Engine Mechanical: Other Nissan Rogue I

FOR USA AND CANADA : 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.

Scheme 144

FOR USA AND CANADA : Precaution Necessary for Steering Wheel Rotation After Battery Disconnect

Note. This Procedure is applied only to models with Intelligent Key system and NVIS/IVIS (NISSAN/INFINITI VEHICLE IMMOBILIZER SYSTEM - NATS). Remove and install all control units after disconnecting both battery cables with the ignition knob in the "LOCK" position. Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work.

If DTC is detected, perform trouble diagnosis according to self-diagnostic results.

For models equipped with the Intelligent Key system and NVIS/IVIS, an electrically controlled steering lock mechanism is adopted on the key cylinder.

For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and steering wheel rotation will become impossible.

If steering wheel rotation is required when battery power is interrupted, follow the procedure below before starting the repair operation.

FOR USA AND CANADA : Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"

The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.

Information necessary to service the system safely is included in the SRS AIRBAG and SEAT BELTS articles.

FOR USA AND CANADA : 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.

FOR MEXICO : 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.

FOR MEXICO : Precaution Necessary for Steering Wheel Rotation After Battery Disconnect

Note. This Procedure is applied only to models with Intelligent Key system and NVIS/IVIS (NISSAN/INFINITI VEHICLE IMMOBILIZER SYSTEM - NATS). Remove and install all control units after disconnecting both battery cables with the ignition knob in the "LOCK" position. Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work.

If DTC is detected, perform trouble diagnosis according to self-diagnostic results.

For models equipped with the Intelligent Key system and NVIS/IVIS, an electrically controlled steering lock mechanism is adopted on the key cylinder.

For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and steering wheel rotation will become impossible.

If steering wheel rotation is required when battery power is interrupted, follow the procedure below before starting the repair operation.

FOR MEXICO : 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.

FOR MEXICO : 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 Tools

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

SPECIAL SERVICE TOOLS SPECIFICATION Tool number (Kent-Moore No.) Tool name Description KV10111100 (J37228) Seal cutter Removing oil pan and timing chain case KV10116200 (J26336-A) Valve spring compressor KV10115900 (J26336-20) Attachment KV10109220 ( - ) Adapter Disassembling and assembling valve mechanism Part (1) is a component of KV10116200 (J26336-A), but Part (2) is not so. KV10112100 (BT8653-A) Angle wrench Tightening bolts for bearing cap, cylinder head, etc. KV10117100 (J3647-A) Heated oxygen sensor wrench Loosening or tightening air fuel ratio sensor and heated oxygen sensor with 22 mm (0.87 in) hexagon nut KV10107902 (J38959) Valve oil seal puller KV10116100 Valve oil seal puller adapter Removing valve oil seal KV10115600 (J38958) Valve oil seal drift Installing valve oil seal Use side A. 20 (0.79) dia. 13 (0.51) dia. 10.3 (0.406) dia. 8 (0.31) dia. 10.7 (0.421) dia. 5 (0.20) dia. Unit: mm (in) EM03470000 (J8037) Piston ring compressor Installing piston assembly into cylinder bore ST16610001 (J-23907) Pilot bushing puller Removing pilot converter - (J-45488) Quick connector release Removing fuel tube quick connectors in engine room

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Commercial Service Tools

COMMERCIAL SERVICE TOOLS SPECIFICATION (Kent-Moore No.) Tool name Description ( - ) Spark plug wrench Removing and installing spark plug ( - ) Pulley holder Crankshaft pulley removing and installing ( - ) Pulley puller Removing 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 & 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 & 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.) a : J-43897-18 [18 mm (0.71 in) dia.] a : J-43897-12 [12 mm (0.47 in) dia.] ( - ) Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907) Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads ( - ) Manual lift table caddy Removing and installing engine ( - ) Tube presser Pressing the tube of liquid gasket

Scheme 151

Scheme 152

Scheme 153

Scheme 154

Scheme 155

Checking

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

INSTALLAITON

Installation is the reverse order of removal.

EXHAUST MANIFOLD

1. If stud bolts were removed, install them and tighten to the specified torque below. : 14.7 N.m (1.5 kg-m, 11 ft-lb)
2. Tighten nuts in numerical order as shown in the figure. NOTE: No. 6 to 10 mean double tightening of bolts No. 1 and 5.

HEATED OXYGEN SENSOR

CAMSHAFT JOURNAL DIAMETER

Measure the outer diameter of camshaft journal with a micrometer (A).

Standard: Refer to " CAMSHAFT ".

Scheme 156

Scheme 157

1. Tighten camshaft bracket bolts with specified torque. Refer to " «REMOVAL AND INSTALLATION»(ref-295108-S07532025862008081400000) ".
2. Measure the inner diameter of camshaft bracket with an inside micrometer. Standard: Refer to " «CAMSHAFT»(ref-295108-S07920080392008081400000) ".

CAMSHAFT JOURNAL OIL CLEARANCE

1. (Oil clearance) = (Camshaft bracket inner diameter) - (Camshaft journal diameter) Standard: Refer to " «CAMSHAFT»(ref-295108-S07920080392008081400000) ".
2. If out of the standard, replace either or both camshaft and cylinder head. NOTE: Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head. Replace whole cylinder head assembly.

Camshaft End Play

Scheme 158

Scheme 159

1. Install camshaft in cylinder head. Refer to " «REMOVAL AND INSTALLATION»(ref-295108-S07532025862008081400000) ".
2. Install dial indicator in thrust direction on front end of camshaft. Read the end play of dial indicator when camshaft is moved forward/backward (in direction to axis). Standard: Refer to " «CAMSHAFT»(ref-295108-S07920080392008081400000) ". Measure the following parts if out of the standard. Dimension "A" for camshaft No. 1 journal Standard : 25.800 - 25.848 mm (1.0157 - 1.0176 in) Dimension "B" for cylinder head No. 1 journal Standard : 25.660 - 25.685 mm (1.0102 - 1.0112 in) Refer to the standards above, and then replace camshaft and/or cylinder head.

Camshaft Sprocket Runout

Scheme 160

1. Put V-block on precise flat table, and support No. 2 and 5 journals 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. Measure the camshaft sprocket runout with a dial indicator. (Total indicator reading) Limit: Refer to " «CAMSHAFT»(ref-295108-S07920080392008081400000) ". If it exceeds the limit, replace camshaft sprocket.

Valve Lifter

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

Scheme 161

1. If anything above is found, replace valve lifter. Refer to " «CAMSHAFT»(ref-295108-S07920080392008081400000) ".

Valve Lifter Clearance

Scheme 162

1. Measure the outer diameter of valve lifter with a micrometer (A). Standard: Refer to " «CAMSHAFT»(ref-295108-S07920080392008081400000) ".

VALVE LIFTER HOLE DIAMETER

Measure the diameter of valve lifter hole of cylinder head with an inside micrometer.

Standard: Refer to " CAMSHAFT ".

Scheme 163

1. (Valve lifter clearance) = (Valve lifter hole diameter) - (Valve lifter outer diameter) Standard: Refer to " «CAMSHAFT»(ref-295108-S07920080392008081400000) ".
2. If out of the standard, referring to the each standard of valve lifter outer diameter and valve lifter hole diameter, replace either or both valve lifter and cylinder head.

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 164

Scheme 165

Scheme 166

Scheme 167

1. Remove the engine and the transaxle assembly from the vehicle, and separate the transaxle from the engine. Refer to " «EXPLODED VIEW»(ref-295108-S31450719252008081400000) ".
2. Install engine to engine stand with the following procedure: Remove drive plate. Secure drive plate with a stopper plate and use a suitable tool to remove mounting bolts. Drive plate : size E20 CAUTION: Never disassemble them. Never place them with signal plate facing down. When handling signal plate, take care not to damage or scratch them. Handle signal plate in a manner that prevents them from becoming magnetized. NOTE: The flywheel, two block construction, allows movement in response to transaxle side pressure, or when twisted in its rotation direction. Therefore, some amount of noise is normal. Remove pilot converter using pilot bushing puller (SST) or suitable tool. Lift the engine with a hoist to install it onto widely use engine stand. CAUTION: Use the engine stand that has a load capacity [approximately 135 kg (298 lb) or more] large enough for supporting the engine weight. If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the potential risk of overturning stand. Intake manifold: Refer to " «EXPLODED VIEW»(ref-295108-S01708762182008081400000) ". Exhaust manifold: Refer to " «EXPLODED VIEW»(ref-295108-S30530530062008081400000) ". Rocker cover: Refer to " «EXPLODED VIEW»(ref-295108-S01690322732008081400000) ". NOTE: The figure shows an example of widely used engine stand (A) that can support 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.
3. Drain engine oil. Refer to " «DRAINING»(ref-295124-S40915947592008081400000) ". CAUTION: Be sure to clean drain plug and install with new washer.
4. Drain engine coolant by removing water drain plug from inside of the engine. Tightening torque : Refer to " «EXPLODED VIEW»(ref-295108-S07286710592008081400000) ".

VALVE DIMENSIONS

1. Check dimensions of each valve. For dimensions, refer to " «CYLINDER HEAD»(ref-295108-S29025287422008081400000) ".
2. If dimensions are out of the standard, replace valve.

VALVE GUIDE CLEARANCE

Valve Stem Diameter

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

Standard : Refer to " CYLINDER HEAD ".

Scheme 168

Valve Guide Inner Diameter

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

Standard : Refer to " CYLINDER HEAD ".

Valve Guide Clearance

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

Standard and Limit : Refer to " CYLINDER HEAD ".

1. If it exceeds the limit, replace valve guide and/or valve. When valve guide must be replaced. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-295108-S19457963662008081400000) ".

Scheme 169

1. After confirming that the dimensions of valve guides and valves are within 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 even after the re-check, replace valve seat. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-295108-S19457963662008081400000) ".

Scheme 170

1. Set try square (A) along the side of valve spring and rotate the spring. Measure the maximum clearance between the top of valve spring and try square. CAUTION: Never remove valve spring seat from valve spring. Limit : Refer to " «CYLINDER HEAD»(ref-295108-S29025287422008081400000) ".
2. If it exceeds the limit, replace valve spring (with valve spring seat).

Scheme 171

1. Check valve spring pressure with valve spring seat installed at the specified spring height. CAUTION: Never remove valve spring seat from valve spring. Standard : Refer to " «CYLINDER HEAD»(ref-295108-S29025287422008081400000) ".
2. If the installation load or load with valve open is out of the standard, replace valve spring (with valve spring seat).

PISTON TO PISTON PIN OIL CLEARANCE

Piston Pin Hole Diameter

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

Standard : Refer to " CYLINDER BLOCK ".

Scheme 172

Piston Pin Outer Diameter

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

Standard : Refer to " CYLINDER BLOCK ".

Scheme 173

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 oil clearance is out of the standard, replace piston and piston pin assembly.
2. When replacing piston and piston pin assembly, refer to " «DESCRIPTION»(ref-295108-S21400135482008081400000) ". 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 grades can be selected. (Only grade "0" is available.)

Scheme 174

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

Scheme 175

1. Check that cylinder bore inner diameter is within specification. Refer to " «CYLINDER BORE INNER DIAMETER»(ref-295108-S13184525792008081400000) ".
2. Lubricate with new engine oil to piston (1) and piston ring (2), and then insert (A) piston ring until middle of cylinder (B) with piston, and measure piston ring end gap with a feeler gauge (C). Standard and Limit : Refer to " «CYLINDER BLOCK»(ref-295108-S10211579842008081400000) ".
3. If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, re-bore cylinder and use oversized piston and piston rings.

Scheme 176

1. Check with a connecting rod aligner. Bend and Torsion : Refer to " «CYLINDER BLOCK»(ref-295108-S10211579842008081400000) ".
2. If it exceeds the limit, replace connecting rod assembly.

Scheme 177

1. Install connecting rod cap (1) without connecting rod bearing installed, and tightening connecting rod bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-295108-S03350969422008081400000) " for the tightening procedure. 2 : Connecting rod A : Example B : Measuring direction of inner diameter
2. Measure the inner diameter of connecting rod big end with an inside micrometer. Standard : Refer to " «CYLINDER BLOCK»(ref-295108-S10211579842008081400000) ".
3. If out of the standard, replace connecting rod assembly.

CONNECTING ROD BUSHING OIL CLEARANCE

Connecting Rod Bushing Inner Diameter

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

Standard : Refer to " CYLINDER BLOCK ".

Scheme 178

Piston Pin Outer Diameter

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

Standard : Refer to " CYLINDER BLOCK ".

Connecting Rod Bushing Oil Clearance

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

Standard : Refer to " CYLINDER BLOCK ".

1. If the measured value is out of the standard. Replace connecting rod assembly and/or piston and piston pin assembly.
2. If replacing piston and piston pin assembly. Refer to " «PISTON»(ref-295108-S40914781532008081400000) ".
3. If replacing connecting rod assembly. Refer to " «CONNECTING ROD BEARING»(ref-295108-S11578925562008081400000) " to select connecting rod bearing.

Scheme 179

1. Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or other contamination. CAUTION: Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.
2. Measure the distortion on the cylinder block upper face at some different points in six directions with a straight edge (A) and feeler gauge (B). Limit : Refer to " «CYLINDER BLOCK»(ref-295108-S10211579842008081400000) ".
3. If it exceeds the limit, replace cylinder block.

Scheme 180

1. Install lower cylinder block without main bearings installed, and tighten lower cylinder block mounting bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-295108-S03350969422008081400000) " for the tightening procedure.
2. Measure the inner diameter of main bearing housing with a bore gauge. Standard : Refer to " «CYLINDER BLOCK»(ref-295108-S10211579842008081400000) ".
3. If out of the standard, replace cylinder block (1) and lower cylinder block (2) assembly. NOTE: Cylinder block cannot be replaced as a single, because it is machined together with lower cylinder block.

Scheme 181

1. Using a bore gauge, measure the cylinder bore for wear, out-of-round and taper at six different points on each cylinder. ("X" and "Y" directions at "A", "B" and "C") ("Y" is in longitudinal direction of engine) NOTE: When determining cylinder bore grade, measure the cylinder bore at "B" position. Standard: Cylinder bore inner diameter : Refer to " «CYLINDER BLOCK»(ref-295108-S10211579842008081400000) ". Limit: Out-of-round (Difference between "X" and "Y") Taper (Difference between "A" and "B") : Refer to " «CYLINDER BLOCK»(ref-295108-S10211579842008081400000) ".
2. If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, hone or re-bore the cylinder inner wall.
3. Oversize piston is provided. When using oversize piston, re-bore the cylinder so that the clearance of the piston to cylinder bore satisfies the standard. CAUTION: When using oversize piston, use it 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).

Standard : Refer to " CYLINDER BLOCK ".

Scheme 182

Piston to Cylinder Bore Clearance

Calculate by piston skirt diameter and cylinder bore inner diameter (direction "X", position "B").

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

Standard and Limit : Refer to " CYLINDER BLOCK ".

1. If it exceeds the limit, replace piston and piston pin assembly. Refer to " «PISTON»(ref-295108-S40914781532008081400000) ".

Re-boring Cylinder Bore

1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter. Re-bored size calculation: D = A + B - C where, D: Bored diameter A: Piston diameter as measured B: Piston - to - cylinder bore clearance (standard value) C: Honing allowance 0.02 mm (0.0008 in)
2. Install lower cylinder block, and tighten mounting bolts to the specified torque. Otherwise, cylinder bores may be distorted in final assembly. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-295108-S03350969422008081400000) " for the tightening procedure.
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 specified piston to cylinder bore clearance.
5. Measure the finished cylinder bore for out-of-round and taper. NOTE: Measurement should be done after cylinder bore cools down.

Scheme 183

1. Measure the outer diameter of crankshaft main journals with a micrometer (A). Standard : Refer to " «CYLINDER BLOCK»(ref-295108-S10211579842008081400000) ".
2. If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to " «MAIN BEARING»(ref-295108-S16554934662008081400000) ".

CRANKSHAFT PIN JOURNAL DIAMETER

1. Measure the outer diameter of crankshaft pin journal with a micrometer. Standard : Refer to " «CYLINDER BLOCK»(ref-295108-S10211579842008081400000) ".
2. If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer to " «CONNECTING ROD BEARING»(ref-295108-S03938593222008081400000) ".

Scheme 184

1. Measure the dimensions at four different points as shown in the figure on each main journal and pin journal with a micrometer.
2. Out-of-round is indicated by the difference in dimensions between "X" and "Y" at "A" and "B".
3. Taper is indicated by the difference in dimension between "A" and "B" at "X" and "Y". Limit: Out-of-round (Difference between "X" and "Y") Taper (Difference between "A" and "B") : Refer to " «CYLINDER BLOCK»(ref-295108-S10211579842008081400000) ".
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 main bearing and/or connecting rod bearing. Refer to " «CONNECTING ROD BEARING»(ref-295108-S03938593222008081400000) " and/or " «MAIN BEARING»(ref-295108-S16554934662008081400000) ".

Scheme 185

1. Place a V-block on a precise flat table to support the journals on the both end of the crankshaft.
2. Place a dial indicator straight up on the No. 3 journal.
3. While rotating crankshaft, read the movement of the pointer on the dial indicator. (Total indicator reading) Limit : Refer to " «CYLINDER BLOCK»(ref-295108-S10211579842008081400000) ".
4. If it exceeds the limit, replace crankshaft.

CONNECTING ROD BEARING OIL CLEARANCE

Method by Calculation

Scheme 186

1. Install connecting rod bearings (2) to connecting rod (3) and cap, and tighten connecting rod bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-295108-S03350969422008081400000) " for tightening procedure.
2. Measure the inner diameter of connecting rod bearing with an inside micrometer. (Bearing oil clearance) = (Connecting rod bearing inner diameter) - (Crankshaft pin journal diameter) Standard and Limit : Refer to " «CYLINDER BLOCK»(ref-295108-S10211579842008081400000) ".
3. If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to " «CONNECTING ROD BEARING»(ref-295108-S11578925562008081400000) ".

Method of Using Plastigage

Scheme 187

1. Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.
2. Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
3. Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-295108-S03350969422008081400000) " for the tightening procedure. CAUTION: Never rotate crankshaft.
4. Remove connecting rod cap and bearing, 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".

MAIN BEARING OIL CLEARANCE

Method by Calculation

Scheme 188

1. Install main bearings (3) to cylinder block (1) and lower cylinder block (2), and tighten lower cylinder block mounting bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-295108-S03350969422008081400000) " for the tightening procedure.
2. Measure the inner diameter of main bearing with a bore gauge. (Bearing oil clearance) = (Main bearing inner diameter) - (Crankshaft main journal diameter) Standard and Limit : Refer to " «CYLINDER BLOCK»(ref-295108-S10211579842008081400000) ".
3. If clearance exceeds the limit, select proper main bearing according to main bearing inner diameter and crankshaft main journal diameter to obtain specified bearing oil clearance. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-295108-S03350969422008081400000) ".

Method of Using Plastigage

1. Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.
2. Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes.
3. Install main bearings to cylinder block and lower cylinder block, and tighten lower cylinder block mounting bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-295108-S03350969422008081400000) " for the tightening procedure. CAUTION: Never rotate crankshaft.
4. Remove lower cylinder block 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 189

1. When lower cylinder block is removed after being tightened to the specified torque with main bearings (1) installed, the tip end of bearing must protrude (B). Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-295108-S03350969422008081400000) " for the tightening procedure. Standard: There must be crush height.
2. If the standard is not met, replace main bearings.

CONNECTING ROD BEARING CRUSH HEIGHT

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 (B). Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-295108-S03350969422008081400000) " for the tightening procedure. Standard : There must be crush height.
2. If the standard is not met, replace connecting rod bearings.

Scheme 190

1. Perform only with M10 bolts.
2. Measure the outer diameters ("d1", "d2") at two positions as shown in the figure.
3. If reduction appears in "A" range, regard it as "d2". Limit ("d1"-"d2"): 0.13 mm (0.0051 in)
4. If it exceeds the limit (a large difference in dimensions), replace lower cylinder block mounting bolt with a new one.

Scheme 191

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

PISTON SELECTION TABLE

PISTON SELECTION

Note. There is no piston grade "1". Piston is available together with piston pin as an assembly. The piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no grades can be selected. (Only grade "0" is available.)

Scheme 192

1. Apply connecting rod big end diameter grade stamped on connecting rod side face to the row in the "Connecting Rod Bearing Selection Table".
2. Apply crankshaft pin journal diameter grade stamped on crankshaft front side to the column in the "Connecting Rod Bearing Selection Table".
3. Read the symbol at the cross point of selected row and column in the "Connecting Rod Bearing Selection Table".
4. Apply the symbol obtained to the "Connecting Rod Bearing Grade Table" to select connecting rod bearing.

WHEN CRANKSHAFT AND CONNECTING ROD ARE REUSED

1. Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter individually. Refer to " «INSPECTION»(ref-295108-S28407779032008081400000) ".
2. Apply the measured dimension to the "Connecting Rod Bearing Selection Table".
3. Read the symbol at the cross point of selected row and column in the "Connecting Rod Bearing Selection Table".
4. Apply the symbol obtained to the "Connecting Rod Bearing Grade Table" to select connecting rod bearing.

Scheme 193

UNDERSIZE BEARINGS USAGE GUIDE

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

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

Scheme 194

CONNECTING ROD BEARING GRADE TABLE

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

WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE USED

1. "Main Bearing Selection Table" rows correspond to main bearing housing grade on rear left side of cylinder block. If there is a corrected stamp mark on cylinder block, use it as a correct reference.
2. Apply main journal diameter grade stamped on crankshaft front side to column in the "Main Bearing Selection Table".
3. Read the symbol at the cross point of selected row and column in the "Main Bearing Selection Table". CAUTION: There are two main bearing selection tables. One is for odd-numbered journals (No. 1, 3 and 5) and the other is for even-numbered journals (No. 2 and 4). Make certain to use the appropriate table. This is due to differences in the specified clearances.
4. Apply the symbol obtained to the "Main Bearing Grade Table" to select main bearing. NOTE: Service part is available as a set of both upper and lower.

WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED

1. Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main journal diameter individually. Refer to " «INSPECTION»(ref-295108-S28407779032008081400000) ".
2. Apply the measured dimension to the "Main Bearing Selection Table".
3. Read the symbol at the cross point of selected row and column in the "Main Bearing Selection Table". CAUTION: There are two main bearing selection tables. One is for odd-numbered journals (No. 1, 3 and 5) and the other is for even-numbered journals (No. 2 and 4). Make certain to use the appropriate table. This is due to differences in the specified clearances.
4. Apply the symbol obtained to the "Main Bearing Grade Table" to select main bearing. NOTE: Service part is available as a set of both upper and lower.

Scheme 195

Scheme 196

MAIN BEARING GRADE TABLE (ALL JOURNALS)

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

USE UNDERSIZE BEARING USAGE GUIDE

1. When the specified main bearing oil clearance is not obtained with standard size main bearings, use undersize (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.

Bearing undersize table : Refer to " MAIN BEARING ".

DRIVE BELT

DRIVE BELT SPECIFICATION

SPARK PLUG

DRIVE BELT SPECIFICATIONS

INTAKE MANIFOLD

INTAKE MANIFOLD SPECIFICATIONS

EXHAUST MANIFOLD SPECIFICATIONS

CAMSHAFT

CAMSHAFT SPECIFICATIONS Unit: mm (in) Items Standard Limit Camshaft journal oil clearance 0.045 - 0.086 (0.0018 - 0.0034) - Camshaft bracket inner diameter No. 1 28.000 - 28.021 (1.1024 - 1.1032) - No. 2, 3, 4, 5 23.500 - 23.521 (0.9252 - 0.9260) - Camshaft journal diameter No. 1 27.935 - 27.955 (1.0998 - 1.1006) - No. 2, 3, 4, 5 23.435 - 23.455 (0.9226 - 0.9234) - Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) - Camshaft cam height "A" Intake Except for California 44.815 - 45.005 (1.7644 - 1.7718) 0.2 (0.008) (1) For California 45.015 - 45.205 (1.7722 - 1.7797) Exhaust 43.975 - 44.165 (1.7313 - 1.7388) Camshaft runout [TIR (2) ] Less than 0.02 mm (0.0008) - Camshaft sprocket runout [TIR (2) ] - 0.15 (0.0059) (1) Cam wear limit (2) Total indicator reading

VALVE LIFTER

VALVE LIFTER SPECIFICATIONS

VALVE CLEARANCE

VALVE CLEARANCE SPECIFICATIONS

AVAILABLE VALVE LIFTER

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

CYLINDER HEAD

CYLINDER HEAD SPECIFICATIONS Unit: mm (in) Items Standard Limit Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004) Normal cylinder head height "H" 129.3 - 129.5 (5.09 - 5.10)

VALVE DIMENSIONS Unit: mm (in) Valve head diameter "D" Intake 35.5 - 35.8 (1.398 - 1.409) Exhaust 30.3 - 30.6 (1.193 - 1.205) Valve length "L" Intake 96.84 (3.8126) Exhaust 97.9 (3.854) Valve stem diameter "d" Intake 5.965 - 5.980 (0.2348 - 0.2354) Exhaust 5.955 - 5.970 (0.2344 - 0.2350) Valve seat angle "α" Intake 45°15' - 45°45' Exhaust Valve margin "T" Intake 1.1 (0.043) Exhaust 1.4 (0.055) Valve margin "T" limit 0.5 (0.020) Valve stem end surface grinding limit 0.2 (0.008)

Scheme 197

VALVE GUIDE

VALVE GUIDE SPECIFICATIONS 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 - 0.063 (0.0012 - 0.0025) 0.09 (0.0035) Projection length "L" Intake 10.1 - 10.3 (0.398 - 0.406) Exhaust 10.0 - 10.4 (0.394 - 0.409)

VALVE SEAT

VALVE SEAT SPECIFICATIONS Unit: mm (in) Items Standard Oversize (Service) [0.5 (0.020)] Cylinder head seat recess diameter "D" Intake 36.500 - 36.516 (1.4370 - 1.4376) 37.000 - 37.016 (1.4567 - 1.4573) Exhaust 31.500 - 31.516 (1.2402 - 1.2408) 32.000 - 32.016 (1.2598 - 1.2605) Valve seat outer diameter "d" Intake 36.597 - 36.613 (1.4408 - 1.4415) 37.097 - 37.113 (1.4605 - 1.4611) Exhaust 31.600 - 31.616 (1.2441 - 1.2447) 32.100 - 32.116 (1.2638 - 1.2644) Valve seat interference fit Intake 0.081 - 0.113 (0.0032 - 0.0044) Exhaust 0.084 - 0.116 (0.0033 - 0.0046) Diameter "d1" (1) Intake 33.5 (1.319) Exhaust 28.0 (1.102) Diameter "d2" (2) Intake 34.8 - 35.3 (1.370 - 1.390) Exhaust 29.6 - 30.1 (1.165 - 1.185) 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 0.99 - 1.35 (0.0390 - 0.0531) Exhaust 1.19 - 1.55 (0.0469 - 0.0610) 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) 4.91 - 5.01 (0.1933 - 0.1972) 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

VALVE SPRING SPECIFICATIONS

CYLINDER BLOCK

CYLINDER BLOCK SPECIFICATIONS Unit: mm (in) Surface distortion Limit 0.1 (0.004) Cylinder bore Inner diameter Standard Grade No. 2 89.010 - 89.020 (3.5043 - 3.5047) Grade No. 3 89.020 - 89.030 (3.5047 - 3.5051) Wear limit 0.2 (0.008) Out-of-round (Difference between "X" and "Y") Limit 0.015 (0.0006) Taper (Difference between "A" and "C") 0.01 (0.0004) Main bearing housing inner diameter grade Grade No. A 58.944 - 58.945 (2.3206 - 2.3207) Grade No. B 58.945 - 58.946 (2.3207 - 2.3207) Grade No. C 58.946 - 58.947 (2.3207 - 2.3207) Grade No. D 58.947 - 58.948 (2.3207 - 2.3208) Grade No. E 58.948 - 58.949 (2.3208 - 2.3208) Grade No. F 58.949 - 58.950 (2.3208 - 2.3209) Grade No. G 58.950 - 58.951 (2.3209 - 2.3209) Grade No. H 58.951 - 58.952 (2.3209 - 2.3209) Grade No. J 58.952 - 58.953 (2.3209 - 2.3210) Grade No. K 58.953 - 58.954 (2.3210 - 2.3210) Grade No. L 58.954 - 58.955 (2.3210 - 2.3211) Grade No. M 58.955 - 58.956 (2.3211 - 2.3211) Grade No. N 58.956 - 58.957 (2.3211 - 2.3211) Grade No. P 58.957 - 58.958 (2.3211 - 2.3212) Grade No. R 58.958 - 58.959 (2.3212 - 2.3212) Grade No. S 58.959 - 58.960 (2.3212 - 2.3213) Grade No. T 58.960 - 58.961 (2.3213 - 2.3213) Grade No. U 58.961 - 58.962 (2.3213 - 2.3213) Grade No. V 58.962 - 58.963 (2.3213 - 2.3214) Grade No. W 58.963 - 58.964 (2.3214 - 2.3214) Grade No. X 58.964 - 58.965 (2.3214 - 2.3215) Grade No. Y 58.965 - 58.966 (2.3215 - 2.3215) Grade No. 4 58.966 - 58.967 (2.3215 - 2.3215) Grade No. 7 58.967 - 58.968 (2.3215 - 2.3216) Difference in inner diameter between cylinders Standard Less than 0.03 (0.0012)

AVAILABLE PISTON

AVAILABLE PISTON SPECIFICATIONS Unit: mm (in) Piston skirt diameter "A" Standard Grade No. 2 88.990 - 89.000 (3.5035 - 3.5039) Grade No. 3 89.000 - 89.010 (3.5039 - 3.5043) Oversize (Service) [0.20 (0.008)] 89.180 - 89.210 (3.5110 - 3.5122) Piston height "H" dimension 37.5 (1.476) Piston pin hole diameter Grade No. 0 19.993 - 19.999 (0.7871 - 0.7874) Grade No. 1 19.999 - 20.005 (0.7874 - 0.7876) Piston to cylinder bore clearance Standard 0.010 - 0.030 (0.0004 - 0.0012) Limit 0.08 (0.0031)

PISTON RING

PISTON RING SPECIFICATIONS

PISTON PIN

PISTON PIN SPECIFICATIONS

CONNECTING ROD

CONNECTING ROD SPECIFICATIONS

CRANKSHAFT

CRANKSHAFT SPECIFICATIONS Unit: mm (in) Center distance "r" 49.96 - 50.04 (1.9669 - 1.9701) Out-of-round (Difference between "X" and "Y") Limit 0.005 (0.0002) Taper (Difference between "A" and "B") Limit 0.005 (0.0002) Runout [TIR (1) ] Limit 0.05 (0.0020) Crankshaft end play Standard 0.10 - 0.26 (0.0039 - 0.0102) Limit 0.3 (0.012) Pin journal diameter grade. "Dp" Grade No. A 44.974 - 44.973 (1.7706 - 1.7706) Grade No. B 44.973 - 44.972 (1.7706 - 1.7705) Grade No. C 44.972 - 44.971 (1.7705 - 1.7705) Grade No. D 44.971 - 44.970 (1.7705 - 1.7705) Grade No. E 44.970 - 44.969 (1.7705 - 1.7704) Grade No. F 44.969 - 44.968 (1.7704 - 1.7704) Grade No. G 44.968 - 44.967 (1.7704 - 1.7704) Grade No. H 44.967 - 44.966 (1.7704 - 1.7703) Grade No. J 44.966 - 44.965 (1.7703 - 1.7703) Grade No. K 44.965 - 44.964 (1.7703 - 1.7702) Grade No. L 44.964 - 44.963 (1.7702 - 1.7702) Grade No. M 44.963 - 44.962 (1.7702 - 1.7702) Grade No. N 44.962 - 44.961 (1.7702 - 1.7701) Grade No. P 44.961 - 44.960 (1.7701 - 1.7701) Grade No. R 44.960 - 44.959 (1.7701 - 1.7700) Grade No. S 44.959 - 44.958 (1.7700 - 1.7700) Grade No. T 44.958 - 44.957 (1.7700 - 1.7700) Grade No. U 44.957 - 44.956 (1.7700 - 1.7699) Main journal diameter grade. "Dm" Grade No. A 54.979 - 54.978 (2.1645 - 2.1645) Grade No. B 54.978 - 54.977 (2.1645 - 2.1644) Grade No. C 54.977 - 54.976 (2.1644 - 2.1644) Grade No. D 54.976 - 54.975 (2.1644 - 2.1644) Grade No. E 54.975 - 54.974 (2.1644 - 2.1643) Grade No. F 54.974 - 54.973 (2.1643 - 2.1643) Grade No. G 54.973 - 54.972 (2.1643 - 2.1642) Grade No. H 54.972 - 54.971 (2.1642 - 2.1642) Grade No. J 54.971 - 54.970 (2.1642 - 2.1642) Grade No. K 54.970 - 54.969 (2.1642 - 2.1641) Grade No. L 54.969 - 54.968 (2.1641 - 2.1641) Grade No. M 54.968 - 54.967 (2.1641 - 2.1641) Grade No. N 54.967 - 54.966 (2.1641 - 2.1640) Grade No. P 54.966 - 54.965 (2.1640 - 2.1640) Grade No. R 54.965 - 54.964 (2.1640 - 2.1639) Grade No. S 54.964 - 54.963 (2.1639 - 2.1639) Grade No. T 54.963 - 54.962 (2.1639 - 2.1639) Grade No. U 54.962 - 54.961 (2.1639 - 2.1638) Grade No. V 54.961 - 54.960 (2.1638 - 2.1638) Grade No. W 54.960 - 54.959 (2.1638 - 2.1637) Grade No. X 54.959 - 54.958 (2.1637 - 2.1637) Grade No. Y 54.958 - 54.957 (2.1637 - 2.1637) Grade No. 4 54.957 - 54.956 (2.1637 - 2.1636) Grade No. 7 54.956 - 54.955 (2.1636 - 2.1636) (1) Total indicator reading

MAIN BEARING

MAIN BEARING SPECIFICATIONS Unit: mm (in) Grade number Thickness Identification color Remarks 0 1.973 - 1.976 (0.0777 - 0.0778) Black Grade and color are the same for upper and lower bearings. 1 1.976 - 1.979 (0.0778 - 0.0779) Brown 2 1.979 - 1.982 (0.0779 - 0.0780) Green 3 1.982 - 1.985 (0.0780 - 0.0781) Yellow 4 1.985 - 1.988 (0.0781 - 0.0783) Blue 5 1.988 - 1.991 (0.0783 - 0.0784) Pink 6 1.991 - 1.994 (0.0784 - 0.0785) Purple 7 1.994 - 1.997 (0.0785 - 0.0786) White 01 UPR 1.973 - 1.976 (0.0777 - 0.0778) Black Grade and color are different for upper and lower bearings. LWR 1.976 - 1.979 (0.0778 - 0.0779) Brown 12 UPR 1.976 - 1.979 (0.0778 - 0.0779) Brown LWR 1.979 - 1.982 (0.0779 - 0.0780) Green 23 UPR 1.979 - 1.982 (0.0779 - 0.0780) Green LWR 1.982 - 1.985 (0.0780 - 0.0781) Yellow 34 UPR 1.982 - 1.985 (0.0780 - 0.0781) Yellow LWR 1.985 - 1.988 (0.0781 - 0.0783) Blue 45 UPR 1.985 - 1.988 (0.0781 - 0.0783) Blue LWR 1.988 - 1.991 (0.0783 - 0.0784) Pink 56 UPR 1.988 - 1.991 (0.0783 - 0.0784) Pink LWR 1.991 - 1.994 (0.0784 - 0.0785) Purple 67 UPR 1.991 - 1.994 (0.0784 - 0.0785) Purple LWR 1.994 - 1.997 (0.0785 - 0.0786) White

UNDERSIZE

UNDERSIZE SPECIFICATIONS

MAIN BEARING OIL CLEARANCE SPECIFICATIONS

CONNECTING ROD BEARING

CONNECTING ROD BEARING SPECIFICATIONS

UNDERSIZE SPECIFICATIONS

CONNECTING ROD BEARING OIL CLEARANCE SPECIFICATIONS