Engine Mechanical: Diagnosis Nissan Rogue I

FOR USA AND CANADA : Inspection, Repair and Replacement

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

FOR MEXICO : Inspection, Repair and Replacement

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

INSPECTION AFTER REMOVAL

Use standard type spark plug for normal condition.

Spark plug (standard) : Refer to " SPARK PLUG ".

Scheme 18

Scheme 19

INSPECTION

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.

Scheme 20

Scheme 21

Scheme 22

Scheme 23

1. Start the engine and warm it up.
2. Stop the engine.
3. Remove rocker cover. Refer to " «EXPLODED VIEW»(ref-295108-S01690322732008081400000) ".
4. Remove splash guard on RH fender protector.
5. Measure the valve clearance with the following procedure: Set No. 1 cylinder at TDC of its compression stroke. Rotate crankshaft pulley clockwise and align TDC mark to timing indicator on front cover. At the same time, check that both intake and exhaust cam noses of No. 1 cylinder face outside as shown in the figure. If they do not face outside, rotate crankshaft pulley once more (360 degrees) and align as shown in the figure. Use a feeler gauge, measure the clearance between valve lifter and camshaft. Valve clearance : Refer to " «CAMSHAFT»(ref-295108-S07920080392008081400000) ". By referring to the figure, measure the valve clearances at locations marked "x" as shown in the table below (locations indicated with black arrow in the figure) with a feeler gauge. No. 1 cylinder compression TDC VALVE CLEARANCES SPECIFICATION Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL. No. 1 cylinder at compression TDC INT x x EXH x x Rotate crankshaft pulley one revolution (360 degrees) and align TDC mark to timing indicator on front cover. By referring to the figure, measure the valve clearance at locations marked "x" as shown in the table below (locations indicated with black arrow in the figure) with a feeler gauge. No. 4 cylinder compression TDC VALVE POSITION Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL. No. 4 cylinder at compression TDC INT x x EXH x x
6. If out of standard, perform adjustment. Refer to " «ADJUSTMENT»(ref-295108-S19655331642008081400000) ".

Inspect air duct and resonator assembly for crack or tear.

1. If anything found, replace air duct and resonator assembly.

Scheme 24

Scheme 25

Scheme 26

1. Release fuel pressure. Refer to " «INSPECTION»(ref-295106-S38449173432008081400000) ".
2. Remove cowl top cover. Refer to " «EXPLODED VIEW»(ref-295102-S20668103882008081400000) ".
3. Remove air cleaner case and mass air flow sensor assembly and air duct and resonator assembly. Refer to " «EXPLODED VIEW»(ref-295108-S07007942622008081400000) ".
4. Remove electric throttle control actuator with the following procedure: Disconnect harness connector. Loosen mounting bolts in reverse order as shown in the figure, and remove electric throttle control actuator and gasket. CAUTION: Handle carefully to avoid any shock to electric throttle control actuator. Never disassemble. NOTE: When removing only intake manifold, move electric throttle control actuator without disconnecting the water hose.
5. Disconnect harness, vacuum hose and PCV hose from intake manifold, and move them aside.
6. Remove intake manifold support.
7. Disconnect harness connector from tumble control valve motor. (For California)
8. Loosen mounting bolts and nuts in reverse order as shown in the figure, and remove intake manifold and gasket. CAUTION: Cover engine openings to avoid entry of foreign materials. NOTE: Disregard No. 6 when loosening.
9. Disconnect sub-harness from fuel injector. Refer to " «EXPLODED VIEW»(ref-295108-S39536330872008081400000) ".
10. Remove fuel tube and fuel injector assembly from intake manifold adaptor. Refer to " «EXPLODED VIEW»(ref-295108-S39536330872008081400000) ".
11. Remove EVAP canister purge volume control solenoid valve from intake manifold, if necessary.

Surface Distortion

Scheme 27

1. Using straightedge (A) and feeler gauge (B), check the surface distortion of both the intake manifold adaptor mating surface. Limit : Refer to " «INTAKE MANIFOLD»(ref-295108-S24934465862008081400000) ".
2. If it exceeds the limit, replace intake manifold adaptor.

Scheme 28

Scheme 29

Scheme 30

1. Remove air fuel ratio sensor 1 and heated oxygen sensor 2 with the following procedure: Disconnect harness connector of air fuel ratio sensor 1 and heated oxygen sensor 2 and harness from bracket and middle clamp. Using heated oxygen sensor wrench [SST: KV10117100 (J3647-A)] (A), remove air fuel ratio sensor 1 (1). CAUTION: Be careful not to damage air fuel ratio sensor 1 and heated oxygen sensor 2. Discard any air fuel ratio sensor 1 and heated oxygen sensor 2 which has been dropped onto a hard surface such as a concrete floor. Replace with a new one. NOTE: This figure shows air fuel ratio sensor 1 as an example.
2. Remove exhaust front tube. Refer to " «EXPLODED VIEW»(ref-295123-S20064475632008081400000) ".
3. Remove alternator. Refer to " «EXPLODED VIEW»(ref-295109-S22590187712008081400000) ".
4. Remove exhaust manifold cover (upper).
5. Loosen nuts in reverse order as shown in the figure to remove exhaust manifold and three way catalyst assembly. NOTE: Disregard No. 6 to 10 when loosening.
6. Remove gasket. CAUTION: Cover engine openings to avoid entry of foreign materials.
7. Remove exhaust manifold cover (lower) and three way catalyst cover from exhaust manifold and three way catalyst assembly.

Installation

Note the following, and install in the reverse order of removal.

Surface Distortion

Scheme 31

1. Check the surface distortion of the exhaust manifold mating surface with a straightedge and a feeler gauge. Limit : Refer to " «EXHAUST MANIFOLD»(ref-295108-S33628019072008081400000) ".
2. If it exceeds the limit, replace exhaust manifold.

Scheme 32

Refer to OIL FILTER .

INSPECTION AETER INSTALLATION

1. Check engine oil level and adjust engine oil. Refer to " «INSPECTION»(ref-295124-S27437280252008081400000) ".
2. Start engine, and check there is no leaks of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again. Refer to " «INSPECTION»(ref-295124-S27437280252008081400000) ".

INSPECTION AFTER INSTALLATION

1. Check engine oil level and adjust engine oil. Refer to " «INSPECTION»(ref-295124-S27437280252008081400000) ".
2. Start engine, and check there is no leaks of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again. Refer to " «INSPECTION»(ref-295124-S27437280252008081400000) ".

Scheme 33

Refer to OIL FILTER .

1. Check engine oil level and adjust engine oil. Refer to " «INSPECTION»(ref-295124-S27437280252008081400000) ".
2. Start engine, and check there is no leaks of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again. Refer to " «INSPECTION»(ref-295124-S27437280252008081400000) ".

Scheme 34

Refer to REMOVAL AND INSTALLATION .

Scheme 35

1. Remove air duct and resonator assembly. Refer to " «EXPLODED VIEW»(ref-295108-S07007942622008081400000) ".
2. Remove electric throttle control actuator without disconnecting water hose. Refer to " «EXPLODED VIEW»(ref-295108-S01708762182008081400000) ".
3. Loosen intake manifold mounting bolts and nuts.
4. Remove intake manifold. Refer to " «REMOVAL AND INSTALLATION»(ref-295108-S11821435882008081400000) ".
5. Disconnect harness connector from ignition coil.
6. Support the bottom surface of engine using a transmission jack.
7. Remove ground cable and harness from engine mounting bracket (RH).
8. Remove ignition coil. CAUTION: Never drop or shock ignition coil. Never disassemble ignition coil.
9. Disconnect PCV hose from rocker cover.
10. Remove engine mounting bracket (RH). Refer to " «EXPLODED VIEW»(ref-295108-S13605773992008081400000) ".
11. Remove PCV valve and O-ring from rocker cover, if necessary.
12. Remove oil filler cap from rocker cover, if necessary.
13. Loosen bolts in reverse order shown in the figure.
14. Remove rocker cover gasket from rocker cover.
15. 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.

Scheme 36

1. Apply liquid gasket to the position shown in the figure (4 places of cylinder head front and back) with the following procedure: Refer to figure "a" to apply liquid gasket to joint part of camshaft bracket (No. 1) and cylinder head. Refer to figure "b" to apply liquid gasket in 90 degrees to figure "a". Use Genuine RTV Silicone Sealant or equivalent Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-295085-S25948978912008081400000) ". CAUTION: Attaching should be done within 5 minutes after liquid gasket application.
2. Install rocker cover gasket to rocker cover.
3. Install rocker cover. Check if rocker cover gasket is not dropped from the installation groove of rocker cover.
4. Tighten bolts in two steps separately in numerical order as shown in the figure. 1st step : 1.96 N.m (0.2 kg-m, 17 in-lb) 2nd step : 8.33 N.m (0.85 kg-m, 74 in-lb)
5. Install in the reverse order of removal after this step.

Scheme 37

Refer to REMOVAL AND INSTALLATION .

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 leaks 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 leaks at connection points. CAUTION: Never touch the engine immediately after stopped, as the engine becomes extremely hot.

Scheme 38

Refer to REMOVAL AND INSTALLATION .

Camshaft Runout

Scheme 39

1. Put V-block on a precise flat table, and support No. 2 and 5 journal of camshaft. CAUTION: Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations.
2. Set dial indicator (A) vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the camshaft runout on dial indicator. (Total indicator reading) Standard: Refer to " «CAMSHAFT»(ref-295108-S07920080392008081400000) ".
4. If out of the standard, replace camshaft.

Camshaft Cam Height

Scheme 40

1. Measure the camshaft cam height with a micrometer (A). Standard and Limit: Refer to " «CAMSHAFT»(ref-295108-S07920080392008081400000) ".
2. If it exceeds the limit, replace camshaft.

Camshaft Journal Oil Clearance

Inspection of Camshaft Sprocket (INT) Oil Groove

Scheme 41

1. Check engine oil level. Refer to " «INSPECTION»(ref-295124-S27437280252008081400000) ".
2. Perform the following procedure so as to prevent the engine from being unintentionally started while checking. Release the fuel pressure. Refer to " «INSPECTION»(ref-295105-S04323263622008081400000) ". Disconnect ignition coil and injector harness connectors. Refer to " «EXPLODED VIEW»(ref-295108-S01690322732008081400000) ".
3. Remove intake valve timing control solenoid valve. Refer to " «EXPLODED VIEW»(ref-295108-S13605773992008081400000) ".
4. Crank engine, and then check that engine oil comes out from intake valve timing control solenoid valve hole. End crank after checking. WARNING: Be careful not to touch rotating parts. (drive belts, idler pulley, and crankshaft pulley, etc.) CAUTION: Prevent splashing by using a shop cloth so as to prevent the worker from injury from engine oil and so as to prevent engine oil contamination. Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to engine and vehicle. Especially, be careful no to apply engine oil to rubber parts of drive belts, engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed. Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to " «ENGINE LUBRICATION SYSTEM»(ref-295124-S01331222762008081400000) ".
5. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT), and then check each oil groove for clogging. Clean oil groove if necessary. Refer to " «ENGINE LUBRICATION SYSTEM»(ref-295124-S01331222762008081400000) ".
6. After inspection, install removed parts in the reverse order.

Scheme 42

Scheme 43

1. Remove camshafts. Refer to " «EXPLODED VIEW»(ref-295108-S04945981832008081400000) ".
2. Remove valve lifters. Refer to " «EXPLODED VIEW»(ref-295108-S04945981832008081400000) ".
3. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve from dropping into cylinder. CAUTION: When rotating crankshaft, be careful to avoid scarring front cover with timing chain.
4. Remove valve collet. Compress valve spring with valve spring compressor, attachment and adapter [SST: KV10116200 (J26336-A)] (A). Remove valve collet with a magnet hand. CAUTION: When working, be careful not to damage valve lifter holes.
5. Remove valve spring retainer and valve spring. CAUTION: Never remove valve spring seat from valve spring.
6. Remove valve oil seal with a valve oil seal puller (SST).

Scheme 44

1. Apply new engine oil to valve oil seal joint surface and seal lip.
2. Press in valve oil seal to the height "H" shown in the figure with a valve oil seal drift (SST).
3. Install in the reverse order of removal after this step.

Scheme 45

1. Remove the following parts. Under cover Front fender protector: Refer to " «EXPLODED VIEW»(ref-295102-S41180941832008081400000) ". Drive belt: Refer to " «REMOVAL AND INSTALLATION»(ref-295108-S15202389272008081400000) ". Crankshaft pulley: Refer to " «EXPLODED VIEW»(ref-295108-S13605773992008081400000) ".
2. Remove front oil seal with a suitable tool. CAUTION: Be careful not to damage front cover and crankshaft.

Scheme 46

Scheme 47

1. Apply new engine oil to new front oil seal joint surface and seal lip.
2. Install front oil seal so that each seal lip is oriented as shown in the figure. Dust seal lip Oil seal lip Press-fit front oil seal until it is flush with front end surface of front cover using a suitable drift with outer diameter 56 mm (2.20 in) and inner diameter 48 mm (1.89 in). CAUTION: Be careful not to damage front cover and crankshaft. Press-fit oil seal straight to avoid causing burrs or tilting.
3. Install in the reverse order of removal after this step.

Inspection for Leaks

The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.

1. Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to " «FOR NORTH AMERICA : FLUIDS AND LUBRICANTS»(ref-295130-S34661417002008081400000) " (Except for Mexico) or " «FOR MEXICO : FLUIDS AND LUBRICANTS»(ref-295130-S06898715472008081400000) " (for Mexico).
2. Use procedure below to check for fuel leakage. Turn ignition switch "ON" (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. Start engine. With engine speed increased, check again for fuel leakage at connection points.
3. Run engine to check for unusual noise and vibration.
4. Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant.
5. Bleed air from lines and hoses of applicable lines, such as in cooling system.
6. After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.

Summary of the inspection items

INSPECTION CHART

Timing Chain

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

Scheme 48

Balancer Unit Mounting Bolt Outer Diameter

Scheme 49

1. Measure the outer diameters ("d1", "d2") at two positions as shown in the figure.
2. If reduction appears in "A" range, regard it as "d2". Limit ("d1"-"d2") : 0.15 mm (0.0059 in)
3. If it exceeds the limit (large difference in dimensions), replace it with a new one.

Inspection for Leaks

The following are procedures for checking fluids leak, lubricates leak.

1. Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to " «FOR NORTH AMERICA : FLUIDS AND LUBRICANTS»(ref-295130-S34661417002008081400000) " (Except for Mexico) or " «FOR MEXICO : FLUIDS AND LUBRICANTS»(ref-295130-S06898715472008081400000) " (for Mexico).
2. Use procedure below to check for fuel leakage. Turn ignition switch "ON" (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. Start engine. With engine speed increased, check again for fuel leakage at connection points.
3. Run engine to check for unusual noise and vibration.
4. Warm up engine thoroughly to check there is no leakage of fuel, or any oil/fluids including engine oil and engine coolant.
5. Bleed air from lines and hoses of applicable lines, such as in cooling system.
6. After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.

Summary of the inspection items

INSPECTION CHART

Scheme 50

Refer to REMOVAL AND INSTALLATION .

Scheme 51

Scheme 52

1. Release fuel pressure. Refer to " «INSPECTION»(ref-295105-S04323263622008081400000) ".
2. Drain engine coolant and engine oil. Refer to " «DRAINING»(ref-295111-S26518184832008081400000) " and " «DRAINING»(ref-295124-S40915947592008081400000) ".
3. Remove the following components and related parts. Exhaust manifold and three way catalyst assembly: Refer to " «REMOVAL AND INSTALLATION»(ref-295108-S05377374502008081400000) ". Intake manifold and fuel tube assembly: Refer to " «REMOVAL AND INSTALLATION»(ref-295108-S11821435882008081400000) " and " «EXPLODED VIEW»(ref-295108-S39536330872008081400000) ". Water control valve and water control valve housing (water outlet): Refer to " «EXPLODED VIEW»(ref-295111-S04326926112008081400000) ". NOTE: Can be removed and installed even when assembled with cylinder head.
4. Remove front cover and timing chain. Refer to " «EXPLODED VIEW»(ref-295108-S13605773992008081400000) ".
5. Remove camshafts. Refer to " «REMOVAL AND INSTALLATION»(ref-295108-S07532025862008081400000) ".
6. Securely support bottom of cylinder block with a jack or equivalent tool, and release the hoist that was supporting it.
7. Remove cylinder head loosening bolts in reverse order as shown in the figure. Using TORX socket (size E20), loosen cylinder head bolts.
8. Remove cylinder head gasket.

Scheme 53

1. Install cylinder head gasket.
2. Tighten cylinder head bolts in numerical order as shown in figure with the following procedure, and install cylinder head. CAUTION: If cylinder head bolts are reused, check their outer diameters before installation. Refer to " «INSPECTION»(ref-295108-S35237803992008081400000) ". Apply new engine oil to threads and seating surface of mounting bolts. Tighten all bolts. : 50.0 N.m (5.1 kg-m, 37 ft-lb) Turn all bolts 60 degrees clockwise (angle tightening). Completely loosen. : 0 N.m (0 kg-m, 0 ft-lb) CAUTION: In this step, loosen bolts in reverse order of that indicated in the figure. Tighten all bolts. : 39.2 N.m (4.0 kg-m, 29 ft-lb) Turn all bolts 75 degrees clockwise (angle tightening). Turn all bolts 75 degrees clockwise again (angle tightening). CAUTION: Check and confirm the tightening angle by using an angle wrench (SST) or protractor. Avoid judgment by visual inspection without the tool.
3. Install in the reverse order of removal after this step.

Scheme 54

Scheme 55

Scheme 56

1. Remove spark plug with spark plug wrench (commercial service tool).
2. Remove spark plug tube, if necessary. Using pliers, remove it from cylinder head. CAUTION: Be careful not to damage cylinder head. Never remove spark plug tube if not necessary. Once removed, spark plug tube cannot be reused because of deformation.
3. Remove valve lifter. Identify installation positions, and store them without mixing them up.
4. Remove valve collet. Compress valve spring with valve spring compressor, attachment and adapter [SST: KV10116200 (J26336-A)] (A). Remove valve collet with a magnet hand (B). CAUTION: When working, be careful not to damage valve lifter holes.
5. Remove valve spring retainer and valve spring (with valve spring seat). CAUTION: Never remove valve spring seat from valve spring.
6. Push valve stem to combustion chamber side, and remove valve. Identify installation positions, and store them without mixing them up.
7. Remove valve oil seal with a valve oil seal puller (SST).
8. Remove valve seat, if valve seat must be replaced. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess in cylinder head. Set the machine depth stop to ensure this. Refer to " «CYLINDER HEAD»(ref-295108-S29025287422008081400000) ". CAUTION: Prevent to scratch cylinder head by excessive boring.
9. Remove valve guide, if valve guide must be replaced. To remove valve guide, heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil (A). Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US ton, 2.0 lmp ton) pressure] or hammer and suitable tool. CAUTION: Cylinder head contains heat, when working, wear protective equipment to avoid getting burned.

Scheme 57

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Scheme 62

Scheme 63

1. Install valve guide if removed. CAUTION: Replace with oversize [0.2 mm (0.008 in)] valve guide. Ream cylinder head valve guide hole with a valve guide reamer (commercial service tool) (A). For service parts : Oversize [0.2 mm (0.008 in)] Refer to " «CYLINDER HEAD»(ref-295108-S29025287422008081400000) ". Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil (A). Press valve guide from camshaft side to dimensions as shown in the figure. Projection "H" : Refer to " «CYLINDER HEAD»(ref-295108-S29025287422008081400000) ". CAUTION: Cylinder head contains heat, when working, wear protective equipment to avoid getting burned. Apply reamer finish to valve guide with a valve guide reamer (commercial service tool) (A). Standard : Refer to " «CYLINDER HEAD»(ref-295108-S29025287422008081400000) ".
2. Install valve seat if removed. CAUTION: Replace with oversize [0.5 mm (0.020 in)] valve seat. Ream cylinder head (1) recess diameter for service valve seat. 2 : Valve seat For service parts : Oversize [0.5 mm (0.020 in)] Refer to " «CYLINDER HEAD»(ref-295108-S29025287422008081400000) ". Be sure to ream in circles concentric to the valve guide center. This will enable valve seat to fit correctly. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil (A). Provide valve seats cooled well with dry ice. Press-fit valve seat into cylinder head. CAUTION: Avoid directly to touching cold valve seats. Cylinder head contains heat, when working, wear protective equipment to avoid getting burned. Using valve seat cutter set (commercial service tool) or valve seat grinder, finish valve seat to the specified dimensions. For dimensions, refer to " «CYLINDER HEAD»(ref-295108-S29025287422008081400000) ". CAUTION: When using valve seat cutter, firmly grip the cutter handle with both hands. Then, press on the contacting surface all around the circumference to cut in a single drive. Improper pressure on with the cutter or cutting many different times may result in stage valve seat. Using compound, grind to adjust valve fitting. Check again for normal contact. Refer to " «INSPECTION»(ref-295108-S35237803992008081400000) ".
3. Install valve oil seal. Install with a valve oil seal drift (SST) to match dimension in the figure. NOTE: Dimension "H" is height that measured before installing valve spring (with valve spring seat). Height "H" : 11.8 - 12.4 mm (0.465 - 0.488 in)
4. Install valve. Install larger diameter to intake side.
5. Install valve spring (with valve spring seat). Install smaller pitch (valve spring seat side) to cylinder head side. Confirm identification color of valve spring. Intake : Pink Exhaust : Yellowish green
6. Install valve spring retainer.
7. Install valve collet. Compress valve spring with a valve spring compressor, attachment and adapter [SST: KV10116200 (J26336-A)] (A). Install valve collet with a magnet hand (B). CAUTION: When working, be careful not to damage valve lifter holes. Tap valve stem edge lightly with a plastic hammer after installation to check its installed condition.
8. Install valve lifter. Install it in the original position.
9. Install spark plug tube if removed. Press-fit it into cylinder head with the following procedure: Remove old thread locking sealant from cylinder head side installation hole. Apply thread locking sealant all round on spark plug tube within approximately 12 mm (0.47 in) width from edge of spark plug tube on the press-fit side. Use Genuine RTV Silicone Sealant or equivalent Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-295085-S25948978912008081400000) ". Using a drift, press-fit spark plug tube so that height is as same as "H" shown in figure. Standard press-fit height "H": 41.2 - 42.2 mm (1.622 - 1.661 in) CAUTION: When press-fitting, be careful not to deform spark plug tube. After press-fitting, wipe off any protruding thread locking sealant on top surface of cylinder head.
10. Install spark plug with spark plug wrench (commercial service tool).

Cylinder Head Bolts Outer Diameter

Scheme 64

1. Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between "A" and "B" exceeds the limit, replace them with new one. Limit ("B"-"A") : 0.23 mm (0.0091 in)
2. If reduction of outer diameter appears in a position other than "d2", use it as "d2" point.

Cylinder Head Distortion

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

Scheme 65

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. Limit : Refer to " «CYLINDER HEAD»(ref-295108-S29025287422008081400000) ". If it exceeds the limit, replace cylinder head.

Inspection for Leaks

The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.

1. Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to " «FOR NORTH AMERICA : FLUIDS AND LUBRICANTS»(ref-295130-S34661417002008081400000) " (Except for Mexico) or " «FOR MEXICO : FLUIDS AND LUBRICANTS»(ref-295130-S06898715472008081400000) " (for Mexico).
2. Use procedure below to check for fuel leakage. Turn ignition switch "ON" (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. Start engine. With engine speed increased, check again for fuel leakage at connection points.
3. Run engine to check for unusual noise and vibration.
4. Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant.
5. Bleed air from lines and hoses of applicable lines, such as in cooling system.
6. After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.

Summary of the inspection items

INSPECTION CHART

Scheme 66

Refer to DISASSEMBLY AND ASSEMBLY .

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

1. Remove cylinder head. Refer to " «EXPLODED VIEW»(ref-295108-S25944583362008081400000) ".
2. Remove knock sensor. CAUTION: Carefully handle knock sensor avoiding shocks.
3. Remove crankshaft position sensor (POS). CAUTION: Avoid impacts such as a dropping. Never disassemble. Keep it away from metal particles. Never place sensor in a location where it is exposed to magnetism.
4. Remove piston and connecting rod assembly with the following procedure: Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to " «INSPECTION»(ref-295108-S28407779032008081400000) ". Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center. Remove connecting rod cap. Using a hammer handle or similar tool, push piston and connecting rod assembly out to the cylinder head side. CAUTION: Be careful not to damage the cylinder wall, resulting from an interference of the connecting rod big end.
5. Remove connecting rod bearings. CAUTION: When removing them, note the installation position. Keep them in the correct order.
6. Remove piston rings form piston. Use a piston ring expander (commercial service tool) (A). CAUTION: When removing piston rings, be careful not to damage the piston. Be careful not to damage piston rings by expanding them excessively.
7. Remove piston from connecting rod with the following procedure: Using snap ring pliers (A), remove snap ring. Heat piston to 60 to 70°C (140 to 158°F) with an industrial use drier (A) or equivalent. Push out piston pin with stick of outer diameter approximately 19 mm (0.75 in).
8. Remove lower cylinder block mounting bolts. Loosen them in reverse order as shown in the figure, and remove them. Use TORX socket (size E14) for bolts No. 1 to 10. Before loosening lower cylinder block mounting bolts, measure crankshaft end play. Refer to " «INSPECTION»(ref-295108-S28407779032008081400000) ".
9. Remove lower cylinder block. Use a seal cutter [SST: KV10111100 (J37228)] or equivalent tool to cut liquid gasket for removal. CAUTION: Be careful not to damage the mounting surface.
10. Remove crankshaft. CAUTION: Be careful not damage or deform signal plate mounted on crankshaft. When setting crankshaft on a flat floor surface, use a block of wood to avoid interference between signal plate and the floor surface. Never remove signal plate unless it is necessary to do so. NOTE: When removing or installing signal plate, use TORX socket (size T30).
11. Pull rear oil seal out from rear end of crankshaft. NOTE: When replacing rear oil seal without removing lower cylinder block, use a screwdriver to pull it out from between crankshaft and cylinder block. CAUTION: Be careful not to damage crankshaft and cylinder block.
12. Remove main bearings and thrust bearings from cylinder block and lower cylinder block. CAUTION: Identify installation positions, and store them without mixing them up.

Scheme 75

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Scheme 89

1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to remove any foreign material. CAUTION: Use a goggle to protect your eye.
2. Install each plug to cylinder block as shown in the figure. Apply liquid gasket to the thread of water drain plug "A". Use Genuine RTV Silicone Sealant or equivalent Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-295085-S25948978912008081400000) ". NOTE: Do not apply liquid gasket to the thread of plug "B". Tighten each plug as specified below. TIGHTENING TORQUE SPECIFICATIONS Part Washer Tightening torque A No 9.8 N.m (1.0 kg-m, 87 in-lb) B Yes 53.9 N.m (5.5 kg-m, 40 ft-lb)
3. Install oil jet. Insert oil jet dowel pin (A) into cylinder block dowel pin hole, and tighten mounting bolts.
4. Install main bearings and thrust bearings with the following procedure: Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block and lower cylinder block. Install thrust bearings to the both sides of the No. 3 journal housing on cylinder block. Install thrust bearings with the oil groove facing crankshaft arm (outside). Install the main bearings paying attention to the direction. Main bearing with an oil hole and groove goes on cylinder block. The one without them goes on lower cylinder block. Only main bearing (on cylinder block) for No. 3 journal has different specifications. Before installing main bearings, apply new engine oil to the bearing surface (inside). Do not apply new engine oil to the back surface, but thoroughly clean it. When installing, align main bearing stopper to the notch. Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.
5. Install signal plate to crankshaft if removed. Position crankshaft and signal plate using a dowel pin, and tighten mounting bolts. Remove dowel pin. CAUTION: Be sure to remove dowel pin. NOTE: Dowel pin of crankshaft and signal plate is provided as a set for each. If dowel pin is not available (when reusing crankshaft and signal), use M6 bolt [length 10 mm (0.39 in) or more] as a substitute.
6. Install crankshaft to cylinder block. While turning crankshaft by hand, check that it turns smoothly.
7. Install lower cylinder block with the following procedure: Apply liquid gasket with a tube presser (commercial service tool) to lower cylinder block as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-295085-S25948978912008081400000) ". CAUTION: After liquid gasket is applied, rear oil seal installation must be finished within 5 minutes. Therefore, the following procedure must be performed quickly. NOTE: Lower cylinder block cannot be replaced as a single part, because it is machined together with cylinder block. Tighten lower cylinder block mounting bolts with the following procedure: Apply new engine oil to threads and seat surfaces of mounting bolts. Tighten M8 bolts in numerical order from No. 11 to 22 in the figure. : 25.1 N.m (2.6 kg-m, 19 ft-lb) NOTE: There are more processes to complete the tightening of mounting bolts. However stop procedure here to install rear oil seal. Install rear oil seal. Refer to " «REAR OIL SEAL : Removal and Installation»(ref-295108-S18118903172008081400000) ". Restart tightening of lower cylinder block mounting bolts with the following procedure: Tighten M10 bolts in numerical order from No. 1 to 10. : 39.2 N.m (4.0 kg-m, 29 ft-lb) Turn M10 bolts 60 degrees clockwise (angle tightening) in order from No. 1 to 10 in the figure. CAUTION: Check and confirm the tightening angle by using an angle wrench [SST: KV10112100 (BT8653-A)] (A) or protractor. Avoid judgment by visual inspection without the tool. After installing mounting bolts, check that crankshaft can be rotated smoothly by hand. Wipe off completely any protruding liquid gasket on front side of engine. Check crankshaft end play. Refer to " «INSPECTION»(ref-295108-S28407779032008081400000) ".
8. Install piston to connecting rod with the following procedure: Using snap ring pliers, install new snap ring to the groove of the piston rear side. Insert it fully into groove to install. Assemble piston to connecting rod. Using an industrial use drier or similar tool, heat the piston until the piston pin can be pushed in by hand without excess force [approx. 60 to 70°C (140 to 158°F)]. From the front to the rear, insert piston pin into piston and connecting rod. Assemble so that the front mark on the piston head and the oil holes and the cylinder number on connecting rod are positioned as shown in the figure. Install new snap ring to the groove of the piston front side. Insert it fully into groove to install. After installing, check that connecting rod moves smoothly.
9. Using a piston ring expander (commercial service tool), install piston rings. CAUTION: Be careful not to damage piston. Position each ring with the gap as shown in the figure referring to the piston front mark. Install second ring with the stamped surface facing upward. Stamped mark: Top ring : - Second ring : 2 K NOTE: If there is no stamped mark on piston ring, no specific orientation is required for installation.
10. Install connecting rod bearings to connecting rod and connecting rod cap. When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Do not apply new engine oil to the back surface, but thoroughly clean it. When installing, align the connecting rod bearing stopper protrusion with the cutout of connecting rod and connecting rod cap to install. Ensure the oil hole on connecting rod and that on the corresponding bearing are aligned.
11. Install piston and connecting rod assembly to crankshaft. Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center. Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin. Match the cylinder position with the cylinder number on connecting rod to install. Using a piston ring compressor [SST: EM03470000 (J-8037)] (A) or suitable tool, install piston with the front mark on the piston head facing the front of the engine. CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
12. Install connecting rod cap. Match the stamped cylinder number marks on connecting rod with those on connecting rod cap to install.
13. Tighten connecting rod bolt with the following procedure: Apply new engine oil to the threads and seats of connecting rod bolts. Tighten bolts. : 27.4 N.m (2.8 kg-m, 20 ft-lb) Completely loosen bolts. : 0 N.m (0 kg-m, 0 ft-lb) Tighten bolts. : 19.6 N.m (2.0 kg-m, 14 ft-lb) Then turn all bolts 90 degrees clockwise (Angle tightening). CAUTION: Check and confirm the tightening angle by using an angle wrench [SST: KV10112100 (BT8653-A)] (A) or protractor. Avoid judgment by visual inspection without the tool. After tightening connecting rod bolt, check that crankshaft rotates smoothly. Check the connecting rod side clearance. Refer to " «INSPECTION»(ref-295108-S28407779032008081400000) ".
14. Install drive plate. CAUTION: Check that dowel pin is installed at the rear end of crankshaft. When installing drive plate to crankshaft, check that align crankshaft side dowel pin with drive plate side dowel pin hole correctly. CAUTION: If these are not aligned correctly, engine runs roughly and "MIL" turns on. Secure crankshaft with a stopper plate, and tighten mounting bolts crosswise over several times. Install drive plate (1), reinforcement plate (2) and pilot converter (3) as shown in figure. Using a drift of 33 mm (1.30 in) in diameter, press-fit pilot converter into the end of crankshaft until it stops.
15. Install knock sensor. Install knock sensor with harness connector facing lower left as shown in the figure. CAUTION: Never tighten mounting bolts while holding the harness connector. If any impact by dropping is applied to knock sensor, replace it with a new one. NOTE: Check that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor. Check that knock sensor does not interfere with other parts.
16. Install crankshaft position sensor (POS).
17. Assemble in the reverse order of disassembly after this step.

Scheme 90

1. Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with a dial indicator (A). Standard and Limit : Refer to " «CYLINDER BLOCK»(ref-295108-S10211579842008081400000) ".
2. If the measured value exceeds the limit, replace thrust bearings, and measure again. If it still exceeds the limit, replace crankshaft also.

Scheme 91

1. Measure the side clearance between connecting rod and crankshaft arm with a feeler gauge (A). Standard and Limit : Refer to " «CYLINDER BLOCK»(ref-295108-S10211579842008081400000) ".
2. If the measured value exceeds the limit, replace connecting rod, and measure again. If it still exceeds the limit, replace crankshaft also.