Engine Mechanical: Other Nissan Quest IV

Precaution for Procedure without Cowl Top Cover

When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. to prevent damage to windshield.

Scheme 206

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"

The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the " SRS AIRBAG " and " SEAT BELTS " articles of this Service Information.

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

Precautions Necessary for Steering Wheel Rotation After Battery Disconnection

For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and cannot be turned.

If turning the steering wheel is required with the battery disconnected or discharged, follow the operation procedure below before starting the repair operation.

DISCONNECTING FUEL PIPING

1. Before starting work, check 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 Tool

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

Tool number (Kent-Moore No.) Tool name Description KV10116200 (J-26336-A) Valve spring compressor KV10115900 (J-26336-20) Attachment KV10109220 (-) Adapter Disassembling valve mechanism Part (1) is a component of KV10116200 (J-26336-A), but Part (2) is not so. KV10107902 (J-38959) Valve oil seal puller Replacing valve oil seal KV10115600 (J-38958) Valve oil seal drift Installing valve oil seal Use side A. 20 mm (0.79 in) dia. 13 mm (0.51 in) dia. 10.3 mm (0.406 in) dia. 8 mm (0.31 in) dia. 10.7 mm (0.421 in) 5 mm (0.20 in) EM03470000 (J-8037) Piston ring compressor Installing piston assembly into cylinder bore ST16610001 (J-23907) Pilot bushing puller Removing pilot converter KV10111100 (J-37228) Seal cutter Removing oil pan (lower and upper), front and rear timing chain case, etc. KV10112100 (BT8653-A) Angle wrench Tightening bolts for connecting rod bearing cap, cylinder head, etc. in angle KV10117100 (J-3647-A) Heated oxygen sensor wrench Loosening or tightening air fuel ratio sensor 1 For 22 mm (0.87 in) width hexagon nut KV10114400 (J-38365) Heated oxygen sensor wrench Loosening or tightening heated oxygen sensor 2 22 mm (0.87 in)

Scheme 207

Scheme 208

Scheme 209

Commercial Service Tool

(Kent-Moore No.) Tool name Description (J-45488) Quick connector release Removing fuel tube quick connectors in engine room (-) Power tool Loosening bolts and nuts (-) Tube presser Pressing the tube of liquid gasket (-) Manual lift table caddy Removing and installing engine (J-24239-01) Cylinder head bolt wrench Loosening and tightening cylinder head bolt, and used with the angle wrench [SST: KV10112100 (BT8653-A)] 13 mm (0.51 in) dia. 12 mm (0.47 in) 10 mm (0.39 in) (-) Compression tester Adapter Checking compression pressure (-) Spark plug wrench Removing and installing spark plug 14 mm (0.55 in) (-) Pulley holder Removing and installing crankshaft pulley (-) 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 and Exhaust: 9.5 mm (0.374 in) dia. 5.5 mm (0.217 in) dia. (-) Valve guide reamer Reaming valve guide inner hole Reaming hole for oversize valve guide Intake and Exhaust: d1: 6.0 mm (0.236 in) dia. d2: 10.2 mm (0.402 in) dia. (J-43897-18) (J-43897-12) Oxygen sensor thread cleaner Reconditioning the exhaust system threads before installing a new air fuel ratio sensor and heated oxygen sensor (Use with anti-seize lubricant shown below.) J-43897-18 [18 mm (0.71 in) dia.] for zirconia heated oxygen sensor and air fuel ratio sensor J-43897-12 [12 mm (0.47 in) dia.] for titania heated oxygen sensor (-) Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907) Lubricating air fuel ratio sensor and oxygen sensor threads cleaning tool when reconditioning exhaust system threads

Scheme 210

Scheme 211

Scheme 212

Scheme 213

Scheme 214

Scheme 215

Scheme 216

Checking

1. Check that the indicator (A) of drive belt auto-tensioner is within the possible use range (B). NOTE: Check the drive belt auto-tensioner indication when the engine is cold. When new drive belt is installed, the indicator should be within the range (C) in the figure.
2. Visually check entire drive belt for wear, damage or cracks.
3. If the indicator is out of the possible use range or belt is damaged, replace drive belt.

Intake Manifold Collector

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

Scheme 217

Scheme 218

1. Tighten mounting bolts in numerical order as shown in the figure below.
2. Perform the " «THROTTLE VALVE CLOSED POSITION LEARNING»(ref-672625-S27171223262014112400000) " when harness connector of electric throttle control actuator is disconnected. Refer to " «DESCRIPTION»(ref-672625-S00341600962014112400000) ".
3. Perform the " «IDLE AIR VOLUME LEARNING»(ref-672625-S34961152882014112400000) " and "Throttle Valve Closed Position Learning" when electric throttle control actuator is replaced. Refer to " «DESCRIPTION»(ref-672625-S19297177582014112400000) ".

Scheme 219

Scheme 220

1. Release fuel pressure. Refer to " «WORK PROCEDURE»(ref-672625-S22980190582014112400000) ".
2. Remove intake manifold collector. Refer to " «REMOVAL AND INSTALLATION»(ref-672620-S14030500572014112400000) ".
3. Remove fuel tube and fuel injector assembly. Refer to " «EXPLODED VIEW»(ref-672620-S01496591682014112400000) ".
4. Loosen mounting nuts and bolts in the reverse order as shown in the figure below to remove intake manifold with power tool. CAUTION: Put identification marks on the intake manifold and cylinder head with paint for installing in the right direction. Cover the opening with tape to prevent the entry of foreign matter into the engine.
5. Remove gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

Exhaust Manifold Gasket

Install in the direction indicated in the figure.

Scheme 221

Scheme 222

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

Note. No. 7 and 8 mean double tightening of nuts No. 1 and 2.

Scheme 223

1. Temporarily tighten upper side bolts (B) and lower side bolt (A) shown in the figure below.
2. Tighten the upper side bolts (B) shown in the figure below. (specified torque)
3. Tighten all the lower side bolts [the other four except (B)]. (specified torque)

Three Way Catalyst Supports

1. Temporarily tighten three way catalyst support mounting bolts.
2. Tighten three way catalyst support mounting bolts to oil pan (upper).
3. Tighten three way catalyst support mounting bolts to three way catalyst.

Scheme 224

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

Scheme 225

1. Check the surface distortion of the exhaust manifold mating surface with a straightedge and a feeler gauge. Limit: Refer to " «EXHAUST MANIFOLD»(ref-672620-S01799633242014112400000) ".
2. If it exceeds the limit, replace exhaust manifold.

Scheme 226

Check on Fuel Leakage

1. Turn ignition switch "ON" (with the engine stopped). With fuel pressure applied to fuel piping, check there are no fuel leakage at connection points. NOTE: Use mirrors for checking at points out of clear sight.
2. Start the engine. With engine speed increased, check again that there are no fuel leakage at connection points. CAUTION: Never touch the engine immediately after stopped, as the engine becomes extremely hot.

Scheme 227

Scheme 228

Scheme 229

1. Removal the following parts: Engine cover: Refer to " «EXPLODED VIEW»(ref-672620-S40358377172014112400000) ". Air cleaner cases (upper and lower) and air duct assembly: Refer to " «EXPLODED VIEW»(ref-672620-S30704453622014112400000) ". Intake manifold collector: Refer to " «EXPLODED VIEW»(ref-672620-S20207820862014112400000) ".
2. Disconnect PCV hose from rocker cover.
3. Remove camshaft position sensor (PHASE) (bank 1 and bank 2). CAUTION: Handle carefully to avoid dropping and shocks. Never disassemble Never allow metal powder to contact magnetic part at sensor tip. Never place sensors in a location where they are exposed to magnetism.
4. Remove PCV valve and O-ring from rocker cover, if necessary.
5. Remove oil filler cap from rocker cover, if necessary.
6. Remove ignition coil. CAUTION: Never shock ignition coil.
7. Remove harness clips on the rocker cover.
8. Loosen bolts in the reverse order shown in the figure below.
9. Remove rocker cover gasket from rocker cover.
10. Use scraper to remove all traces of liquid gasket from cylinder head and camshaft bracket (No. 1). CAUTION: Never scratch or damage the mating surface when cleaning off old liquid gasket.

Outline

At first, remove the engine and the transaxle assembly with front suspension member downward. Then separate the engine and the transaxle.

Preparation

1. Release fuel pressure. Refer to " «WORK PROCEDURE»(ref-672625-S22980190582014112400000) ".
2. Drain engine coolant. Refer to " «DRAINING»(ref-672622-S03082931862014112400000) ". CAUTION: Perform this step when the engine is cold. Never spill engine coolant on drive belt.
3. Remove the following parts: Engine cover: Refer to " «REMOVAL AND INSTALLATION»(ref-672620-S21929366542014112400000) ". Engine under cover. Front road wheel and tires Splash guards (RH and LH): Refer to " «EXPLODED VIEW»(ref-672623-S22478781722014112400000) ". Air duct (inlet), air cleaner cases (upper and lower) with mass air flow sensor and air duct assembly: Refer to " «EXPLODED VIEW»(ref-672620-S30704453622014112400000) ". Battery and battery tray: Refer to " «EXPLODED VIEW»(ref-672612-S30530544732014112400000) ". Reservoir tank of radiator: Refer to " «REMOVAL AND INSTALLATION»(ref-672622-S19093988162014112400000) ". Front wiper arm and extension cowl top: Refer to " «EXPLODED VIEW»(ref-672623-S24692554682014112400000) ".
4. Disconnect engine room harness at the TCM, ECM, and other sides. CAUTION: To keep clean harness connector and avoid damage and foreign materials, cover them completely with plastic bags or something similar.
5. Remove battery bracket with ECM and TCM.

Engine Room

1. Disconnect heater hoses at engine side. Refer to " «EXPLODED VIEW»(ref-672622-S39090581092014112400000) ". Install plug to avoid leakage of engine coolant.
2. Remove EVAP hose. Refer to " «EXPLODED VIEW»(ref-672620-S20207820862014112400000) ".
3. Remove fuel feed hose at engine side. Refer to " «EXPLODED VIEW»(ref-672620-S01496591682014112400000) ". Install plug to avoid leakage of fuel.
4. Disconnect transaxle shift control cable from transaxle. Refer to " «REMOVAL AND INSTALLATION»(ref-672632-S01101349222014112400000) ".
5. Disconnect brake booster vacuum hose. Refer to " «EXPLODED VIEW»(ref-672620-S20207820862014112400000) ".
6. Remove radiator hose (upper and lower) at engine side. Refer to " «REMOVAL AND INSTALLATION»(ref-672622-S19093988162014112400000) ".
7. Remove return hose and high pressure piping from the power steering oil pump assembly. CAUTION: Fit plugs onto disconnected hoses to prevent fuel leakage.
8. Disconnect ground cable.
9. Remove A/C compressor with piping connected, and temporarily secure it to aside. Refer to " «COMPRESSOR: REMOVAL AND INSTALLATION»(ref-672613-S13536270442014112400000) ".
10. Disconnect CVT fluid cooler hoses from radiator. Refer to " «EXPLODED VIEW»(ref-672622-S30559909872014112400000) ".

Vehicle Underbody

1. Remove oil filter. Refer to " «REMOVAL AND INSTALLATION»(ref-672629-S01674900242014112400000) ".
2. Remove oil cooler. Refer to " «REMOVAL AND INSTALLATION»(ref-672629-S24000213292014112400000) ".
3. Remove exhaust front tube. Refer to " «EXPLODED VIEW»(ref-672628-S26761624652014112400000) ".
4. Remove heat insulator. Refer to " «EXPLODED VIEW»(ref-672626-S30228936602014112400000) ".
5. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Refer to " «EXPLODED VIEW»(ref-672626-S30228936602014112400000) ".
6. Disconnect front stabilizer connecting rod. Refer to " «EXPLODED VIEW»(ref-672631-S31664588562014112400000) ".
7. Remove front wheel sensor (RH and LH) for ABS from steering knuckle. Refer to " «FRONT WHEEL SENSOR: REMOVAL AND INSTALLATION»(ref-672633-S01683157092014112400000) ".
8. Remove front brake caliper assembly with piping connected, and temporarily secure it to aside for vehicle side. Refer to " «BRAKE CALIPER ASSEMBLY: EXPLODED VIEW»(ref-672634-S22508546562014112400000) ".
9. Remove the connector of auto levelizer control unit and clip. Refer to " «EXPLODED VIEW»(ref-672635-S34081661702014112400000) ".
10. Remove strut assembly and steering knuckle fixing nuts and bolts. Refer to " «REMOVAL AND INSTALLATION»(ref-672631-S21304490972014112400000) " and " «EXPLODED VIEW»(ref-672631-S06650575382014112400000) ".
11. Remove front drive shaft. (LH and RH). Refer to " «EXPLODED VIEW»(ref-672630-S39377233802014112400000) ".
12. Disconnect power steering piping at a vehicle side. Refer to " «EXPLODED VIEW»(ref-672626-S11815896182014112400000) ". Install plug to avoid leakage of power steering fluid.
13. Remove rear plate cover from oil pan. Refer to " «EXPLODED VIEW»(ref-672620-S21429898042014112400000) ".
14. Remove bolts fixing drive plate to torque converter. Refer to " «EXPLODED VIEW»(ref-672632-S20698915192014112400000) ".
15. Remove bolts tightening oil pan and transaxle. Refer to " «EXPLODED VIEW»(ref-672620-S21429898042014112400000) ".
16. Remove crankshaft position sensor (POS). Refer to " «EXPLODED VIEW»(ref-672620-S21429898042014112400000) ". CAUTION: Handle carefully to avoid dropping and shocks. Never disassemble. Never allow metal powder to contact magnetic part at sensor tip. Never place sensors in a location where they are exposed to magnetism.

Scheme 230

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 upper torque rod mounting bolt on the engine side and engine mount insulator (RH) mounting nut on the engine side.
3. Remove mounting bolt between transverse link and front suspension member with power tool. Refer to " «EXPLODED VIEW»(ref-672631-S06650575382014112400000) ".
4. Remove front suspension member mounting nuts and bolts. Refer to " «EXPLODED VIEW»(ref-672631-S06650575382014112400000) ".
5. Carefully lower jack, or raise lift to remove the engine and the transaxle assembly and front suspension member. When performing work, observe the following caution: CAUTION: Confirm there is no interference with the vehicle. Check 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 231

1. Install engine slingers into front of cylinder head (bank 1) (3) and rear of cylinder head (bank 2) (2).
2. Remove vacuum tube (front) and rear vacuum tube (upper and lower).
3. Lift with hoist the engine and the transaxle assembly and 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.
4. Remove rear torque rod and rear torque rod bracket.
5. Remove each engine mounting insulator and each engine mounting bracket from engine.
6. Lift with hoist and separate the engine and the transmission assembly from front suspension member.
7. Remove starter motor. Refer to " «REMOVAL AND INSTALLATION»(ref-672636-S41170459782014112400000) ".
8. Separate engine and transaxle assembly. Refer to " «UNIT REMOVAL AND INSTALLATION»(ref-672632-S33817568782014112400000) ".

Setting

Note. Explained here is how to disassemble with engine stand supporting transaxle surface. When using different type of engine stand, note with difference in steps and etc.

Scheme 232

Scheme 233

Scheme 234

1. Remove the engine assembly from the vehicle. Refer to " «EXPLODED VIEW»(ref-672620-S33173820222014112400000) ".
2. Remove the parts that may restrict installation of engine to widely use engine stand. NOTE: The procedure is described assuming that you use a widely use engine stand holding the surface, to which transaxle is installed. Remove drive plate. Fix crankshaft pulley with the pulley holder (commercial service tool), and remove mounting bolts. Loosen mounting bolts in diagonal order. Check for deformation or damage drive plate. CAUTION: Never disassemble drive plate. Never 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.
3. Remove pilot converter using the pilot bushing puller (SST) if necessary.
4. Lift the engine with hoist to install it onto the widely use engine stand. CAUTION: Use an engine stand that has a load capacity [220 kg (485 lb) or more] large enough for supporting the engine weight. If the load capacity of the stand is not adequate, remove the following parts beforehand to reduce the potential risk of overturning the stand. Remove intake manifold collector. Refer to " «EXPLODED VIEW»(ref-672620-S20207820862014112400000) ". Remove intake manifold. Refer to " «EXPLODED VIEW»(ref-672620-S06144586132014112400000) ". Remove fuel injector and fuel tube assembly. Refer to " «EXPLODED VIEW»(ref-672620-S01496591682014112400000) ". Remove ignition coil. Refer to " «EXPLODED VIEW»(ref-672620-S14189085292014112400000) ". Remove rocker cover. Refer to " «EXPLODED VIEW»(ref-672620-S14189085292014112400000) ". Remove exhaust manifold. Refer to " «EXPLODED VIEW»(ref-672620-S26863074632014112400000) ". Other removable brackets. NOTE: The figure shows an example of widely use engine stand (A) that can hold mating surface of transaxle with drive plate removed. CAUTION: Before removing the hanging chains, check the engine stand is stable and there is no risk of overturning.
5. Drain engine oil. Refer to " «DRAINING»(ref-672629-S13228114362014112400000) ".
6. Drain engine coolant by removing water drain plugs (A) and (B) from cylinder block both sides as shown in the figure below. Tightening torque: Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-672620-S28667100012014112400000) ". NOTE: For Canada, water drain plug (A) in the figure is not water drain plug but block heater. Refer to " «EXPLODED VIEW»(ref-672620-S26513912932014112400000) ".

Timing Chain

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

Scheme 235

Camshaft Journal Oil Clearance

CAMSHAFT JOURNAL DIAMETER

Scheme 236

1. Measure the outer diameter of camshaft journal with a micrometer (A). Standard and limit: Refer to " «CAMSHAFT»(ref-672620-S10622127142014112400000) ".

CAMSHAFT BRACKET INNER DIAMETER

Scheme 237

1. Tighten camshaft bracket bolt with the specified torque. Refer to " «INSTALLATION»(ref-672620-S23754882132014112400000) " for the tightening procedure.
2. Measure inner diameter (A) of camshaft bracket with a bore gauge. Standard: Refer to " «CAMSHAFT»(ref-672620-S10622127142014112400000) ".

CAMSHAFT JOURNAL OIL CLEARANCE

1. (Oil clearance) = (Camshaft bracket inner diameter) - (Camshaft journal diameter). Standard and limit: Refer to " «CAMSHAFT»(ref-672620-S10622127142014112400000) ".
2. If the calculated value exceeds the limit, replace either or both camshaft and cylinder head.

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

Scheme 238

Scheme 239

1. Install a dial indicator in thrust direction on front end of camshaft. Measure the end play of a dial indicator when camshaft is moved forward/backward (in direction to axis). Standard and limit: Refer to " «CAMSHAFT»(ref-672620-S10622127142014112400000) ".
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 240

1. Put V-block on precise flat table, and support No. 2 and 4 journals of camshaft. CAUTION: Never support No. 1 journal (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: Refer to " «CAMSHAFT»(ref-672620-S10622127142014112400000) ".
3. If it exceeds the limit, replace camshaft sprocket.

Valve Lifter

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

Scheme 241

1. If anything above is found, replace valve lifter. Refer to " «CAMSHAFT»(ref-672620-S10622127142014112400000) ".

Valve Lifter Clearance

VALVE LIFTER OUTER DIAMETER

Scheme 242

1. Measure the outer diameter at 1/2 height of valve lifter with a micrometer (A) since valve lifter is in barrel shape. Standard (Intake and exhaust): Refer to " «CAMSHAFT»(ref-672620-S10622127142014112400000) ".

VALVE LIFTER HOLE DIAMETER

Scheme 243

1. Measure the inner diameter of valve lifter hole of cylinder head with an inside micrometer. Standard (Intake and exhaust): Refer to " «CAMSHAFT»(ref-672620-S10622127142014112400000) ".

VALVE LIFTER CLEARANCE

1. (Valve lifter clearance) = (Valve lifter hole diameter) - (Valve lifter outer diameter) Standard (Intake and exhaust): Refer to " «CAMSHAFT»(ref-672620-S10622127142014112400000) ".
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.

Cylinder Head Distortion

Note. When performing this inspection, cylinder block distortion should be also checking. Refer to " INSPECTION ".

Scheme 244

1. Using a scraper, wipe off oil, scale, gasket, sealant and carbon deposits from surface of cylinder head. CAUTION: Never 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 (A), (B), (C), (D), (E), and (F). Limit: Refer to " «CYLINDER HEAD»(ref-672620-S38541631342014112400000) ". If it exceeds the limit, replace cylinder head.

Valve Dimensions

1. Check the dimensions of each valve. For the dimensions, refer to " «CYLINDER HEAD»(ref-672620-S38541631342014112400000) ".
2. If dimensions are out of the standard, replace valve and check valve seat contact. Refer to " «VALVE SEAT CONTACT»(ref-672620-S32254138802014112400000) ".

Valve Guide Clearance

Valve Stem Diameter

1. Measure the diameter of valve stem with micrometer (A).

Standard (Intake and exhaust): Refer to " CYLINDER HEAD ".

Valve Guide Inner Diameter

1. Measure the inner diameter of valve guide with bore gauge.

Standard (Intake and exhaust): Refer to " CYLINDER HEAD ".

Valve Guide Clearance

Scheme 245

1. (Valve guide clearance) = (Valve guide inner diameter) - (Valve stem diameter) Valve guide clearance Standard and limit (Intake and exhaust): Refer to " «CYLINDER HEAD»(ref-672620-S38541631342014112400000) ".
2. If the calculated value exceeds the limit, replace valve and/or valve guide. When valve guide must be replaced, refer to " «DISASSEMBLY AND ASSEMBLY»(ref-672620-S11903818272014112400000) ".

Scheme 246

1. After confirming that the dimensions of valve guides and valves are within the specifications, perform this procedure.
2. Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve contact on the surface.
3. Check if the contact area band is continuous all around the circumference.
4. If not, grind to adjust valve fitting and check again. If the contacting surface still has "NG" conditions (B) even after the recheck, replace valve seat. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-672620-S11903818272014112400000) ".

Scheme 247

1. Set a try square (A) along the side of valve spring and rotate spring. Measure the maximum clearance between the top of spring and try square. Limit: Refer to " «CYLINDER HEAD»(ref-672620-S38541631342014112400000) ".
2. If it exceeds the limit, replace valve spring.

Scheme 248

1. Check the valve spring pressure at specified spring height. Standard (Intake and exhaust): Refer to " «CYLINDER HEAD»(ref-672620-S38541631342014112400000) ". Free height Installation height Installation load Height during valve open Load with valve open
2. If the installation load or load with valve open is out of the standard, replace valve spring.

Piston Pin Hole Diameter

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

Standard: Refer to " CYLINDER BLOCK ".

Scheme 249

Piston to Piston Pin Oil Clearance

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

Standard: Refer to " CYLINDER BLOCK ".

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 " «DESCRIPTION»(ref-672620-S14275131552014112400000) ". 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 250

1. Measure the side clearance of piston ring (1) and piston ring groove with a feeler gauge (C). Standard and limit: Refer to " «CYLINDER BLOCK»(ref-672620-S24296865982014112400000) ".
2. If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, replace piston also.

Scheme 251

1. Check that the cylinder bore inner diameter is within the specification. Refer to " «CYLINDER BLOCK»(ref-672620-S24296865982014112400000) ".
2. Lubricate with new engine oil to piston (1) and piston ring (2), and then insert piston ring until middle of cylinder with piston, and measure the piston ring end gap with a feeler gauge (B). Standard and limit: Refer to " «CYLINDER BLOCK»(ref-672620-S24296865982014112400000) ".
3. If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, rebore cylinder and use oversize piston and piston rings.

Scheme 252

1. Check with a connecting rod aligner. Bend limit Torsion limit: Refer to " «CYLINDER BLOCK»(ref-672620-S24296865982014112400000) ".
2. If it exceeds the limit, replace connecting rod assembly.

Scheme 253

1. Install connecting rod bearing cap without installing connecting rod bearing, and tightening connecting rod bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-672620-S28667100012014112400000) " for the tightening procedure.
2. Measure the inner diameter of connecting rod big end with an inside micrometer. Standard: Refer to " «CYLINDER BLOCK»(ref-672620-S24296865982014112400000) ".
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 (A).

Standard: Refer to " CYLINDER BLOCK ".

Scheme 254

Connecting Rod Bushing Oil Clearance

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

Standard and limit: Refer to " CYLINDER BLOCK ".

Scheme 255

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 " «DESCRIPTION»(ref-672620-S14275131552014112400000) ".
3. If replacing connecting rod assembly, refer to " «CONNECTING ROD BEARING»(ref-672620-S21708568582014112400000) " to select the connecting rod bearing.

Factory installed parts grading

Scheme 256

1. Service parts apply only to grade "0".

Scheme 257

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 (C), (D), (E), (F), (G), and (H) with a straightedge (A) and a feeler gauge (B). Limit: Refer to " «CYLINDER BLOCK»(ref-672620-S24296865982014112400000) ".
3. If it exceeds the limit, replace cylinder block.

Scheme 258

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 " «DISASSEMBLY AND ASSEMBLY»(ref-672620-S28667100012014112400000) " for the tightening procedure.
2. Measure the inner diameter of main bearing housing with a bore gauge. Standard: Refer to " «CYLINDER BLOCK»(ref-672620-S24296865982014112400000) ".
3. If out of the standard, replace cylinder block (1) and main bearing caps (2) as assembly. NOTE: Cylinder block cannot be replaced as a single part, because it is machined together with main bearing caps.

Scheme 259

Scheme 260

1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper at six different points on each cylinder. [(A) and (B) directions at (C), (D) and (E)] is in longitudinal direction of engine. f: 10 mm (0.39 in) g: 60 mm (2.36 in) h: 120 mm (4.72 in) Standard and limit: Refer to " «CYLINDER BLOCK»(ref-672620-S24296865982014112400000) ".
2. If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, hone or rebore the inner wall.
3. Oversize piston is provided. When using oversize piston, rebore 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 (O/S): 0.2 mm (0.008 in)

Piston Skirt Diameter

Measure the outer diameter of piston skirt with a micrometer (A).

Measure point

Standard: Refer to " CYLINDER BLOCK ".

Scheme 261

Piston-to-Cylinder Bore Clearance

Calculate by piston skirt diameter and cylinder bore inner diameter [direction (B), position (D)].

Scheme 262

(Clearance) = (Cylinder bore inner diameter) - (Piston skirt diameter).

Standard and limit: Refer to " CYLINDER BLOCK ".

1. If the calculated value exceeds the limit, replace piston and piston pin assembly. Refer to " «PISTON»(ref-672620-S08251871802014112400000) ".

Reboring Cylinder Bore

1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter. Rebored size calculation: D = A + B - C where , Piston skirt diameter as measured Piston to cylinder bore clearance (standard value) Honing allowance 0.02 mm (0.0008 in) Bored diameter
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: Refer to " «CYLINDER BLOCK»(ref-672620-S24296865982014112400000) ".
2. If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to " «MAIN BEARING»(ref-672620-S37984416472014112400000) ".

Scheme 263

1. Measure the outer diameter of crankshaft pin journal with a micrometer (A). Standard: Refer to " «CYLINDER BLOCK»(ref-672620-S24296865982014112400000) ".
2. If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer to " «CONNECTING ROD BEARING»(ref-672620-S21708568582014112400000) ".

Scheme 264

1. Measure the dimensions at four different points as shown in the figure below on each main journal and pin journal with a micrometer.
2. Out-of-round is indicated by the difference in the dimensions between (d) and (c) at (a) and (b).
3. Taper is indicated by the difference in the dimensions between. Limit: Refer to " «CYLINDER BLOCK»(ref-672620-S24296865982014112400000) ".
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»(ref-672620-S37984416472014112400000) " and/or " «CONNECTING ROD BEARING»(ref-672620-S21708568582014112400000) ".

Scheme 265

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 and limit: Refer to " «CYLINDER BLOCK»(ref-672620-S24296865982014112400000) ".
4. If it exceeds the limit, replace crankshaft.

Scheme 266

1. Install connecting rod bearings (1) to connecting rod (2) and connecting rod cap, and tighten connecting rod bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-672620-S28667100012014112400000) " 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 and limit: Refer to " «CONNECTING ROD BEARING»(ref-672620-S15654409002014112400000) ".
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 " «CONNECTING ROD BEARING»(ref-672620-S21708568582014112400000) ".

Scheme 267

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 " «DISASSEMBLY AND ASSEMBLY»(ref-672620-S28667100012014112400000) " for the tightening procedure. CAUTION: Never 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 268

1. Install main bearings (3) to cylinder block (1) and main bearing caps (2), and main bearing cap bolts with main bearing beam to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-672620-S28667100012014112400000) " 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 and limit: Refer to " «MAIN BEARING»(ref-672620-S31349301652014112400000) ".
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 " «MAIN BEARING»(ref-672620-S37984416472014112400000) ".

Method of Using Plastigage

1. Remove engine oil and dust on crankshaft 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 bearing to cylinder block and main bearing caps, and tighten main bearing cap bolts with main bearing beam to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-672620-S28667100012014112400000) " for the tightening procedure. CAUTION: Never 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".

Scheme 269

1. When main bearing cap is removed after being tightened to the specified torque with main bearings (1) installed, the tip end of bearing must protrude. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-672620-S28667100012014112400000) " for the tightening procedure. Standard: There must be crush height.
2. If the standard is not met, replace main bearings.

Scheme 270

1. When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings (1) installed, the tip end of bearing must protrude. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-672620-S28667100012014112400000) " for the tightening procedure. Standard: There must be crush height.
2. If the standard is not met, replace connecting rod bearings.

Scheme 271

1. Measure the outer diameters (c), (d) at two positions as shown in the figure below.
2. If reduction appears in (a) range, regard it (c). Limit [(d) - (c)]: 0.11 mm (0.0043 in)
3. If it exceeds the limit (large difference in dimensions), replace main bearing cap bolt with new one.

Scheme 272

1. Measure the outer diameter (d) at position shown in the figure below.
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 273

1. Check drive plate and signal plate (A) for deformation or damage. CAUTION: Never disassemble drive plate. Never 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 274

1. Using a clean plastic stick, press check valve in oil jet relief valve. Check that valve moves smoothly with proper reaction force.
2. If it is not satisfied, replace oil jet relief valve.

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 275

Scheme 276

1. Measure the cylinder bore inner diameter. Refer to " «INSPECTION»(ref-672620-S01955854212014112400000) ".
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

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.

Scheme 277

1. 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.

WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED

1. Measure the connecting rod big end diameter. Refer to " «INSPECTION»(ref-672620-S01955854212014112400000) ".
2. Check that the connecting rod big end diameter is within the standard value.
3. Measure the crankshaft pin journal diameter. Refer to " «INSPECTION»(ref-672620-S01955854212014112400000) ".
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 BEARING GRADE TABLE

Connecting rod bearing grade table: Refer to " CONNECTING ROD BEARING ".

UNDERSIZE BEARING 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.

Bearing undersize table: Refer to " CONNECTING ROD BEARING ".

Scheme 278

Scheme 279

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".
4. Apply sign at crossing in above step 3 to "MAIN BEARING GRADE TABLE". NOTE: "MAIN BEARING GRADE TABLE" applies to all journals. Service parts is available as a set of both upper and lower.

WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED

1. Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter. Refer to " «INSPECTION»(ref-672620-S01955854212014112400000) ".
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. Follow step 3 and later in "When New Cylinder Block and Crankshaft are Used".

Scheme 280

MAIN BEARING GRADE TABLE (ALL JOURNALS)

Main bearing grade table (All journals): Refer to " MAIN BEARING ".

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. CAUTION: In grinding crankshaft main journal to use undersize bearings, keep the fillet R (A) [1.5 - 1.7 mm (0.059 - 0.067 in)]. Bearing undersize table: Refer to " «MAIN BEARING»(ref-672620-S31349301652014112400000) ".

DRIVE BELT

SPARK PLUG

INTAKE MANIFOLD

EXHAUST MANIFOLD

CAMSHAFT

Unit: mm (in) Items Standard Limit Camshaft journal oil clearance No. 1 0.045 - 0.086 (0.0018 - 0.0034) 0.15 (0.0059) No. 2, 3, 4 0.035 - 0.076 (0.0014 - 0.0030) Camshaft bracket inner diameter No. 1 26.000 - 26.021 (1.0236 - 1.0244) - No. 2, 3, 4 23.500 - 23.521 (0.9252 - 0.9260) - Camshaft journal diameter No. 1 25.935 - 25.955 (1.0211 - 1.0218) - No. 2, 3, 4 23.445 - 23.465 (0.9230 - 0.9238) - Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) 0.24 (0.0094) Camshaft cam height "A" Intake 45.465 - 45.655 (1.7900 - 1.7974) 0.2 (0.008) (1) Exhaust 45.475 - 45.665 (1.7904 - 1.7978) 0.2 (0.008) (1) Camshaft runout [TIR (2) ] Less than 0.02 mm (0.0008) 0.05 (0.0020) Camshaft sprocket runout [TIR (2) ] - 0.15 (0.0059) (1) Cam wear limit (2) Total indicator reading

VALVE CLEARANCE

AVAILABLE VALVE LIFTER

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

CYLINDER HEAD

Unit: mm (in) Items Standard Limit Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004) Normal cylinder head height "H" 126.3 - 126.5 (4.97 - 4.98)

Unit: mm (in) Valve head diameter "D" Intake 36.6 - 36.9 (1.441 - 1.453) Exhaust 30.2 - 30.5 (1.189 - 1.201) Valve length "L" Intake 97.13 (3.8240) Exhaust 94.67 (3.7272) Valve stem diameter "d" Intake 5.965 - 5.980 (0.2348 - 0.2354) Exhaust 5.962 - 5.970 (0.2347 - 0.2350) Valve seat angle "α" Intake 45°15' - 45°45' Exhaust Valve margin "T" Intake 1.1 (0.043) Exhaust 1.3 (0.051) Valve margin "T" limit 0.5 (0.020) Valve stem end surface grinding limit 0.2 (0.008)

Scheme 281

VALVE GUIDE

Unit: mm (in) Items Standard Oversize (Service) [0.2 (0.008)] Valve guide Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029) Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369) Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014) Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023) Items Standard Limit Valve guide clearance Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031) Exhaust 0.030 - 0.056 (0.0012 - 0.0022) 0.09 (0.0035) Projection length "L" 12.6 - 12.8 (0.496 - 0.504)

VALVE SEAT

Unit: mm (in) Items Standard Oversize (Service) [0.5 (0.02)] Cylinder head seat recess diameter "D" Intake 38.000 - 38.016 (1.4961 - 1.4967) 38.500 - 38.516 (1.5157 - 1.5164) Exhaust 31.600 - 31.616 (1.2441 - 1.2447) 32.100 - 32.116 (1.2638 - 1.2644) Valve seat outer diameter "d" Intake 38.097 - 38.113 (1.4999 - 1.5005) 38.597 - 38.613 (1.5196 - 1.5202) Exhaust 31.680 - 31.696 (1.2472 - 1.2479) 32.180 - 32.196 (1.2669 - 1.2676) Valve seat interference fit Intake 0.081 - 0.113 (0.0032 - 0.0044) Exhaust 0.064 - 0.096 (0.0025 - 0.0038) Diameter "d1" (1) Intake 34.6 (1.362) Exhaust 27.7 (1.091) Diameter "d2" (2) Intake 35.9 - 36.4 (1.413 - 1.433) Exhaust 29.3 - 29.8 (1.154 - 1.173) Angle "α1" Intake 60° Exhaust 60° Angle "α2" Intake 88°45' - 90°15' Exhaust 88°45' - 90°15' Angle "α3" Intake 120° Exhaust 120° Contacting width "W" (3) Intake 1.0 - 1.4 (0.039 - 0.055) Exhaust 1.2 - 1.6 (0.047 - 0.063) Height "h" Intake 5.9 - 6.0 (0.232 - 0.236) 5.0 - 5.1 (0.197 - 0.201) Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.9 - 5.0 (0.193 - 0.197) Depth "H" 6.0 (0.236) (1) Diameter made by intersection point of conic angles "α1" and "α2" (2) Diameter made by intersection point of conic angles "α2" and "α3" (3) Machining data

VALVE SPRING

CYLINDER BLOCK

Unit: mm (in) Surface flatness Standard Less than 0.03 (0.0012) Limit 0.1 (0.004) Main bearing housing inner diameter Standard 63.993 - 64.017 (2.5194 - 2.5203) Cylinder bore Inner diameter Standard Grade No. 1 95.500 - 95.510 (3.7598 - 3.7602) Grade No. 2 95.510 - 95.520 (3.7602 - 3.7606) Grade No. 3 95.520 - 95.530 (3.7606 - 3.7610) Wear limit 0.2 (0.008) Out-of-round Limit 0.015 (0.0006) Taper 0.010 (0.0004) Main bearing housing inner diameter grade (Without bearing) Grade No. A 63.993 - 63.994 (2.5194 - 2.5194) Grade No. B 63.994 - 63.995 (2.5194 - 2.5195) Grade No. C 63.995 - 63.996 (2.5195 - 2.5195) Grade No. D 63.996 - 63.997 (2.5195 - 2.5196) Grade No. E 63.997 - 63.998 (2.5196 - 2.5196) Grade No. F 63.998 - 63.999 (2.5196 - 2.5196) Grade No. G 63.999 - 64.000 (2.5196 - 2.5197) Grade No. H 64.000 - 64.001 (2.5197 - 2.5197) Grade No. J 64.001 - 64.002 (2.5197 - 2.5198) Grade No. K 64.002 - 64.003 (2.5198 - 2.5198) Grade No. L 64.003 - 64.004 (2.5198 - 2.5198) Grade No. M 64.004 - 64.005 (2.5198 - 2.5199) Grade No. N 64.005 - 64.006 (2.5199 - 2.5199) Grade No. P 64.006 - 64.007 (2.5199 - 2.5200) Grade No. R 64.007 - 64.008 (2.5200 - 2.5200) Grade No. S 64.008 - 64.009 (2.5200 - 2.5200) Grade No. T 64.009 - 64.010 (2.5200 - 2.5201) Grade No. U 64.010 - 64.011 (2.5201 - 2.5201) Grade No. V 64.011 - 64.012 (2.5201 - 2.5202) Grade No. W 64.012 - 64.013 (2.5202 - 2.5202) Grade No. X 64.013 - 64.014 (2.5202 - 2.5202) Grade No. Y 64.014 - 64.015 (2.5202 - 2.5203) Grade No. 4 64.015 - 64.016 (2.5203 - 2.5203) Grade No. 7 64.016 - 64.017 (2.5203 - 2.5203) Difference in inner diameter between cylinders Standard Less than 0.03 (0.0012)

AVAILABLE PISTON

Unit: mm (in) Items Standard Oversize (Service) [0.2 (0.008)] Piston skirt diameter "A" Grade No. 1 95.480 - 95.490 (3.7590 - 3.7594) - Grade No. 2 95.490 - 95.500 (3.7594 - 3.7598) - Grade No. 3 95.500 - 95.510 (3.7598 - 3.7602) - Service - 95.680 - 95.710 (3.7669 - 3.7681) Items Standard Limit "a" dimension 38.0 (1.496) - Piston pin hole diameter Grade No. 0 21.993 - 21.999 (0.8659 - 0.8661) - Grade No. 1 21.999 - 22.005 (0.8661 - 0.8663) - Piston to cylinder bore clearance 0.010 - 0.030 (0.0004 - 0.0012) 0.08 (0.0031)

Scheme 282

PISTON RING

PISTON PIN

CONNECTING ROD

CRANKSHAFT

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

MAIN BEARING

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

Scheme 283

UNDERSIZE

MAIN BEARING OIL CLEARANCE

CONNECTING ROD BEARING

CONNECTING ROD BEARING OIL CLEARANCE