Engine Mechanical: Other Nissan Murano Z50

Precautions for Disconnecting Fuel Piping

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

Special Service Tools

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

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1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of the engine.
4. Check specified noise source. If necessary, repair or replace these parts.

Checking Drive Belts

Scheme 240

1. Inspect belts for cracks, fraying, wear and oil. If necessary, replace.
2. Inspect drive belt deflection or tension at a point on belt midway between pulleys. Inspection should be done only when the engine is cold, or over 30 minutes after engine is stopped. Measure the belt tension with belt tension gauge (commercial service tool: BT3373-F or equivalent) at points marked shown in the figure. When measuring deflection, apply 98 N (10 kg, 22 lb) at the marked point. Adjust if the belt deflection exceeds the limit or if the belt tension is not within specifications.

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Scheme 242

POWER STEERING OIL PUMP BELT

1. Remove splash guard (RH).
2. Loosen lock bolt (C).
3. Loosen power steering oil pump mounting bolt (D). Bolt head (D) is engine rear side.
4. Adjust tension by turning adjusting bolt (E). For the specified belt tension, Refer to «CHECKING DRIVE BELTS»(ref-233993-S00247116512006052800000) . NOTE: Adjusting bolt (E) is loosened with counterclockwise rotation.
5. Tighten lock bolt (C). 28.0 N.m (2.9 kg-m, 21 ft-lb)
6. Tighten power steering oil pump mounting bolt (D). 43.2 N.m (4.4 kg-m, 32 ft-lb)

Power Valve

Tighten mounting bolts in numerical order as shown in the figure.

Scheme 243

Intake Manifold Collector (Upper)

Tighten mounting bolts in numerical order as shown in the figure.

Scheme 244

Intake Manifold Collector (Lower)

Tighten mounting nuts and bolts in numerical order as shown in the figure.

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Scheme 246

1. Install gasket with positioning no-protrusion surface upward or downward.
2. Tighten mounting bolts in numerical order as shown in the figure.
3. Perform the "Throttle Valve Closed Position Learning" when harness connector of electric throttle control actuator is disconnected. Refer to «THROTTLE VALVE CLOSED POSITION LEARNING»(ref-233996-S24202039362006052700000) .
4. Perform the "Idle Air Volume Learning" and "Throttle Valve Closed Position Learning" when electric throttle control actuator is replaced. Refer to «IDLE AIR VOLUME LEARNING»(ref-233996-S23216179462006052700000) and «THROTTLE VALVE CLOSED POSITION LEARNING»(ref-233996-S24202039362006052700000) .

Scheme 247

Scheme 248

1. Release fuel pressure. Refer to «FUEL PRESSURE RELEASE»(ref-233996-S05768987042006052700000) .
2. Remove intake manifold collectors (upper and lower). Refer to «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) .
3. Remove fuel tube and fuel injector assembly. Refer to «FUEL INJECTOR AND FUEL TUBE»(ref-233993-S41105589972006052800000) .
4. Loosen mounting nuts and bolts in reverse order as shown in the figure to remove intake manifold with power tool.
5. Remove gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

Scheme 249

1. Check the surface distortion of the intake manifold mating surfaces with a straightedge and a feeler gauge. Limit: 0.1 mm (0.004 in)
2. If it exceeds the limit, replace intake manifold.

Exhaust Manifold Gasket

Install in the direction indicated in the figure.

Scheme 250

Scheme 251

1. If stud bolts were removed, install them and tighten to the torque specified below. 15.4 N.m (1.6 kg-m, 11 ft-lb)
2. Tighten mounting nuts in numerical order as shown in the figure.

Scheme 252

1. Temporarily tighten three way catalyst support mounting bolts.
2. Tighten three way catalyst support mounting bolts to specified torque in numerical order as shown in the figure.

Scheme 253

1. Install air fuel ratio sensor 1 and heated oxygen sensor 2 in the original position.
2. Install referring the following if the installation positions cannot be identified. Glass tube color Air fuel ratio sensor 1: Black Heated oxygen sensor 2: White CAUTION: Before installing a new air fuel ratio sensor and a new heated oxygen sensor, clean exhaust system threads using oxygen sensor thread cleaner (commercial service tool: J-43897-18 or J43897-12) and apply anti-seize lubricant (commercial service tool). Do not over torque air fuel ratio sensor and heated oxygen sensor. Doing so may cause damage to air fuel ratio sensor and heated oxygen sensor, resulting in "MIL" coming on.

Scheme 254

2WD Model

Note. When removing oil pan (lower) or oil strainer only, take step 1 then step 10 and step 11 .

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1. Drain engine oil. Refer to «CHANGING ENGINE OIL»(ref-233994-S33124697692006052700000) . CAUTION: Perform this step when the engine is cold. Do not spill engine oil on drive belts.
2. Drain engine coolant. Refer to «CHANGING ENGINE COOLANT»(ref-233995-S01322841342006052700000) . CAUTION: Perform this step when engine is cold. Do not spill engine coolant on drive belts.
3. Remove following parts: Engine cover; Refer to «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) . Undercover Splash guard (RH) Exhaust front tube; Refer to «EXHAUST SYSTEM»(ref-233998-S33151466512006052700000) . Drive belts; Refer to «DRIVE BELTS»(ref-233993-S14607392772006052800000) .
4. Remove A/C compressor with piping connected, and temporarily secure it to aside. Refer to «COMPONENTS»(ref-234022-S35152859912006052700000) .
5. Remove three way catalysts (right and left banks) from exhaust manifolds (right and left banks). Refer to «EXHAUST MANIFOLD AND THREE WAY CATALYST»(ref-233993-S37636481532006052800000) .
6. Remove oil pressure switch. Refer to «OIL PRESSURE CHECK»(ref-233994-S07857832862006052700000) .
7. Remove crankshaft position sensor (POS) and harness bracket. CAUTION: Handle carefully to avoid dropping and shocks. Do not disassemble. Do not allow metal powder to adhere to magnetic part at sensor tip. Do not place sensor in a location where it is exposed to magnetism.
8. Remove oil filter. Refer to «OIL FILTER»(ref-233994-S32054289992006052700000) .
9. Remove oil cooler and water pipes. Refer to «OIL COOLER»(ref-233994-S25994909912006052700000) .
10. Remove oil pan (lower) as follows: Loosen mounting bolts in reverse order as shown in the figure. Insert the seal cutter [SST] between oil pan (lower) and oil pan (upper). CAUTION: Be careful not to damage the mating surfaces. Do not insert a screwdriver, this will damage the mating surfaces. Slide the seal cutter by tapping on the side of the tool with a hammer. Remove oil pan (lower).
11. Remove oil strainer.
12. Remove oil pan (upper) as follows: Remove transaxle joint bolts which pierce oil pan (upper). Refer to «TRANSAXLE ASSEMBLY»(ref-234000-S38984770662006052700000) . Loosen mounting bolts in reverse order as shown in the figure. Insert a suitable tool into the notch of oil pan (upper) as shown (1). Pry off oil pan (upper) by moving tool up and down as shown (2) to remove oil pan (upper).
13. Remove O-rings from the bottom of cylinder block and oil pump.
14. Remove oil pan gaskets.

AWD Model

Note. When removing oil pan (lower) or oil strainer only, take step 3 then step 8 and step 9 .

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1. Remove engine assembly from vehicle, and separate front suspension member, transaxle and transfer assembly from engine. Refer to «ENGINE ASSEMBLY»(ref-233993-S16501809062006052800000) .
2. install engine sub-attachment to right side of cylinder block, then lift engine, and mount it onto engine stand. Refer to «CYLINDER BLOCK»(ref-233993-S21665934002006052800000) .
3. Drain engine oil. Refer to «CHANGING ENGINE OIL»(ref-233994-S33124697692006052700000) .
4. Remove oil pressure switch. Refer to «OIL PRESSURE CHECK»(ref-233994-S07857832862006052700000) .
5. Remove oil filter. Refer to «OIL FILTER»(ref-233994-S32054289992006052700000) .
6. Remove oil cooler and water pipes. Refer to «OIL COOLER»(ref-233994-S25994909912006052700000) .
7. Remove three way catalysts (right and left banks) from exhaust manifolds (right and left banks). Refer to «EXHAUST MANIFOLD AND THREE WAY CATALYST»(ref-233993-S37636481532006052800000) .
8. Remove oil pan (lower) as follows: Loosen mounting bolts in reverse order as shown in the figure. Insert the seal cutter [SST] between oil pan (lower) and oil pan (upper). CAUTION: Be careful not to damage the mating surfaces. Do not insert screwdriver, this will damage the mating surfaces. Slide the seal cutter by tapping on the side of the tool with a hammer. Remove oil pan (lower).
9. Remove oil strainer.
10. Remove oil pan (upper) as follows: Loosen mounting bolts in reverse order as shown in the figure. Insert a suitable tool into the notch of oil pan (upper) as shown (1). Pry off oil pan (upper) by moving tool up and down as shown (2) to remove oil pan (upper).
11. Remove O-rings from the bottom of cylinder block and oil pump.
12. Remove oil pan gaskets.

Check on Fuel Leakage

1. Turn ignition switch "ON" (with engine stopped). With fuel pressure applied to fuel piping, make sure there no fuel leakage at connection points. NOTE: Use mirrors for checking at points out of clear sight.
2. Start engine. With engine speed increased, make sure again that there are no fuel leakage at connection points. CAUTION: Do not touch the engine immediately after stopped, as the engine becomes extremely hot.

Scheme 270

Scheme 271

1. Remove engine cover. Refer to «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) .
2. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leakage. Refer to «CHANGING ENGINE COOLANT»(ref-233995-S01322841342006052700000) and «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) . CAUTION: Perform this step when the engine is cold.
3. Remove front wiper arm and extension cowl top panel (lower and upper). Refer to «FRONT WIPER AND WASHER SYSTEM»(ref-234026-S29844305442006052700000) and «COWL TOP»(ref-234018-S27219738992006052700000) .
4. Remove intake manifold collectors (upper and lower). (At the right bank side remove) Refer to «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) .
5. Remove ignition coil. Refer to «IGNITION COIL»(ref-233993-S03131100382006052800000) .
6. Remove PCV hoses from rocker covers.
7. Remove PCV valve and O-ring from rocker cover (right bank), if necessary.
8. Remove oil filler cap from rocker cover (left bank), if necessary.
9. Loosen mounting bolts in reverse order shown in the figure.
10. Remove rocker cover gaskets from rocker covers.
11. Use a scraper to remove all trances of liquid gasket from cylinder head and camshaft bracket (No. 1). CAUTION: Do not scratch or damage the mating surface when cleaning off old liquid gasket.

Scheme 272

Scheme 273

1. Apply liquid gasket with the tube presser [SST: WS39930000 ( - )] to joint part among rocker cover, cylinder head and camshaft bracket (No. 1) as follows: Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000) . NOTE: The figure shows an example of left bank side [zoomed in shows camshaft bracket (No. 1)]. Refer to the figure "a" to apply liquid gasket to joint part of camshaft bracket (No. 1) and cylinder head. Refer to the figure "b" to apply liquid gasket to the figure "a" squarely.
2. Install new rocker cover gasket to rocker cover.
3. Install rocker cover. Check if rocker cover gasket is not dropped from installation groove of rocker cover.
4. Tighten mounting bolts two steps separately in numerical order as shown in the figure. 1st step 1.96 N.m (0.20 kg-m, 17 in-lb) 2nd step 8.33 N.m (0.85 kg-m, 74 in-lb)
5. Install oil filer cap to rocker cover (left bank), if removed.
6. Install new O-ring and PCV valve to rocker cover (right bank), if removed.
7. Install PCV hoses. Insert PCV hose by 25 to 30 mm (0.98 to 1.18 in) from connector end. When installing, be careful not to twist or come in contact with other parts.
8. Install in the reverse order of removal after this step.

Timing Chain

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

Scheme 274

CAMSHAFT JOURNAL OIL CLEARANCE

1. (Oil clearance) = (Camshaft bracket inner diameter) - (Camshaft journal diameter). Standard: No. 1: 0.045 - 0.086 mm (0.0018 - 0.0034 in) No. 2, 3, 4: 0.035 - 0.076 mm (0.0014 - 0.0030 in) Limit: 0.15 mm (0.0059 in)
2. If the calculated value exceeds the limit, replace either or both camshaft and cylinder head.

Note. Camshaft brackets cannot be replaced as single part, because there are machined together with cylinder head. Replace whole cylinder head assembly.

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Scheme 276

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

Scheme 277

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

Valve Lifter

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

Scheme 278

1. If anything above is found, replace valve lifter. Refer to «AVAILABLE VALVE LIFTER»(ref-233993-S34670040782006052800000) .

Scheme 279

1. Measure the outer diameter at 1/2 height of valve lifter with a micrometer since valve lifter is in barrel shape. Standard (Intake and exhaust): 33.977 - 33.987 mm (1.3377 - 1.3381 in)

Scheme 280

1. Measure the inner diameter of valve lifter hole of cylinder head with an inside micrometer. Standard (Intake and exhaust): 34.000 - 34.016 mm (1.3386 - 1.3392 in)

VALVE LIFTER CLEARANCE

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

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1. Install timing chain tensioners (secondary) on both sides of cylinder head. Install timing chain tensioner with its stopper pin attached. Install timing chain tensioner with sliding part facing downward on right-side cylinder head, and with sliding part facing upward on left-side cylinder head. Install new O-rings as shown in the figure.
2. Install valve lifters. Install it in the original position.
3. Install camshafts. Install camshaft with dowel pin attached to its front end face on the exhaust side. Follow your identification marks made during removal, or follow the identification marks that are present on new camshafts for proper placement and direction. Install camshaft so that dowel pin hole and dowel pin on front end face are positioned as shown in figure. (No. 1 cylinder TDC on its compression stroke) NOTE: Large and small pin holes are located on front end face of camshaft (INT), at intervals of 180 degrees. Face small dia. side pin hole upward (in cylinder head upper face direction). Though camshaft does not stop at the portion as shown in the figure, for the placement of cam nose, it is generally accepted camshaft is placed for the same direction of the figure.
4. Install camshaft brackets. Remove foreign material completely from camshaft bracket backside and from cylinder head installation face. Install camshaft bracket in original position and direction as shown in figure. Install camshaft brackets (No. 2 to 4) aligning the stamp marks as shown in the figure. NOTE: There are no identification marks indicating left and right for camshaft bracket (No. 1). Apply liquid gasket to mating surface of camshaft bracket (No. 1) as shown on right and left banks. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000) .
5. Tighten camshaft bracket bolts in the following steps, in numerical order as shown. Tighten No. 7 to 10 in order as shown. 1.96 N.m (0.20 kg-m, 1 ft-lb) Tighten No. 1 to 6 in order as shown. 1.96 N.m (0.20 kg-m, 1 ft-lb) Tighten No. 1 to 10 in numerical order as shown. 5.88 N.m (0.60 kg-m, 4 ft-lb) Tighten No. 1 to 6 in numerical order as shown. 10.4 N.m (1.1 kg-m, 8 ft-lb) Tighten No. 7 to 10 in numerical order as shown. 9.3 N.m (0.95 kg-m, 82 ft-lb) CAUTION: After tightening mounting bolts of camshaft brackets (No. 1), be sure to wipe off excessive liquid gasket from the parts list below. Mating surface of rocker cover Mating surface of rear timing chain case
6. Measure difference in levels between front end faces of camshaft bracket (No. 1) and cylinder head. Standard: -0.14 to 0.14 mm (-0.0055 to 0.0055 in) Measure two positions (both intake and exhaust side) for a single bank. If the measured value is out of the standard, re-install camshaft bracket (No. 1).
7. Inspect and adjust the valve clearance. Refer to «VALVE CLEARANCE»(ref-233993-S13110531292006052800000) .
8. Install in the reverse order of removal after this step.

Cylinder Head Distortion

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

Scheme 291

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

Scheme 292

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1. Install new cylinder head gaskets.
2. Turn crankshaft until No. 1 piston is set at TDC. Crankshaft key should line up with the right bank cylinder center line as shown in the figure.
3. Install cylinder head follow the steps below to tighten cylinder head bolts in numerical order as shown in the figure with cylinder head bolts wrench (commercial service tool). CAUTION: If cylinder head bolts re-used, check their outer diameters before installation. Refer to «CYLINDER HEAD BOLTS OUTER DIAMETER»(ref-233993-S20928516652006052800000) . Apply new engine oil to threads and seat surfaces of cylinder head bolts. Tighten all cylinder head bolts. 98.1 N.m (10 kg-m, 72 ft-lb) Completely loosen all cylinder head bolts. :0 N.m (0 kg-m, 0 ft-lb) CAUTION: In step " c ", loosen bolts in reverse order of that indicated in the figure. Tighten all cylinder head bolts. 39.2 N.m (4.0 kg-m, 29 ft-lb) Turn all cylinder head bolts 90 degrees clockwise. (Angle tightening) CAUTION: Check the tightening angle by using the angle wrench [SST]. Avoid judgment by visual inspection without tool. Check tightening angle indicated on the angle wrench indicator plate. Turn all cylinder head bolts 90 degrees clockwise again. (Angle tightening) After installing cylinder head, measure distance between front end faces of cylinder block and cylinder head (left and right banks). Standard: 14.1 - 14.9 mm (0.555 - 0.587 in) If the measured value is out of the standard, re-install cylinder head. Install in the reverse order of removal after this step.

VALVE DIMENSIONS

1. Check dimensions of each valve. For the dimensions, Refer to «VALVE DIMENSIONS»(ref-233993-S41462370902006052800000) .
2. If dimensions are out of the standard, replace valve and check valve seat contact. Refer to «VALVE SEAT CONTACT»(ref-233993-S19889113702006052800000) .

Valve Stem Diameter

Measure the diameter of valve stem with a micrometer.

Scheme 296

1. Standard Intake: 5.965 - 5.980 mm (0.2348 - 0.2354 in) Exhaust: 5.955 - 5.970 mm (0.2344 - 0.2350 in)

Valve Guide Inner Diameter

Measure the inner diameter of valve guide with an inside micrometer.

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

Valve Guide Clearance

(Valve guide clearance) = (Valve guide inner diameter) - (Valve stem diameter)

1. Valve guide clearance
2. Standard Intake: 0.020 - 0.053 mm (0.0008 - 0.0021 in) Exhaust: 0.030 - 0.063 mm (0.0012 - 0.0025 in)
3. Limit Intake: 0.08 mm (0.003 in) Exhaust: 0.10 mm (0.004 in)

1. If the calculated value exceeds the limit, replace valve and/or valve guide When valve guide must be replaced, Refer to «VALVE GUIDE REPLACEMENT»(ref-233993-S14759751022006052800000) .

Outline

At first, remove the engine, the transaxle and transfer (AWD models) assembly with front suspension member downward. Then separate the engine, the transaxle and transfer (AWD models).

Preparation

1. Release fuel pressure. Refer to «FUEL PRESSURE RELEASE»(ref-233996-S05768987042006052700000) .
2. Drain engine coolant. Refer to «CHANGING ENGINE COOLANT»(ref-233995-S01322841342006052700000) . CAUTION: Perform this step when the engine is cold. Do not spill engine coolant on drive belts.
3. Remove the following parts: Engine cover; Refer to «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) . Hood assembly; Refer to «HOOD»(ref-234015-S19609313172006052700000) . Front road wheel and tires Undercover and splash guards (RH and LH) Air duct (inlet), air cleaner case (upper) with mass air flow sensor and air duct assembly; Refer to «AIR CLEANER AND AIR DUCT»(ref-233993-S13601402462006052800000) . Battery, battery tray and battery tray bracket; Refer to «BATTERY»(ref-234023-S11698902302006052700000) . Drive belts; Refer to «DRIVE BELTS»(ref-233993-S14607392772006052800000) . Radiator, reservoir tank of radiator, and system hoses. Refer to «RADIATOR»(ref-233995-S41746158612006052700000) . Front wiper arm; Refer to «FRONT WIPER AND WASHER SYSTEM»(ref-234026-S29844305442006052700000) . Extension cowl top panel (lower and upper); Refer to «COWL TOP»(ref-234018-S27219738992006052700000) .
4. Disconnect engine room harness at the ECM side. CAUTION: To keep clean harness connector and avoid damage and foreign materials, cover them completely with plastic bags or something similar.

Engine Room

1. Disconnect heater hoses. Refer to «WATER OUTLET AND WATER PIPING»(ref-233995-S09088542642006052700000) . Install plug to avoid leakage of engine coolant.
2. Remove EVAP hose. Refer to «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) .
3. Disconnect fuel feed hose (with fuel damper) quick connector at centralized under-floor piping side. Refer to «FUEL INJECTOR AND FUEL TUBE»(ref-233993-S41105589972006052800000) . Install plug to avoid leakage of fuel.
4. Disconnect transaxle shift control cable at transaxle side. Refer to «SHIFT CONTROL SYSTEM»(ref-234000-S23038561412006052700000) .
5. Disconnect brake booster vacuum hose at engine side. Refer to «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) .
6. Remove alternator. Refer to «CHARGING SYSTEM»(ref-234023-S04076612042006052700000) .
7. Remove A/C compressor with piping connected, and temporarily secure it to aside. Refer to «COMPONENTS»(ref-234022-S35152859912006052700000) .
8. Disconnect suction hoses of power steering oil pump at reservoir tank side. Refer to «HYDRAULIC LINE»(ref-234012-S14474342682006052700000) . Install plug to avoid leakage of power steering fluid.

Vehicle Underbody

1. Remove front drive shafts (right and left sides). Refer to «FRONT DRIVE SHAFT»(ref-234004-S19365758292006052700000) .
2. Remove exhaust front tube. Refer to «EXHAUST SYSTEM»(ref-233998-S33151466512006052700000) .
3. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Refer to «POWER STEERING GEAR AND LINKAGE»(ref-234012-S16971899032006052700000) .
4. Disconnect front stabilizer connecting rod. Refer to «STABILIZER BAR»(ref-234006-S40230685602006052700000) .
5. Remove strut assembly and steering knuckle fixing nuts and bolts. Refer to «FRONT SUSPENSION ASSEMBLY»(ref-234006-S21840569942006052700000) .
6. Remove front brake cylinder body with piping connected, and temporarily secure it to aside for vehicle side. Refer to «FRONT DISC BRAKE»(ref-234009-S34196212272006052700000) .
7. Remove propeller shaft (AWD models). Refer to «REAR PROPELLER SHAFT»(ref-234002-S13531087652006052700000) .
8. Disconnect power steering piping at a point between vehicle and engine. Refer to «HYDRAULIC LINE»(ref-234012-S14474342682006052700000) . Install plug to avoid leakage of power steering fluid.
9. Remove rear plate cover from oil pan (upper). Then remove bolts fixing drive plate to torque converter. Refer to «OIL PAN AND OIL STRAINER»(ref-233993-S25354294872006052800000) and «TRANSAXLE ASSEMBLY»(ref-234000-S38984770662006052700000) .
10. Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to «TRANSAXLE ASSEMBLY»(ref-234000-S38984770662006052700000) .
11. Remove crankshaft position sensor (POS). CAUTION: Handle carefully to avoid dropping and shocks. Do not disassemble. Do not allow metal powder to adhere to magnetic part at sensor tip. Do not place sensors in a location where they are exposed to magnetism.

Scheme 297

1. Use a manual lift table caddy (commercial service tool) or equivalently rigid tool such as a transmission jack. Securely support bottom of front suspension member. CAUTION: Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.
2. Remove RH engine mounting insulator and RH engine mounting bracket.
3. Remove mounting bolt between transverse link and front suspension member with power tool.
4. Remove front suspension member mounting nuts and bolts. Refer to «FRONT SUSPENSION ASSEMBLY»(ref-234006-S21840569942006052700000) .
5. Carefully lower jack, or raise lift to remove the engine, the transaxle and transfer (AWD models) assembly and front suspension member. When performing work, observe the following caution: CAUTION: Confirm there is no interference with the vehicle. Make sure all connection points have been disconnected. Keep in mind the center of vehicle gravity changes. If necessary, use jack(s) to support the vehicle at rear jacking point(s) to prevent it from falling it off the lift.

Scheme 298

1. Install engine slingers into front of cylinder head (right bank) and rear of cylinder head (left bank).
2. Remove power steering oil pump, power steering piping and power steering bracket from engine, transaxle and transfer (AWD models) assembly. Refer to «HYDRAULIC LINE»(ref-234012-S14474342682006052700000) .
3. Remove starter motor. Refer to «STARTING SYSTEM»(ref-234023-S06140582382006052700000) .
4. Disconnect harness connector of front engine mounting insulator and rear engine mounting insulator (AWD models).
5. Lift with hoist and separate engine, transaxle and transfer (AWD models) assembly from front suspension member. CAUTION: Before and during this lifting, always check if any harnesses are left connected. Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
6. Remove each engine mounting insulator and each engine mounting bracket from engine, transaxle and front suspension member.
7. Separate engine, transaxle and transfer (AWD models) assembly. Refer to «TRANSAXLE ASSEMBLY»(ref-234000-S38984770662006052700000) .

When New Cylinder Block is Used

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

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

Scheme 299

Scheme 300

1. Measure the cylinder bore inner diameter. Refer to «CYLINDER BORE INNER DIAMETER»(ref-233993-S33680057932006052800000) .
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner diameter of the "Piston Selection Table".
3. Select piston of the same grade.

Piston Selection Table

PISTON GRADE SPECIFICATION

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

When New Connecting Rod and Crankshaft are Used

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

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

Scheme 301

When Crankshaft and Connecting Rod are Reused

1. Measure the connecting rod big end diameter. Refer to «CONNECTING ROD BIG END DIAMETER»(ref-233993-S20930394572006052800000) .
2. Make sure that the connecting rod big end diameter is within the standard value.
3. Measure the crankshaft pin journal diameter. Refer to «CRANKSHAFT PIN JOURNAL DIAMETER»(ref-233993-S35831142542006052800000) .
4. Determine the grade of crankshaft pin diameter grade by corresponding to the measured dimension in "Crankshaft pin journal diameter" column of "Connecting Rod Bearing Selection Table".
5. Select connecting rod bearing of the same grade.

Connecting Rod Bearing Selection Table

CONNECTING ROD BIG END DIAMETER SPECIFICATION

Scheme 302

Undersize Bearings Usage Guide

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

Scheme 303

Bearing undersize table

BEARING THICKNESS REFERENCE

Scheme 304

Scheme 305

1. "Main Bearing Selection Table" rows correspond to bearing housing grade on rear left side of cylinder block.
2. "Main Bearing Selection Table" columns correspond to journal diameter grade on front side of crankshaft.
3. Select main bearing grade at the point where selected row and column meet in "Main Bearing Selection Table".

When Cylinder Block and Crankshaft are Reused

1. Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter. Refer to «MAIN BEARING HOUSING INNER DIAMETER»(ref-233993-S24646574112006052800000) and «CRANKSHAFT MAIN JOURNAL DIAMETER»(ref-233993-S34480933952006052800000) .
2. Correspond the measured dimension in "Cylinder block main bearing housing inner diameter" row of "Main Bearing Selection Table".
3. Correspond the measured dimension in "Crankshaft main journal diameter" column of "Main Bearing Selection Table".
4. Select main bearing grade at the point where selected row and column meet in following selection table.

Scheme 306

Scheme 307

Undersize Bearing Usage Guide

1. When the specified main bearing oil clearance is not obtained with standard size main bearings, use underside (US) bearing.
2. When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and grind main journal so that the main bearing oil clearance satisfies the standard.

Scheme 308

BEARING THICKNESS REFERENCE

Scheme 309

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

Scheme 310

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

Piston Pin Hole Diameter

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

Scheme 311

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

Piston to Piston Pin Oil Clearance

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

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

1. If the calculated value is out of the standard, replace piston and piston pin assembly.
2. When replacing piston and piston pin assembly, Refer to «HOW TO SELECT PISTON»(ref-233993-S27189367442006052800000) .

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

Scheme 312

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

Scheme 313

1. Make sure that the cylinder bore inner diameter is within the specification. Refer to «CYLINDER BORE INNER DIAMETER»(ref-233993-S33680057932006052800000) .
2. Lubricate with new engine oil to piston and piston ring, and then insert piston ring until middle of cylinder with piston, and measure piston ring end gap with feeler gauge. Standard: Top ring: 0.23 - 0.33 mm (0.0091 - 0.0130 in) 2nd ring: 0.33 - 0.48 mm (0.0130 - 0.0189 in) Oil ring: 0.20 - 0.50 mm (0.0079 - 0.0197 in) Limit: Top ring: 0.54 mm (0.0213 in) 2nd ring: 0.80 mm (0.0315 in) Oil ring: 0.95 mm (0.0374 in)
3. If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, re-bore cylinder and use oversize piston and piston rings.

Scheme 314

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

Scheme 315

1. Install connecting rod bearing cap without installing connecting rod bearing, and tightening connecting rod bolts to the specified torque. Refer to «ASSEMBLY»(ref-233993-S32883286472006052800000) for the tightening procedure.
2. Measure the inner diameter of connecting rod big end with an inside micrometer. Standard: 55.000 - 55.013 mm (2.1654 - 2.1659 in)
3. If out of the standard, replace connecting rod assembly.

Connecting Rod Bushing Inner Diameter

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

Scheme 316

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

Connecting Rod Bushing Oil Clearance

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

1. Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 in)
2. Limit: 0.030 mm (0.0012 in)

Scheme 317

1. If the calculated value exceeds the limit, replace connecting rod assembly and/or piston and piston pin assembly.
2. If replacing piston and piston pin assembly, Refer to «HOW TO SELECT PISTON»(ref-233993-S27189367442006052800000) .
3. If replacing connecting rod assembly, Refer to «CONNECTING ROD BEARING OIL CLEARANCE»(ref-233993-S12076727912006052800000) to select the connecting rod bearing.

Scheme 318

1. Service parts apply only to grade "0". PISTON GRADE REFERENCE Grade 0 1 Connecting rod bushing inner diameter (1) 22.000 - 22.006 (0.8661 - 0.8664) 22.006 - 22.012 (0.8664 - 0.8666) Piston pin hole diameter 21.993 - 21.999 (0.8659 - 0.8661) 21.999 - 22.005 (0.8661 - 0.8663) Piston pin outer diameter 21.989 - 21.995 (0.8657 - 0.8659) 21.995 - 22.001 (0.8659 - 0.8662) (1) After installing in connecting rod

Scheme 319

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

Scheme 320

1. Install main bearing caps and main bearing beam without installing main bearings, and tighten main bearing cap bolts to the specified torque. Refer to «ASSEMBLY»(ref-233993-S32883286472006052800000) for the tightening procedure.
2. Measure the inner diameter of main bearing housing with bore gauge. Standard: 63.993 - 64.017 mm (2.5194 - 2.5203 in)
3. If out of the standard, replace cylinder block and main a bearing caps as assembly. NOTE: Cylinder block cannot be replaced as a single part, because it is machined together with main bearing caps.

Scheme 321

Scheme 322

1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper at six different points on each cylinder. ("X" and "Y" directions at "A", "B" and "C") ("Y" is in longitudinal direction of engine)
2. Standard inner diameter: 95.500 - 95.530 mm (3.7598 - 3.7610 in)
3. Wear limit: 0.2 mm (0.008 in)
4. Out-of-round (Difference between "X" and "Y"): Limit: 0.015 mm (0.0006 in)
5. Taper (Difference between "A" and "C"): Limit: 0.01 mm (0.0004 in)
6. If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, hone or re-bore the inner wall.
7. Oversize piston is provided. When using oversize piston, re-bore cylinder so that the clearance of the piston-to-cylinder bore satisfies the standard. CAUTION: When using oversize piston, use oversize pistons for all cylinders with oversize piston rings. Oversize (OS): 0.2 mm (0.008 in)

Piston Skirt Diameter

Measure the outer diameter of piston skirt with a micrometer

Scheme 323

1. Measure point Distance from the top 41.0 mm (1.614 in)
2. Standard 95.480 - 95.510 mm (3.7590 - 3.7602 in)

Piston to Cylinder Bore Clearance

Calculate by piston skirt diameter and cylinder bore inner diameter (direction "Y", position "B"). (Clearance) = (Cylinder bore inner diameter) - (Piston skirt diameter).

1. Standard: 0.010 - 0.030 mm (0.0004 - 0.0012 in)
2. Limit: 0.08 mm (0.0031 in)

1. If the calculated value exceeds the limit, replace piston and piston pin assembly. Refer to «HOW TO SELECT PISTON»(ref-233993-S27189367442006052800000) .

Re-boring Cylinder Bore

1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter. Re-bored size calculation: D = A + B - C where, D: Bored diameter A: Piston skirt diameter as measured B: Piston to cylinder bore clearance (standard value) C: Honing allowance 0.02 mm (0.0008 in)
2. Install main bearing caps and main bearing beam, and tighten to the specified torque. Otherwise, cylinder bores may be distorted in final assembly.
3. Cut cylinder bores. NOTE: When any cylinder needs boring, all other cylinders must also be bored. Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a time.
4. Hone cylinders to obtain the specified piston to cylinder bore clearance.
5. Measure finished cylinder bore for the out-of-round and taper. NOTE: Measurement should be done after cylinder bore cools down.

CRANKSHAFT MAIN JOURNAL DIAMETER

1. Measure the outer diameter of crankshaft main journals with a micrometer. Standard: 59.951 - 59.975 mm (2.3603 - 2.3612 in) dia.
2. If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to «MAIN BEARING OIL CLEARANCE»(ref-233993-S40102552452006052800000) .

Scheme 324

1. Measure the outer diameter of crankshaft pin journal with a micrometer. Standard: 51.956 - 51.974 mm (2.0455 - 2.0462 in) dia.
2. If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer to «CONNECTING ROD BEARING OIL CLEARANCE»(ref-233993-S12076727912006052800000) .

Scheme 325

1. Measure the dimensions at four different points as shown in the figure on each main journal and pin journal with a micrometer.
2. Out-of-round is indicated by the difference in the dimensions between "X" and "Y" at "A" and "B".
3. Taper is indicated by the difference in the dimensions between "A" and "B" at "X" and "Y". Limit: Out-of-round (Difference between "X" and "Y") 0.002 mm (0.0001 in) Taper (Difference between "A" and "B") 0.002 mm (0.0001 in)
4. If the measured value exceeds the limit, correct or replace crankshaft.
5. If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select the main bearing and/or connecting rod bearing. Refer to «MAIN BEARING OIL CLEARANCE»(ref-233993-S40102552452006052800000) and/or «CONNECTING ROD BEARING OIL CLEARANCE»(ref-233993-S12076727912006052800000) .

Scheme 326

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

Scheme 327

1. Install connecting rod bearings to connecting rod and connecting rod cap, and tighten connecting rod bolts to the specified torque. Refer to «ASSEMBLY»(ref-233993-S32883286472006052800000) for the tightening procedure.
2. Measure the inner diameter of connecting rod bearing with an inside micrometer. (Oil clearance) = (Connecting rod bearing inner diameter) - (Crankshaft pin journal diameter) Standard: 0.034 - 0.059 mm (0.0013 - 0.0023 in) (actual clearance) Limit: 0.070 mm (0.0028 in)
3. If the calculated value exceeds the limit, select proper connecting rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer to «HOW TO SELECT CONNECTING ROD BEARING»(ref-233993-S15273619402006052800000) .

Method of Using Plastigage

1. Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely.
2. Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
3. Install connecting rod bearings to connecting rod and connecting rod bearing cap, and tighten connecting rod bolts to the specified torque. Refer to «ASSEMBLY»(ref-233993-S32883286472006052800000) for the tightening procedure. CAUTION: Do not rotate crankshaft.
4. Remove connecting rod bearing cap and bearings, and using the scale on the plastigage bag, measure the plastigage width.

Note. The procedure when the measured value exceeds the limit is same as that described in the METHOD BY CALCULATION .

Scheme 328

Scheme 329

1. Install main bearings to cylinder block and main bearing caps, and tighten main bearing cap bolts with main bearing beam to the specified torque. Refer to «ASSEMBLY»(ref-233993-S32883286472006052800000) for the tightening procedure.
2. Measure the inner diameter of main bearing with a bore gauge. (Oil clearance) = (Main bearing inner diameter) - (Crankshaft main journal diameter) Standard: 0.035 - 0.045 mm (0.0014 - 0.0018 in) (actual clearance) Limit: 0.065 mm (0.0026 in)
3. If the calculated value exceeds the limit, select proper main bearing according to main bearing inner diameter and crankshaft main journal diameter to obtain the specified bearing oil clearance. Refer to «HOW TO SELECT MAIN BEARING»(ref-233993-S03847363182006052800000) .

Scheme 330

1. Remove oil and dust on crankshaft main journal and the surfaces of each bearing completely.
2. Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
3. Install main bearings to cylinder block and main bearing caps, and tighten main bearing bolts with main bearing beam to the specified torque. Refer to «ASSEMBLY»(ref-233993-S32883286472006052800000) for the tightening procedure. CAUTION: Do not rotate crankshaft.
4. Remove 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 limit is same as that described in the «METHOD BY CALCULATION»(ref-233993-S26577699612006052800000) .

Scheme 331

1. When main bearing cap is removed after being tightened to the specified torque with main bearings installed, the tip end of bearing must protrude. Refer to «ASSEMBLY»(ref-233993-S32883286472006052800000) for the tightening procedure. Standard: There must be crush height.
2. If the standard is not met, replace main bearings.

Scheme 332

1. When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings installed, the tip end of bearing must protrude. Refer to «ASSEMBLY»(ref-233993-S32883286472006052800000) for the tightening procedure. Standard: There must be crush height.
2. If the standard is not met, replace connecting rod bearings.

Scheme 333

1. Measure the outer diameters ("d1", "d2") at two positions as shown in the figure.
2. If reduction appears in "A" range, regard it as "d2". Limit ("d1" - "d2"): 0.11 mm (0.0051 in)
3. If it exceeds the limit (large difference in dimensions), replace main bearing cap bolt with new one.

Scheme 334

1. Measure the outer diameter "d" at position shown in the figure.
2. If the reduction appears in a position other than "d", regard it as "d". Standard: 7.90 - 8.00 mm (0.3110 - 0.3150 in) Limit: 7.75 mm (0.3051 in)
3. When "d" exceeds the limit (when it becomes thinner), replace connecting rod bolt with new one.

Scheme 335

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

OIL JET

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

Scheme 336

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 337

Scheme 338

Scheme 339

SPARK PLUG

SPARK PLUG SPECIFICATIONS

Scheme 340

VALVE LIFTER SPECIFICATIONS

Valve Clearance

VALVE CLEARANCE SPECIFICATIONS

Scheme 341

Scheme 342

Scheme 343

Scheme 344

Scheme 345

Scheme 346

Scheme 347

Scheme 348

Scheme 349

Scheme 350

Scheme 351

Scheme 352

Scheme 353

Undersize

UNDERSIZE SPECIFICATIONS

Main Bearing Oil Clearance

MAIN BEARING OIL CLEARANCE SPECIFICATIONS

CONNECTING ROD BEARING

CONNECTING ROD BEARING SPECIFICATIONS

UNDERSIZE SPECIFICATIONS

Connecting Rod Bearing Oil Clearance

CONNECTING ROD BEARING OIL CLEARANCE SPECIFICATIONS