (2.5198 - 2.5198) Grade No. L 64.003 - 64.004 (2.5198 - 2.5198) Grade No. M 64.004 - 64.005 (2.5198 - 2.5199) Grade No. N 64.005 - 64.006 (2.5199 - 2.5199) Grade No. P 64.006 - 64.007 (2.5199 - 2.5200) Grade No. R 64.007 - 64.008 (2.5200 - 2.5200) Grade No. S 64.008 - 64.009 (2.5200 - 2.5200) Grade No. T 64.009 - 64.010 (2.5200 - 2.5201) Grade No. U 64.010 - 64.011 (2.5201 - 2.5201) Grade No. V 64.011 - 64.012 (2.5201 - 2.5202) Grade No. W 64.012 - 64.013 (2.5202 - 2.5202) Grade No. X 64.013 - 64.014 (2.5202 - 2.5202) Grade No. Y 64.014 - 64.015 (2.5202 - 2.5203) Grade No. 4 64.015 - 64.016 (2.5203 - 2.5203) Grade No. 7 64.016 - 64.017 (2.5203 - 2.5203) Difference in inner diameter between cylinders Standard Less than 0.03 (0.0012)

Scheme 311

AVAILABLE PISTON

AVAILABLE PISTON SPECIFICATIONS SERVICE DATA Unit: mm (in) Items Grade (1) Standard Piston skirt diameter "A" Grade No. 1 95.480 - 95.490 (3.7590 - 3.7594) Grade No. 2 95.490 - 95.500 (3.7594 - 3.7598) Grade No. 3 95.500 - 95.510 (3.7598 - 3.7602) "a" dimension 38.0 (1.496) Piston pin hole diameter Grade No. 0 21.993 - 21.999 (0.8659 - 0.8661) Grade No. 1 21.999 - 22.005 (0.8661 - 0.8663) Piston to cylinder bore clearance 0.010 - 0.030 (0.0004 - 0.0012) (1) Always check with the Parts Department for the latest parts information

Scheme 312

PISTON RING

PISTON RING SPECIFICATIONS SERVICE DATA

PISTON PIN

PISTON PIN SPECIFICATIONS SERVICE DATA

CONNECTING ROD

CONNECTING ROD SPECIFICATIONS SERVICE DATA

CRANKSHAFT

CRANKSHAFT SPECIFICATIONS SERVICE DATA Unit: mm (in) Main journal diameter. "Dm" grade Standard Grade (1) Dimension Grade No. A 59.975 - 59.974 (2.3612 - 2.3612) Grade No. B 59.974 - 59.973 (2.3612 - 2.3611) Grade No. C 59.973 - 59.972 (2.3611 - 2.3611) Grade No. D 59.972 - 59.971 (2.3611 - 2.3611) Grade No. E 59.971 - 59.970 (2.3611 - 2.3610) Grade No. F 59.970 - 59.969 (2.3610 - 2.3610) Grade No. G 59.969 - 59.968 (2.3610 - 2.3609) Grade No. H 59.968 - 59.967 (2.3609 - 2.3609) Grade No. J 59.967 - 59.966 (2.3609 - 2.3609) Grade No. K 59.966 - 59.965 (2.3609 - 2.3608) Grade No. L 59.965 - 59.964 (2.3608 - 2.3608) Grade No. M 59.964 - 59.963 (2.3608 - 2.3607) Grade No. N 59.963 - 59.962 (2.3607 - 2.3607) Grade No. P 59.962 - 59.961 (2.3607 - 2.3607) Grade No. R 59.961 - 59.960 (2.3607 - 2.3606) Grade No. S 59.960 - 59.959 (2.3606 - 2.3606) Grade No. T 59.959 - 59.958 (2.3606 - 2.3605) Grade No. U 59.958 - 59.957 (2.3605 - 2.3605) Grade No. V 59.957 - 59.956 (2.3605 - 2.3605) Grade No. W 59.956 - 59.955 (2.3605 - 2.3604) Grade No. X 59.955 - 59.954 (2.3604 - 2.3604) Grade No. Y 59.954 - 59.953 (2.3604 - 2.3603) Grade No. 4 59.953 - 59.952 (2.3603 - 2.3603) Grade No. 7 59.952 - 59.951 (2.3603 - 2.3603) Pin journal diameter. "Dp" grade Standard Grade No. 0 51.968 - 51.974 (2.0460 - 2.0462) Grade No. 1 51.962 - 51.968 (2.0457 - 2.0460) Grade No. 2 51.956 - 51.962 (2.0445 - 2.0457) Center distance "r" 40.66 - 40.74 (1.6008 - 1.6039) Taper (Difference between "A" and "B") Limit Less than 0.002 (0.0001) Out-of-round (Difference between "X" and "Y") Less than 0.002 (0.0001) Crankshaft runout [TIR (2) ] Standard Less than 0.05 (0.0020) Limit 0.10 (0.0039) Crankshaft end play Standard 0.10 - 0.25 (0.0039 - 0.0098) Limit 0.30 (0.0118) Fillet role of crankshaft journal Standard More than 0.10 (0.0039) (1) Always check with the Parts Department for the latest parts information (2) Total indicator reading

Scheme 313

MAIN BEARING

MAIN BEARING SPECIFICATIONS SERVICE DATA Unit: mm (in) Grade number (1) Thickness Width Identification color Remarks 0 2.000 - 2.003 (0.0787 - 0.0789) 19.9 - 20.1 (0.783 - 0.791) Black Grade is the same for upper and lower bearings. 1 2.003 - 2.006 (0.0789 - 0.0790) Brown 2 2.006 - 2.009 (0.0790 - 0.0791) Green 3 2.009 - 2.012 (0.0791 - 0.0792) Yellow 4 2.012 - 2.015 (0.0792 - 0.0793) Blue 5 2.015 - 2.018 (0.0793 - 0.0794) Pink 6 2.018 - 2.021 (0.0794 - 0.0796) Purple 7 2.021 - 2.024 (0.0796 - 0.0797) White 01 UPR 2.003 - 2.006 (0.0789 - 0.0790) Brown Grade and color are different for upper and lower bearings. LWR 2.000 - 2.003 (0.0787 - 0.0789) Black 12 UPR 2.006 - 2.009 (0.0790 - 0.0791) Green LWR 2.003 - 2.006 (0.0789 - 0.0790) Brown 23 UPR 2.009 - 2.012 (0.0791 - 0.0792) Yellow LWR 2.006 - 2.009 (0.0790 - 0.0791) Green 34 UPR 2.012 - 2.015 (0.0792 - 0.0793) Blue LWR 2.009 - 2.012 (0.0791 - 0.0792) Yellow 45 UPR 2.015 - 2.018 (0.0793 - 0.0794) Pink LWR 2.012 - 2.015 (0.0792 - 0.0793) Blue 56 UPR 2.018 - 2.021 (0.0794 - 0.0796) Purple LWR 2.015 - 2.018 (0.0793 - 0.0794) Pink 67 UPR 2.021 - 2.024 (0.0796 - 0.0797) White LWR 2.018 - 2.021 (0.0794 - 0.0796) Purple (1) Always check with the Parts Department for the latest parts information

Scheme 314

UNDERSIZE

UNDERSIZE SPECIFICATIONS SERVICE DATA

MAIN BEARING OIL CLEARANCE

MAIN BEARING OIL CLEARANCE SPECIFICATIONS SERVICE DATA

CONNECTING ROD BEARING

CONNECTING ROD BEARING SPECIFICATIONS SERVICE DATA

UNDERSIZE SPECIFICATIONS SERVICE DATA

CONNECTING ROD BEARING OIL CLEARANCE

CONNECTING ROD BEARING OIL CLEARANCE SPECIFICATIONS SERVICE DATA

Drive Plate

DRIVE PLATE SPECIFICATIONS SERVICE DATA