Engine Mechanical: Other Nissan Quest III

Precautions for Disconnecting Fuel Piping

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

Special Service Tools

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

SPECIAL SERVICE TOOLS DESCRIPTION Tool number (Kent-Moore No.) Tool name Description ST0501S000 ( - ) Engine stand assembly 1 ST05011000 ( - ) Engine stand 2 ST05012000 ( - ) Base Disassembling and assembling - (J-47242) Engine support table Engine and transmission assembly removal KV10106500 ( - ) Engine stand shaft Disassembling and assembling KV10117000 (J-41262) Engine sub-attachment KV10117000 has been replaced with KV10117001 (KV10117000 is no longer in production, but is usable). KV10117001 ( - ) Engine sub-attachment Installing on the cylinder block KV10116200 (J-26336-B) Valve spring compressor 1 KV10115900 (J-26336-20) Attachment 2 KV1019230 ( - ) Disassembling valve mechanism Part (1) is a component of KV10116200 (J-26336-B), 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 KV991J0120 (J-47128) Seal installer Installing rear main seal EM03470000 (J-8037) Piston ring compressor Installing piston assembly into cylinder bore 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 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 a: 22 mm (0.87 in) Unit: mm (in) KV10114400 (J-38365) Heated oxygen sensor wrench Loosening or tightening rear heated oxygen sensor a: 22 (0.87) Unit: mm (in) KV10117700 (J-44716) Ring gear stopper Removing and installing crankshaft pulley - (J-45488) Quick connector release Disconnecting fuel tube quick disconnect connectors in engine compartment KV10109300 ( - ) Puller holder Removing and installing crankshaft pulley a: 68 (2.68) dia. b: 8 (0.31) Unit: mm (in)

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Commercial Service Tools

COMMERCIAL SERVICE TOOLS DESCRIPTION (Kent-Moore No.) Tool name Description (BT-3373-F) Belt tension gauge Checking drive belt tension (J-24239-01) Cylinder head bolt wrench Loosening and tightening cylinder head bolt a: 13 (0.51) dia. b: 12 (0.47) c: 10 (0.39) Unit: mm (in) 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: a = 9.5 (0.374) dia. b = 5.5 (0.217) Unit: mm (in) Valve guide reamer Reaming valve guide 1 or hole for oversize valve guide 2 Intake & Exhaust: d1 = 6.0 (0.236) dia. d2 = 10.175 - 10.196 (0.4006 - 0.4014) Unit: mm (in) (J-43897-18) (J-43897-12) Oxygen sensor thread cleaner Reconditioning the exhaust system threads before installing a new heated oxygen sensor (Use with anti-seize lubricant shown below.) a = (J-43897-18) 18 mm (0.71 in) for zirconia heated oxygen sensor b = (J-43897-12) 12 mm (0.47 in) for Titania heated oxygen sensor Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907) Lubricating heated oxygen sensor thread cleaning tool when reconditioning exhaust system threads

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Checking Drive Belts

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1. Inspect belt for cracks, fraying, wear or oil adhesion. If necessary, replace with a new one.
2. Inspect drive belt deflections by applying 98 N (10 kg-f, 22 lb-f) on the belt midway between pulleys as shown.
3. Measure the belt tension using Tool at the locations as shown. Tool number : BT-3373-F NOTE: Inspect drive belt deflection or tension when engine is cold. Adjust if belt deflections exceed the limit or if belt tension is not within specifications. CAUTION: When checking belt deflection or tension immediately after installation, first adjust it to the specification value. Then, after turning the crankshaft two turns or more, readjust to the specified value to avoid variation in deflection between pulleys. Tighten idler pulley lock nut by hand and measure deflection or tension without looseness.

Belt Deflection and Tension

BELT DEFLECTION AND TENSION REFERENCE

CHANGING AIR CLEANER FILTER

Note. The viscous paper type filter does not need cleaning between replacement intervals. Refer to " PERIODIC MAINTENANCE ".

Scheme 246

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

Scheme 247

Camshaft Visual Check

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

Scheme 248

1. Put V-block on precise flat bed and support No. 2 and No. 4 journal of camshaft as shown.
2. Set dial gauges vertically to No. 3 journal as shown.
3. Turn camshaft in one direction slowly by hand, measure the camshaft runout on the dial gauges. Runout is the largest indicator reading after one full revolution. Camshaft Runout Standard : Less than 0.02 mm (0.0008 in) Limit : 0.05 mm (0.0020 in) PBIC0929E
4. If actual runout exceeds the limit, replace the camshaft.

Scheme 249

1. Measure camshaft cam lobe height as shown. Refer to " «CAMSHAFT AND CAMSHAFT BEARING»(ref-239942-S11864220952006080400000) ".
2. If wear has reduced the lobe height below specifications, replace the camshaft.

Scheme 250

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

Scheme 251

1. Tighten camshaft bracket bolts to specified torque. Refer to " «INSTALLATION»(ref-239942-S15012588612006080400000) ".
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 252

1. Install the camshaft in the cylinder head. Refer to " «INSTALLATION»(ref-239942-S15012588612006080400000) ".
2. Install dial gauge in thrust direction on front end of camshaft. Measure end play when camshaft is moved forward/backward (in direction to axis) as shown. Standard : 0.115 - 0.188 mm (0.0045 - 0.0074 in) Limit : 0.24 mm (0.0094 in) If out of the specified range, replace with new camshaft and measure again. If out of the specified range again, replace with new cylinder head.

Scheme 253

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

Scheme 254

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

Scheme 255

1. Measure the outer diameter of the valve lifter. Refer to " «VALVE LIFTER»(ref-239942-S39175268132006080400000) ".
2. If out of the specified range, replace the valve lifter.

Scheme 256

1. Using inside micrometer, measure diameter of valve lifter bore of cylinder head. Refer to " «VALVE LIFTER»(ref-239942-S39175268132006080400000) ".
2. If out of the specified range, replace the cylinder head assembly.

Calculation of Valve Lifter Clearance

1. (Valve lifter clearance) = (hole diameter for valve lifter) - (outer diameter of valve lifter). Refer to " «VALVE LIFTER»(ref-239942-S39175268132006080400000) ".
2. If out of specified range, replace either or both valve lifter and cylinder head assembly.

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1. Before installation, remove any old Silicone RTV Sealant from component mating surfaces using suitable tool. CAUTION: Do not scratch or damage the mating surfaces. NOTE: Remove the old Silicone RTV Sealant from the bolt holes and threads.
2. Before installing the No. 1 camshaft bracket, remove the old Silicone RTV Sealant from the mating surface using suitable scraper. CAUTION: Do not scratch or damage the mating surface.
3. Turn the crankshaft until No. 1 piston is set at TDC on the compression stroke. The crankshaft key should line up with the right bank cylinder center line as shown.
4. Install the RH (1) and LH (2) secondary timing chain tensioners (3) on the cylinder heads. Secondary timing chain tensioner bolts : 8.5 N.m (0.87 kg-m, 75 in-lb) O-rings (4) Stopper pins (5)
5. Install valve lifters. NOTE: Install them in original positions.
6. Install exhaust and intake camshafts and camshaft brackets. Intake camshaft has a drill mark on camshaft sprocket mounting flange. Follow your identification marks (2) and (3) made during removal, or follow the identification marks (1) that are present on the new camshafts components for proper placement and direction of the components. <= Indicates engine front IDENTIFICATION MARK REFERENCE Bank INT/EXH Identification mark (1) Drill mark Paint marks M1 (3) M2 (2) RH (4) INT RE Yes Yes No EXH RE No No Yes LH (5) INT LH Yes Yes No EXH LH No No Yes Position the camshafts: RH exhaust camshaft dowel pin at about 10 o'clock. LH exhaust camshaft dowel pin at about 2 o'clock.
7. Before installing No. 1 camshaft brackets, apply sealant to mating surface of No. 1 camshaft bracket. Use Genuine Silicone RTV Sealant, or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-239935-S21612245322006080400000) ". Before installation, wipe off any protruding sealant. Refer to " «PRECAUTIONS FOR LIQUID GASKET»(ref-239942-S20252068932006080400000) ". For GI, go to «GENERAL INFORMATION»(ref-239935) article. Install remaining camshaft brackets in their original positions and direction. Align the stamp marks as shown. If checking and adjusting any part of valve assembly or camshaft, check valve clearance according to the reference data. Refer to " «VALVE CLEARANCE»(ref-239942-S19527434942006080400000) ".
8. Tighten the camshaft brackets in the four steps, in the order as shown. Camshaft bracket bolts Step 1 (bolts 7 - 10) : 1.96 N.m (0.2 kg-m, 17 in-lb) Step 2 (bolts 1 - 6) : 1.96 N.m (0.2 kg-m, 17 in-lb) Step 3 : 5.88 N.m (0.6 kg-m, 52 in-lb) Step 4 : 10.4 N.m (1.1 kg-m, 92 in-lb)
9. Measure difference in levels between front end faces of No.1 camshaft bracket and cylinder head. Standard : - 0.14 (- 0.0055 in) If measurement is outside the specified range, re-install camshaft and camshaft bracket.
10. Install the IVT control solenoid valves with new gaskets. IVT control solenoid valve bolts : 11.3 N.m (1.2 kg-m, 100 in-lb)
11. If necessary, install camshaft position sensor (PHASE) (RH and LH bank.) Camshaft position sensor (PHASE) bolt : 9.6 N.m (0.98 kg-m, 85 in-lb)
12. Install the timing chains. Refer to «REMOVAL»(ref-239942-S40428513742006080400000) .

CHECKING

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

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

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1. Remove the intake manifold collectors. Refer to " «REMOVAL»(ref-239942-S22280383062006080400000) ".
2. Remove the ignition coils. Refer to " «REMOVAL»(ref-239942-S35862248632006080400000) ".
3. Remove the rocker covers. " «REMOVAL»(ref-239942-S07857553182006080400000) ".
4. 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. RH cylinder head (1) <= Engine front
5. Check only the valves as shown. CRANK POSITION REFERENCE Crank Position Valve No. 1 Valve No. 2 Valve No. 3 Valve No. 6 No. 1 TDC Intake Exhaust Exhaust Intake Using a feeler gauge, measure the clearance between the valve lifter and camshaft. Record any valve clearance measurements which are out of specification. They will be used later to determine the required replacement lifter size. Valve Clearance for Checking (cold) Intake : 0.26 - 0.34 mm (0.010 - 0.013 in) Exhaust : 0.29 - 0.37 mm (0.011 - 0.015 in)
6. Turn crankshaft 240°.
7. Set No.3 cylinder at TDC on its compression stroke.
8. Check only those valves as shown. CRANK POSITION REFERENCE Crank Position Valve No. 2 Valve No. 3 Valve No. 4 Valve No. 5 No. 3 TDC Intake Intake Exhaust Exhaust
9. Turn the crankshaft 240° and align as above.
10. Set No.5 cylinder at TDC on its compression stroke.
11. Check only those valves as shown. CRANK POSITION REFERENCE Crank Position Valve No. 1 Valve No. 4 Valve No. 5 Valve No. 6 No. 5 TDC Exhaust Intake Intake Exhaust
12. If all valve clearances are within specification, installation of the remaining components is in the reverse order of removal. If the valve clearances are out of specification, adjust the valve clearances. Refer to " «VALVE ADJUSTING»(ref-239942-S41582646782006080400000) ".

VALVE ADJUSTING

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

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1. Remove the camshaft. Refer to " «REMOVAL»(ref-239942-S22331999262006080400000) ".
2. Remove the valve lifter that was measured as being outside the standard specifications.
3. Measure the center thickness of the removed lifter with a micrometer as shown.
4. Use the equation below to calculate the replacement valve lifter thickness. Valve lifter thickness calculation equation: t = t1 + (C1 - C2) t = thickness of the replacement lifter t1 = thickness of the removed lifter C1 = measured valve clearance C2 = standard valve clearance The thickness of the new valve lifter can be identified by the stamp mark on the reverse side (inside the lifter). Available thickness of the valve lifter (factory setting): 7.88 - 8.40 mm (0.3102 - 0.3307 in), in 0.02 mm (0.0008 in) increments, in 27 sizes (intake/exhaust). Refer to " «VALVE LIFTER»(ref-239942-S39175268132006080400000) ". NOTE: Two types of stamp marks are used for parallel setting and for manufacturer identification. Value lifter thickness Intake : 0.30 mm (0.012 in) Exhaust : 0.33 mm (0.013 in)
5. Install the selected replacement valve lifter.
6. Install the camshaft. Refer to " «INSTALLATION»(ref-239942-S15012588612006080400000) ".
7. Rotate the crankshaft a few turns by hand.
8. Confirm that the valve clearances are within specification.
9. After the engine has been run to full operating temperature, confirm that the valve clearances are within specification. VALVE CLEARANCE REFERENCE 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)

VALVE DIMENSIONS

Check dimensions of each valve, refer to " VALVE DIMENSIONS ".

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1. Measure valve deflection as shown. (Valve and valve guide mostly wear in this direction.) Valve deflection limit (dial gauge reading) Intake : 0.24 mm (0.0094 in) Exhaust : 0.28 mm (0.0110 in)
2. If it exceeds the limit, check valve to valve guide clearance. Measure valve stem diameter and valve guide inner diameter. Check that clearance is within specification. Valve to valve guide clearance standard Intake : 0.020 - 0.053 mm (0.0008 - 0.0021 in) Exhaust : 0.030 - 0.063 mm (0.0012 - 0.0025 in) Valve to valve guide clearance limit Intake : 0.08 mm (0.0031 in) Exhaust : 0.09 mm (0.004 in) SEM938C 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)

Scheme 282

VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD

Check valve spring pressure at specified spring height.

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

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

If it is not within specifications, replace the spring.

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1. Install valve guide. Refer to " «VALVE GUIDE REPLACEMENT»(ref-239942-S23682272572006080400000) ".
2. Install valve seat. Refer to " «VALVE SEAT REPLACEMENT»(ref-239942-S38591085102006080400000) ".
3. Install new valve spring seats and new valve oil seals using Tool. Tool number : (J-39386) Install with valve oil seal drift to match dimension in illustration. NOTE: Dimension "H": Height measured before valve spring seat installation. Height "H" Intake and exhaust : 14.3 - 14.9 mm (0.563 - 0.587 in)
4. Install the valves in their original position, as marked during disassembly.
5. Install valve spring (uneven pitch type). Install smaller pitch end (paint mark) to cylinder head side (valve spring seat side).
6. Install valve spring retainer.
7. Install valve collet. Tool numbers : KV10116200 (J-26336-B) : KV10115900 (J-26336-20) : KV10109230 ( - ) Compress valve spring using Tool and install valve collet. Tap stem edge lightly with plastic hammer after installation to check its installed condition.
8. Install valve lifter.
9. Install spark plug tube as follows: Remove old liquid gasket from all cylinder head holes. Apply liquid gasket to area within approximately 12 mm (0.47 in) from edge of spark plug tube press fit side. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-239935-S21612245322006080400000) ". Press fit the spark plug tube so that it height "H" is as specified, using suitable tool. Standard press fit height "H" : 38.55 - 38.65 mm (1.5177 - 1.5217 in) CAUTION: When press fitting, take care not to deform spark plug tube. After press fitting, wipe off liquid gasket protruding onto cylinder head upper face.
10. Install spark plug with spark plug wrench. Spark plug : 24.5 N.m (2.5 kg-m, 18 ft-lb)

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1. Disconnect battery positive and negative terminals.
2. Drain coolant. Refer to " «DRAINING ENGINE COOLANT»(ref-239944-S37417993932006080300000) ".
3. Drain A/T fluid. Refer to " «CHANGING A/T FLUID»(ref-239943-S20459687922006080300000) ".
4. Remove the cowl top extension. Refer to " «REMOVAL AND INSTALLATION»(ref-239945-S24732396862006080300000) ".
5. Disconnect engine room harness from the PCM and the two connections at the RH strut tower. Disconnect engine harness ground connections.
6. Disconnect the mass air flow sensor electrical connector.
7. Remove the fresh air intake tube and air cleaner to electric throttle control actuator tube attached to air cleaner lid. Remove air cleaner case (lower). Refer to " «REMOVAL AND INSTALLATION»(ref-239942-S12459786952006080400000) ".
8. Remove the engine cover using power tool.
9. Remove the battery and battery tray. Refer to " «REMOVAL AND INSTALLATION»(ref-239946-S29666347162006080300000) ".
10. Release fuel pressure. Refer to " «FUEL PRESSURE RELEASE»(ref-239940-S12688458762006080300000) ".
11. Disconnect fuel hose quick connection at vehicle piping side. Remove connector cap from the fuel hose. Squeeze the two tabs and pull the fuel hose from the fuel line. NOTE: If the connector and the tube are stuck together, push and pull several times until they start to move. Then disconnect them by pulling. CAUTION: The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary. Do not use any tools to remove the quick connector. Keep the resin tube away from heat. Be especially careful when welding near the tube. Prevent acid liquids such as battery electrolyte, etc. from getting on the resin tube. Do not bend or twist the tube during removal or installation. Do not remove the remaining retainer on the tube. When the tube is replaced, also replace the retainer with a new one. To keep the connecting portion clean and to avoid damage and foreign materials entering, cover the ends of the fuel tubes with plastic bags or something similar.
12. Remove the radiator assembly, engine coolant reservoir tank, and system hoses. Refer to " «REMOVAL AND INSTALLATION»(ref-239944-S38082485752006080300000) ".
13. Disconnect the brake booster vacuum hose from the back of the intake manifold collector.
14. Disconnect the EVAP canister purge volume control solenoid valve hose.
15. Disconnect heater hoses at the water outlet and heater pipe.
16. Disconnect the two fusible link connectors at the battery positive terminal.
17. Disconnect two engine harness connectors below mass air flow sensor attached to the strut tower.
18. Disconnect the harness retainers and position the engine harness aside.
19. Remove the ground cable and ground wire from transaxle.
20. Disconnect the transaxle shift controls. Refer to " «SHIFT CONTROL SYSTEM»(ref-239954-S05732812252006080300000) " (4A/T) or " «SHIFT CONTROL SYSTEM»(ref-239954-S05309617622006080300000) " (5A/T).
21. Remove the drive belts. Refer to " «REMOVAL AND INSTALLATION»(ref-239942-S23684646402006080400000) ".
22. Remove the front exhaust tube and hanger using power tools. Refer to " «REMOVAL AND INSTALLATION»(ref-239947-S37880455882006080300000) ".
23. Remove the front drive shafts. Refer to " «FRONT DRIVE SHAFT»(ref-239950-S26467882502006080300000) ".
24. Remove the lower ball joint pinch bolt using power tool, then separate the transverse link from the steering knuckle.
25. Remove the power steering line bracket from the front suspension member.
26. Remove the bolts on the lower side of the steering gear. Refer to " «REMOVAL AND INSTALLATION»(ref-239953-S08866372822006080300000) ".
27. Disconnect the front engine mount electrical connector.
28. Disconnect the connecting rod from the front strut using power tool.
29. Disconnect power steering line brackets from rear engine mounting insulator and rear of lower intake manifold collector.
30. Remove engine oil cooler pipe bolts.
31. Discharge and recover the R134a refrigerant. Refer to " «HFC-134A (R-134A) SERVICE PROCEDURE»(ref-259754-S32572440232007080400000) ".
32. Remove A/C low-pressure flexible hose. Refer to " «REMOVAL AND INSTALLATION FOR LOW-PRESSURE FLEXIBLE HOSE»(ref-259754-S03883162072007080400000) " (ATC) or " «REMOVAL AND INSTALLATION FOR LOW-PRESSURE FLEXIBLE HOSE»(ref-259755-S39902304552007080400000) " (MTC).
33. Remove A/C high-pressure flexible hose. Refer to " «REMOVAL AND INSTALLATION FOR HIGH-PRESSURE FLEXIBLE HOSE»(ref-259754-S32632983092007080400000) " (ATC) or " «REMOVAL AND INSTALLATION FOR HIGH-PRESSURE FLEXIBLE HOSE»(ref-259755-S25795890832007080400000) " (MTC).
34. Remove the A/C compressor using power tools. Refer to " «REMOVAL AND INSTALLATION FOR COMPRESSOR»(ref-259754-S12089851232007080400000) ".
35. Disconnect transaxle breather hose.
36. Disconnect the power steering pressure switch.
37. Disconnect harness retainer from power steering oil pump bracket.
38. Remove the idler pulley and idler pulley bracket and power steering pump, without disconnecting the piping, from the engine and position and secure it aside. Refer to " «REMOVAL AND INSTALLATION»(ref-239953-S07321739182006080300000) "
39. Remove the crankshaft position sensor (POS).
40. Remove the rear cover plate and bolts securing the torque converter to drive plate
41. Position a transmission jack under the engine/transaxle assembly.
42. On 4 A/T equipped vehicles, remove the LH transaxle mount through bolt.
43. Remove the RH engine mounting insulator nuts and bolt.
44. Remove the front suspension member and engine/transaxle assembly as follows: Remove the RH and LH member pin stay bolts. Remove the front suspension member nuts and cups and carefully lower the front suspension member and engine/transaxle assembly avoiding interference with the vehicle body. CAUTION: Make sure to disconnect electrically controlled engine mounting insulator harness clips from the front suspension member prior to removal. Before and during this procedure, always check if any harnesses are left connected. Avoid any damage to, or any oil/grease smearing or spills onto the engine mounting insulators.
45. Remove the starter motor. Refer to " «4-SPEED A/T MODELS»(ref-239946-S23068949552006080300000) " or " «5-SPEED A/T MODELS»(ref-239946-S04097622622006080300000) ".
46. Disconnect the electrical connectors, harness retainers and remove harnesses.
47. Disconnect the ATF cooler hoses and remove the ATF cooler. Refer to " «REMOVAL»(ref-239954-S12769107042006080300000) " (4 A/T) or " «REMOVAL»(ref-239954-S07607293192006080300000) " (5 A/T).
48. Remove the front and rear engine mount through bolts.
49. On 5 A/T models, remove the LH transaxle mount bolts.
50. Raise the engine/transaxle and remove the front suspension member.
51. Remove the ATF cooler valve from the engine with the hoses attached. Refer to " «ATF COOLER»(ref-239954-S27362185072006080300000) ".
52. Separate the engine and transaxle and mount the engine on a suitable engine stand.

4 A/T Models

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

BOLT REFERENCE

Scheme 293

5 A/T Models

When installing the transaxle to the engine, use the specified tightening torque in the numerical sequence as shown.

BOLT REFERENCE

Scheme 294

1. Install converter to drive plate bolts. Converter to drive plate bolts 4 A/T : 51 N.m (5.2 kg-m, 38 ft-lb) Converter to drive plate bolts 5 A/T : 54 N.m (5.5 kg-m, 40 ft-lb) NOTE: With converter installed, rotate crankshaft several turns to check that transaxle rotates freely without binding.
2. Install rear cover plate. Rear cover plate bolt : 6.91 N.m (0.70 kg-m, 61 in-lb)
3. Install crankshaft position sensor (POS). Crankshaft position sensor (POS) bolt : 9.6 N.m (0.98 kg-m, 85 in-lb)
4. Tighten the front suspension member nuts and bolts to specification. Refer to " «REMOVAL AND INSTALLATION»(ref-239942-S40043326392006080400000) ".
5. Install the stabilizer bar bushings and clamps in the specified orientation. Refer to " «REMOVAL AND INSTALLATION»(ref-239948-S07010758132006080300000) ".
6. Tighten the stabilizer bar and connecting rod nuts and bolts to specification. Refer to " «COMPONENTS»(ref-239948-S05929709592006080300000) ".
7. Tighten the steering gear bolts to specification. Refer to " «REMOVAL AND INSTALLATION»(ref-239953-S08866372822006080300000) ".

Piston Selection Table

PISTON SELECTION SPECIFICATIONS

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

When New Connecting Rod and Crankshaft are Used

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

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

Scheme 295

When Crankshaft and Connecting Rod are Reused

1. Measure dimensions of the big end inner diameter of connecting rod and outer diameter of crankshaft pin individually.
2. Confirm the big end inner diameter of connecting rod is within the standard value.
3. Apply the measured dimension to the " «CONNECTING ROD BEARING SELECTION TABLE»(ref-239942-S19816388482006080400000) ".
4. Determine the grade of crankshaft pin diameter grade by comparing the measurement with the values under the crankshaft pin outer diameter of the " «CONNECTING ROD BEARING SELECTION TABLE»(ref-239942-S19816388482006080400000) ".

Connecting Rod Bearing Selection Table

CONNECTING ROD BEARING SELECTION SPECIFICATIONS

Undersize Bearings Usage Guide

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

Bearing Undersize Table

BEARING UNDERSIZE SPECIFICATIONS

Scheme 296

Scheme 297

Scheme 298

1. " «MAIN BEARING SELECTION TABLE»(ref-239942-S25115864802006080400000) " rows correspond to bearing housing grade on rear left side of cylinder block.
2. Apply journal diameter grade stamped on crankshaft front side to column in " «MAIN BEARING SELECTION TABLE»(ref-239942-S25115864802006080400000) ".
3. Find sign (main bearing grade) at crossing of row and column in " «MAIN BEARING SELECTION TABLE»(ref-239942-S25115864802006080400000) ".

When Cylinder Block and Crankshaft are Reused

1. Measure inner diameter of cylinder block main bearing housing and outer diameter of crankshaft journal.
2. Find measured dimension in "Cylinder block bearing housing inner diameter" row of " «MAIN BEARING SELECTION TABLE»(ref-239942-S25115864802006080400000) ".
3. Find the measured dimension in "Crankshaft main journal diameter" column in " «MAIN BEARING SELECTION TABLE»(ref-239942-S25115864802006080400000) ".
4. Select main bearing grade at the point where selected row and column intersect.

Scheme 299

Main Bearing Grade Table (All Journals)

MAIN BEARING GRADE SPECIFICATIONS

Scheme 300

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

BEARING UNDERSIZE GRADE SPECIFICATIONS

Scheme 301

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

Scheme 302

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

Scheme 303

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 304

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

Piston and Piston Pin Interference Fit

Standard Interference Fit = "DP" - "dp"

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

Scheme 305

1. If clearance is exceeds specification, replace piston/piston pin assembly and connecting rod assembly with reference to specification of each part.
2. When replacing piston/piston pin assembly, refer to " «PISTON-TO-CYLINDER BORE CLEARANCE»(ref-239942-S17835553472006080400000) ".

Scheme 306

1. Measure side clearance of piston ring and piston ring groove with feeler gauge. Standard Side Clearance Top ring : 0.045 - 0.080 mm (0.0018 - 0.0031 in) 2nd ring : 0.030 - 0.070 mm (0.0012 - 0.0028 in) Oil ring : 0.065 - 0.135 mm (0.0026 - 0.0053 in) Maximum Limit Top ring : 0.11 mm (0.0043 in) 2nd ring : 0.1 mm (0.004 in) Oil ring
2. If out of specification, replace piston ring assembly. If clearance exceeds maximum limit with new rings, replace piston

Scheme 307

1. Check if inner diameter of cylinder bore is within specification. Refer to " «PISTON-TO-CYLINDER BORE CLEARANCE»(ref-239942-S17835553472006080400000) ".
2. Insert piston ring until it is in the middle of the cylinder bore and measure the end gap. Standard Top ring : 0.23 - 0.33 mm (0.0091 - 0.0130 in) 2nd ring : 0.33 - 0.48 mm (0.0130 - 0.0189 in) Oil ring : 0.20 - 0.50 mm (0.0079 - 0.0197 in) Limit: Top ring : 0.54 mm (0.0213 in) 2nd ring : 0.80 mm (0.0315 in) Oil ring : 0.95 mm (0.0374 in)
3. If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylinder and use oversized piston and piston ring.

CONNECTING ROD BEND AND TORSION

Bend : Limit 0.15 mm (0.0059 in) per 100 mm (3.94 in) length

Torsion : Limit 0.30 mm (0.0118 in) per 100 mm (3.94 in) length

Scheme 308

Scheme 309

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

Scheme 310

1. Install the connecting rod cap without the connecting rod bearing installed. After tightening the connecting rod bolt 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 311

1. Measure inner diameter of piston pin bushings. 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 312

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 313

1. If the measured value exceeds the standard, replace the connecting rod assembly and/or piston and piston pin assembly.
2. If replacing the piston and piston pin assembly, refer to the Table for Selective Fitting for Piston to select the piston corresponding to the applicable bore grade of the cylinder block to be used. Refer to " «PISTON-TO-CYLINDER BORE CLEARANCE»(ref-239942-S17835553472006080400000) ".
3. If replacing the connecting rod assembly, refer to " «CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)»(ref-239942-S18442430112006080400000) ".

Factory installed parts grading

Scheme 314

1. Service parts apply only to grade 0. GRADE SPECIFICATIONS Unit: mm (in) Grade 0 1 Piston pin bushing inner diameter (1) 22.000 - 22.006 (0.8661 - 0.8664) 22.006 - 22.012 (0.8664 - 0.8666) Piston pin outer diameter 21.989 - 21.995 (0.8657 - 0.8659) 21.995 - 22. 001 (0.8659 - 0.8662) Piston pin hole diameter 21.993 - 21.999 (0.8659 - 0.8661) 21.999 - 22.005 (0.8661 - 0.8663) (1) After installing in connecting rod

Scheme 315

1. Remove any old gasket material on the cylinder block surface, and remove any oil, scale, carbon, or other contamination using suitable tool. 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 316

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. Standard : 63.993 - 64.017 mm (2.5194 - 2.5203 in)
3. If out of the standard, replace the cylinder block and main bearing caps as an assembly. NOTE: These components cannot be replaced individually, since they were processed together.

Scheme 317

Scheme 318

Scheme 319

Scheme 320

Scheme 321

1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper. The X axis is in the longitudinal direction of the engine. Cylinder bore inner diameter PISTON-TO-CYLINDER BORE CLEARANCE SPECIFICATIONS 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, re bore all cylinders. Replace cylinder block if necessary. Out-of-round (Difference between, X - Y) : less than 0.015 mm (0.0006 in) Taper (Difference between, C - A) : less than 0.015 mm (0.0006 in)
2. Check for scratches and seizure. If seizure is found, hone it. If both cylinder block and piston are replaced with new ones, select piston of the same grade number punched on cylinder block rear position. These numbers are punched in either Arabic or Roman numerals.
3. Measure piston skirt diameter. Piston diameter "A" : Refer to " «PISTON, PISTON RING AND PISTON PIN»(ref-239942-S39668097872006080400000) ". Measuring point "a" (distance from the top) : 41.0 mm (1.614 in)
4. Check that piston-to-bore clearance is within specification. Piston-to-bore clearance at "B" : 0.010 - 0.030 mm (0.0004 - 0.0012 in) The piston-to-bore clearance is measured at the "B" level in the cylinder as shown.
5. Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. If oversize piston is used, use it for all cylinders with oversize piston ring. Refer to " «PISTON, PISTON RING AND PISTON PIN»(ref-239942-S39668097872006080400000) ".
6. 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)
7. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted after boring.
8. Cut cylinder bores. When any cylinder needs boring, all other cylinders must also be bored. Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a time.
9. Hone cylinders to obtain specified piston-to-bore clearance.
10. Measure finished cylinder bore for out-of-round and taper. Measurement should be done after cylinder bore cools down.

OUTER DIAMETER OF CRANKSHAFT JOURNAL

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

Scheme 322

OUTER DIAMETER OF CRANKSHAFT PIN

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

Scheme 323

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

Scheme 324

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

Scheme 325

Scheme 326

1. Install the connecting rod bearing to the connecting rod and cap.
2. Install the connecting rod cap to the connecting rod. Tighten to specification. Refer to " «ASSEMBLY»(ref-239942-S14484406952006080400000) ".
3. Measure the inner diameter "C" of each connecting rod (big end) as shown.
4. Measure the outer diameter "DP" of each crankshaft pin journal.
5. Calculate the connecting rod bearing clearance. Connecting rod bearing clearance = C - DP Standard : 0.034 - 0.059 mm (0.0013 - 0.0023 in) Limit : 0.070 mm (0.0028 in)
6. If the clearance cannot be adjusted within the standard of any bearing, grind the crankshaft journal and use undersized bearings. Refer to " «HOW TO SELECT CONNECTING ROD BEARINGS»(ref-239942-S17326490422006080400000) ".

Scheme 327

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 bolts to the specified torque. Refer to " «CYLINDER BLOCK»(ref-239942-S37060284972006080400000) " CAUTION: Never rotate the crankshaft.
4. Remove the connecting rod cap and bearings, and using the scale on the Plastigage bag, measure the Plastigage width. NOTE: The procedure when the measured value exceeds the repair limit is same as that described in " «METHOD BY CALCULATION»(ref-239942-S30790839642006080400000) ".

Scheme 328

1. Install the main bearings to the cylinder block and bearing cap. Refer to " «ASSEMBLY»(ref-239942-S14484406952006080400000) ".
2. Calculate the main bearing clearance. (Oil clearance) = (Inner diameter of main bearing) - (Outer diameter of crankshaft journal) Standard : 0.035 - 0.045 mm (0.0014 - 0.0018 in) Limit : 0.065 mm (0.0026 in)
3. If the calculated clearance exceeds the specified limit, replace the bearings. Refer to " «HOW TO SELECT MAIN BEARINGS»(ref-239942-S05067479852006080400000) ".

Scheme 329

1. Remove oil and dust on the crankshaft pin and the surfaces of each bearing completely.
2. Cut a Plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
3. Install the main bearings and main bearing caps. Refer to " «ASSEMBLY»(ref-239942-S14484406952006080400000) ". CAUTION: Never rotate the crankshaft.
4. Remove the main bearing caps and bearings, and using the scale on the Plastigage bag, measure the Plastigage width. NOTE: The procedure when the measured value exceeds the repair limit is same as that described in " «METHOD BY CALCULATION»(ref-239942-S20156040002006080400000) ".

Scheme 330

1. When the bearing cap is removed after being tightened to the specified torque with main bearings installed, the tip end of the bearing must protrude. Refer to " «ASSEMBLY»(ref-239942-S14484406952006080400000) " for tightening procedure. Standard : There must be a crush height.
2. If the standard is not met, replace main bearings.

Scheme 331

1. When the connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings installed, the tip end of the bearing must protrude. Refer to " «ASSEMBLY»(ref-239942-S14484406952006080400000) " for tightening procedure. Standard : There must be a crush height.
2. If the standard is not met, replace connecting rod bearings.

OUTER DIAMETER OF MAIN BEARING CAP BOLTS

Check specifications for the reuse of the main bearing cap bolts.

Scheme 332

1. Measure d1 and d2 as shown.
2. For d2, select the minimum diameter in the measuring area.
3. If the difference between d1 and d2 exceeds the limit, replace the bolts for assembly. Limit (d1 - d2) : 0.11 mm (0.0043 in)

Scheme 333

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

DRIVE PLATE

Check the drive plate and signal plate for deformation or damage.

Scheme 334

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 335

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.

INTAKE MANIFOLD COLLECTOR, INTAKE MANIFOLD AND EXHAUST MANIFOLD

INTAKE MANIFOLD COLLECTOR, INTAKE MANIFOLD AND EXHAUST MANIFOLD SPECIFICATIONS

SPARK PLUG

SPARK PLUG SPECIFICATIONS

CYLINDER HEAD

CYLINDER HEAD SPECIFICATIONS Unit: mm (in) Standard Limit Head surface distortion - 0.1 (0.004) Nominal cylinder head height "H" 126.3 - 126.5 (4.972 - 4.980)

Scheme 336

VALVE DIMENSIONS SPECIFICATIONS Unit: mm (in) Valve head diameter "D" Intake 37.0 - 37.3 (1.4567 - 1.4685) Exhaust 31.2 - 31.5 (1.228 - 1.240) Valve length "L" Intake 96.21 - 96.71 (3.7878 - 3.8075) Exhaust 93.74 - 94.24 (3.6905 - 3.7102) Valve stem diameter "d" Intake 5.965 - 5.980 (0.2348 - 0.2354) Exhaust 5.945 - 5.960 (0.2341 - 0.2346) Valve seat angle "d" degree/minute (degree decimal) Intake 45°25' - 46°75' (45.42° - 46.25°) 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) Valve oil seal installation height 14.3 14.9 mm (0.563 - 0.587 in)

Scheme 337

Valve Clearance

VALVE CLEARANCE SPECIFICATIONS

Valve Spring

VALVE SPRING SPECIFICATIONS

Valve Lifter

VALVE LIFTER SPECIFICATIONS

Available Valve Lifter

AVAILABLE VALVE LIFTER SPECIFICATIONS Identification Mark Thickness mm (in) 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 (03.157) 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)

Scheme 338

Scheme 339

Valve Guide

VALVE GUIDE SPECIFICATIONS Unit: mm (in) Standard Service Valve guide Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029) Valve guide Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369) 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) Standard Limit Valve to valve guide clearance Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031) Exhaust 0.030 - 0.063 (0.0012 - 0.0025) 0.09 (0.0035) Valve deflection Intake - 0.24 (0.0094) Exhaust - 0.28 (0.0110) Projection length "L" 12.6 - 12.8 (0.496 - 0.504)

Valve Seat

VALVE SEAT SPECIFICATIONS Unit: mm (in) Standard Service Cylinder head seat recess diameter (D) Intake 38.000 - 38.016 (1.4961 - 1.4967) 38.500 - 38.516 (1.5157 - 1.5164) Exhaust 32.200 - 32.216 (1.2677 - 1.2683) 32.700 - 32.716 (1.2874 - 1.2880) Valve seat interference fit Intake 0.081 - 0.113 (0.0032 - 0.0044) Exhaust 0.064 - 0.096 (0.0025 - 0.0038) Valve seat outer diameter (d) Intake 38.097 - 38.113 (1.4999 - 1.5005) 38.597 - 38.613 (1.5196 - 1.5202) Exhaust 32.280 - 32.296 (1.2709 - 1.2715) 32.780 - 32.796 (1.2905 - 1.2912) Height (h) Intake 5.9 - 6.0 (0.232 - 0.236) 5.05 - 5.15 (0.1988 - 0.2028) Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.95 - 5.05 (0.1949 - 0.1988) Depth (H) 5.9 - 6.1 (0.232 - 0.240) Valve seat resurface limit (L) Intake 41.07 - 41.67 (1.6169 - 1.6405) Exhaust 41.00 - 41.60 (1.6142 - 1.6378)

Scheme 340

Scheme 341

CAMSHAFT AND CAMSHAFT BEARING

CAMSHAFT AND CAMSHAFT BEARING SPECIFICATIONS

CAM LOBE HEIGHT SPECIFICATIONS Cam lobe height "A" Intake and exhaust 44.865 - 45.055 (1.7663 - 1.7738) Wear limit of cam lobe height 0.2 (0.008)

Scheme 342

CYLINDER BLOCK

CYLINDER BLOCK SPECIFICATIONS Unit: mm (in) Surface distortion Limit 0.10 (0.0039) 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 (Difference between X - Y) Less than 0.015 (0.0006) Taper (Difference between C - A) Less than 0.015 (0.0006) Main journal inner diameter grade (Without bearing) Grade No. A Grade No. B Grade No. C Grade No. D Grade No. E Grade No. F Grade No. G Grade No. H Grade No. J Grade No. K Grade No. L Grade No. M Grade No. N Grade No. P Grade No. R Grade No. S Grade No. T Grade No. U Grade No. V Grade No. W Grade No. X Grade No. Y Grade No. 4 Grade No. 7 63.993 - 63.994 (2.5194 - 2.5194) 63.994 - 63.995 (2.5194 - 2.5195) 63.995 - 63.996 (2.5195 - 2.5195) 63.996 - 63.997 (2.5195 - 2.5196) 63.997 - 63.998 (2.5196 - 2.5196) 63.998 - 63.999 (2.5196 - 2.5196) 63.999 - 64.000 (2.5196 - 2.5197) 64.000 - 64.001 (2.5197 - 2.5197) 64.001 - 64.002 (2.5197 - 2.5198) 64.002 - 64.003 (2.5198 - 2.5198) 64.003 - 64.004 (2.5198 - 2.5198) 64.004 - 64.005 (2.5198 - 2.5199) 64.005 - 64.006 (2.5199 - 2.5199) 64.006 - 64.007 (2.5199 - 2.5200) 64.007 - 64.008 (2.5200 - 2.5200) 64.008 - 64.009 (2.5200 - 2.5200) 64.009 - 64.010 (2.5200 - 2.5201) 64.010 - 64.011 (2.5201 - 2.5201) 64.011 - 64.012 (2.5201 - 2.5202) 64.012 - 64.013 (2.5202 - 2.5202) 64.013 - 64.014 (2.5202 - 2.5202) 64.014 - 64.015 (2.5202 - 2.5203) 64.015 - 64.016 (2.5203 - 2.5203) 64.016 - 64.017 (2.5203 - 2.5203)

Scheme 343

Available Piston

PISTON, PISTON RING AND PISTON PIN SPECIFICATIONS Unit: mm (in) Piston skirt diameter "A" Standard 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) 0.20 (0.0079) oversize (service) 95.680 - 95.710 (3.7669 - 3.7681) "a" measuring point (distance from the top) 41.0 (1.614) 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-bore clearance to cylinder block 0.010 - 0.030 (0.0004 - 0.0012)

Scheme 344

Piston Ring

PISTON RING SPECIFICATIONS

Piston Pin

PISTON PIN SPECIFICATIONS

CONNECTING ROD

CONNECTING ROD SPECIFICATIONS

CRANKSHAFT

CRANKSHAFT SPECIFICATIONS Unit: mm (in) Main journal dia. "DM" grade Grade No. A Grade No. B Grade No. C Grade No. D Grade No. E Grade No. F Grade No. G Grade No. H Grade No. J Grade No. K Grade No. L Grade No. M Grade No. N Grade No. P Grade No. R Grade No. S Grade No. T Grade No. U Grade No. V Grade No. W Grade No. X Grade No. Y Grade No. 4 Grade No. 7 59.975 - 59.974 (2.3612 - 2.3612) 59.974 - 59.973 (2.3612 - 2.3611) 59.973 - 59.972 (2.3611 - 2.3611) 59.972 - 59.971 (2.3611 - 2.3611) 59.971 - 59.970 (2.3611 - 2.3610) 59.970 - 59.969 (2.3610 - 2.3610) 59.969 - 59.968 (2.3610 - 2.3609) 59.968 - 59.967 (2.3609 - 2.3609) 59.967 - 59.966 (2.3609 - 2.3609) 59.966 - 59.965 (2.3609 - 2.3608) 59.965 - 59.964 (2.3608 - 2.3608) 59.964 - 59.963 (2.3608 - 2.3607) 59.963 - 59.962 (2.3607 - 2.3607) 59.962 - 59.961 (2.3607 - 2.3607) 59.961 - 59.960 (2.3607 - 2.3606) 59.960 - 59.959 (2.3606 - 2.3606) 59.959 - 59.958 (2.3606 - 2.3605) 59.958 - 59.957 (2.3605 - 2.3605) 59.957 - 59.956 (2.3605 - 2.3605) 59.956 - 59.955 (2.3605 - 2.3604) 59.955 - 59.954 (2.3604 - 2.3604) 59.954 - 59.953 (2.3604 - 2.3603) 59.953 - 59.952 (2.3603 - 2.3603) 59.952 - 59.951 (2.3603 - 2.3603) Pin journal dia. "DP" 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" 40.36 - 40.44 (1.5890 - 1.5921) Out-of-round (Difference between, X - Y) Standard Less than 0.002 (0.0001) Taper (Difference between, A - B) Standard Less than 0.002 (0.0001) Runout [TIR (1) ] Limit Less than 0.10 (0.0039) End play Standard 0.10 - 0.25 (0.0039 - 0.0098) Limit 0.30 (0.0118) (1) Total indicator reading

Scheme 345

AVAILABLE MAIN BEARING

AVAILABLE MAIN BEARING SPECIFICATIONS Grade number Thickness "T" mm (in) Width "W" mm (in) Identification color (UPR/LWR) 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/Black Grade is different for upper and lower bearings. LWR 2.000 - 2.003 (0.0787 - 0.0789) 12 UPR 2.006 - 2.009 (0.0790 - 0.0791) Green/Brown LWR 2.003 - 2.006 (0.0789 - 0.0790) 23 UPR 2.009 - 2.012 (0.0791 - 0.0792) Yellow/Green LWR 2.006 - 2.009 (0.0790 - 0.0791) 34 UPR 2.012 - 2.015 (0.0792 - 0.0793) Blue/Yellow LWR 2.009 - 2.012 (0.0791 - 0.0792) 45 UPR 2.015 - 2.018 (0.0793 - 0.0794) Pink/Blue LWR 2.012 - 2.015 (0.0792 - 0.0793) 56 UPR 2.018 - 2.021 (0.0794 - 0.0796) Purple/Pink LWR 2.015 - 2.018 (0.0793 - 0.0794) 67 UPR 2.021 - 2.024 (0.0796 - 0.0797) White/Purple LWR 2.018 - 2.021 (0.0794 - 0.0796)

Scheme 346

Undersize

UNDERSIZE SPECIFICATIONS

CONNECTING ROD BEARING

CONNECTING ROD BEARING SPECIFICATIONS

UNDERSIZE SPECIFICATIONS

BEARING CLEARANCE

BEARING CLEARANCE SPECIFICATIONS