Engine Mechanical: Other Nissan Rogue II

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 article of this Service Information.

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

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.

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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 leaks.

Special Cautions to Ensure the Safe Disposal of Sodium-filled Exhaust Valves

Handling and disposal of sodium-filled exhaust valves requires special care and consideration. Under conditions such as breakage with subsequent contact with water, metal sodium which lines the inner portion of exhaust valve will react violently, forming sodium hydroxide and hydrogen which may result in an explosion. Sodium-filled exhaust valve is identified on the top of its stem as shown in illustration.

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DEALER DISPOSAL INSTRUCTIONS

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1. Clamp valve stem in a vice.
2. The valve has a specially-hardened surface. To cut through it, first remove a half-round section, approximately 30 mm (1.18 in) long using air-powered grinder until black color is removed and silver color appears.
3. Use hacksaw to cut through approximately half the diameter of valve stem. Make the serration at a point 40 mm (1.57 in) from the end of valve stem.
4. Cover the serrated end of the valve with a large shop towel (A). Strike the valve face end with a hammer, separating it into two pieces.
5. Fill a bucket, such as a 20 (5-1/4 US gal, 4-3/8 Imp gal) oil can, with at least 10 (2-5/8 US gal, 2-1/4 lmp gal) of water. Carefully place the already cut (serrated) valves into the water one-at-a-time using a set of large tweezers and quickly move away at least 2.7 m (9 ft).
6. The valves should be placed in a standing position as shown in the illustration to allow complete reaction. After the bubbling action has subsided, additional valves can be placed into the bucket allowing each subsequent chemical reaction to subside. However, no more than 8 valves should be placed in the same 10 (2-5/8 US gal, 2-1/4 lmp gal) amount of water. The complete chemical reaction may take as long as 4 to 5 hours. Remove the valves using a set of large tweezers after the chemical reaction has stopped. Afterwards, valves can be disposed as ordinary scrap.

Scheme 93

1. After removing the bolts and nuts, separate the mating surface and remove the liquid gasket using Tool (A). Tool Number: KV10111100 (J-37228) CAUTION: Be careful not to damage the mating surfaces.
2. In areas where the cutter is difficult to use, use a plastic hammer to lightly tap (1) the cutter where the liquid gasket is applied. Use a plastic hammer to slide (2) the cutter by tapping on the side.

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1. Using suitable tool (A), remove old liquid gasket from the liquid gasket application surface and the mating surface. Remove liquid gasket completely from the groove of the liquid gasket application surface, bolts, and bolt holes.
2. Thoroughly clean the mating surfaces and remove moisture, grease and foreign materials.
3. Attach liquid gasket tube to the suitable tool. Use Genuine Silicone RTV Sealant, or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-616709-S30035767112014051900000) ".
4. Apply liquid gasket without gaps to the specified location according to the specified dimensions. If there is a groove for liquid gasket application, apply liquid gasket to the groove. As for bolt holes (B), normally apply liquid gasket inside the holes. Occasionally, it should be applied outside the holes. Check to read the text of this information. Within five minutes of liquid gasket application, install the mating component. If liquid gasket protrudes, wipe it off immediately. Do not retighten bolts or nuts after the installation. After 30 minutes or more have passed from the installation, fill engine oil and engine coolant. CAUTION: If there are specific instructions in the procedures contained in this information concerning liquid gasket application, observe them.

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Special Service Tools

The actual shape of the tools may differ from those illustrated here.

Tool number (TechMate No.) Tool name Description - (J-48891) Spark plug socket Removing and installing spark plug KV10111100 (J-37228) Seal cutter Removing oil pan and timing chain case KV10112100 (BT-8653-A) Torque angle meter Tightening bolts for bearing cap, cylinder head, etc

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Commercial Service Tools

Tool number (TechMate No.) Tool name Description Pulley puller Removing crankshaft pulley Piston ring compressor Installing piston assembly into cylinder bore Pulley holder Crankshaft pulley removing and installing Valve seat cutter set Finishing valve seat dimensions Socket Removing and installing flywheel Size: T55 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. Anti-seize lubricant i.e.: (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 KV10107902 (J-38959) Valve oil seal puller with adapter (1) Removing valve oil seal KV10115600 (J-38958) 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) Tube presser Pressing the tube of liquid gasket Exhaust gas sensor wrench Removing exhaust gas sensor 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

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Checking

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

CHANGING THE AIR CLEANER FILTER

1. Remove air duct assembly from air cleaner case (upper).
2. Open the air cleaner case.
3. Remove the air cleaner filter.
4. Install a new air cleaner filter.
5. Close the air cleaner case.
6. Secure the air cleaner case clips.

Camshaft valve clearance

1. Perform this inspection as follows after removal, installation, or replacement of the camshaft or any valve parts, or if there are any unusual engine conditions due to changes in valve clearance over time (starting, idling, and/or noise).

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1. Remove the fender protector side cover (RH). Refer to " «FENDER PROTECTOR: EXPLODED VIEW»(ref-616717-S39205674252014051900000) ".
2. Remove the rocker cover. Refer to " «EXPLODED VIEW»(ref-616715-S18655366402014051900000) ".
3. Turn crankshaft pulley clockwise when viewed from front to align TDC identification mark (B) with timing indicator (A). NOTE: Do not confuse TDC mark (B) with paint marks (C).
4. At this time, check that the both intake and exhaust cam lobes of No. 1 cylinder face outside. If they do not face outside, turn crankshaft pulley once more.
5. Measure valve clearances with a suitable tool at locations marked (X) in the table below. No. 1 cylinder compression TDC. Cylinder No. 1 (A) No. 2 (B) No. 3 (C) No. 4 (D) Valve INT (E) EXH (F) INT (E) EXH (F) INT (E) EXH (F) INT (E) EXH (F) Measure x x x x Use a suitable tool to measure the clearance between valve lifter and camshaft. Valve clearance: Refer to " «CAMSHAFT»(ref-616715-S28504132322014051900000) ".
6. Turn crankshaft one complete revolution (360°) and align mark on crankshaft pulley with pointer.
7. Measure valve clearances with a suitable tool at locations marked (X) in the table below. No. 4 cylinder compression TDC. Cylinder No. 1 (A) No. 2 (B) No. 3 (C) No. 4 (D) Valve INT (E) EXH (F) INT (E) EXH (F) INT (E) EXH (F) INT (E) EXH (F) Measure x x x x If out of specifications, make necessary adjustment.

Intake Manifold

1. Securely install gasket to groove. CAUTION: Do not reuse gasket.
2. If studs were removed, install them and tighten to specification. Studs: 9.4 N.m (0.96 kg-m, 83 in-lb)
3. Tighten in numerical order as shown below. CAUTION: After tightening the five bolts in the order shown below, the 1, 6 position designates that the first bolt tightened is to be retightened to specification. Nuts/Bolts 1, 2, 3, 4, 5, 6: 25 N.m (2.6 kg-m, 18 ft-lb)

Electric Throttle Control Actuator

1. Install a new O-ring on the electric throttle control actuator. CAUTION: Do not reuse electric throttle control actuator O-ring.
2. Tighten the bolts of electric throttle control actuator equally and diagonally in several steps in numerical order as shown below.

Exhaust Manifold

Installation is in the reverse order of removal.

Scheme 113

1. Install studs in cylinder head studs and exhaust manifold and three way catalyst (if removed). Then tighten to specification. CAUTION: Do not reuse cylinder head or exhaust manifold studs.
2. Install the exhaust manifold and exhaust manifold and three way catalyst gasket. Then tighten the nuts to specification in the numerical order shown below. CAUTION: Do not reuse exhaust manifold and three way catalyst gasket.
3. Install the air fuel ratio (A/F) sensor 1 (1) using Tool (A) and tighten to specification. Tool number: KV10117100 (J-36471-A) CAUTION: Be careful not to damage air fuel ratio (A/F) sensor. Discard any air fuel ratio (A/F) sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; replace with a new one. Do not over-tighten the air fuel ratio (A/F) sensor 1. Doing so may cause damage to the air fuel ratio (A/F) sensor 1, resulting in a malfunction and the MIL coming on.

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Timing Chain

Check the timing chain for cracks (A) or excessive wear (B). If a defect is found, replace the timing chain.

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1. Measure outer diameters (d1, d2) at the two positions as shown below.
2. Measure d2 within the range (A).
3. If the value difference (d1 - d2) exceeds the limit, replace the balancer unit bolt with a new one. Limit: 0.15 mm (0. 0059 in) or more

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1. Make sure the crankshaft key points straight up.
2. Install the balancer unit and tighten the bolts in the numerical order as shown below: CAUTION: When reusing a bolt, check its outer diameter before installation. Follow the Balancer Unit Bolt Outer Diameter procedure. Apply new engine oil to threads and seating surfaces of bolts. Check tightening angle with an angle wrench (A) or a protractor. Do not make judgment by visual check alone. Tool number: KV10112100 (BT-8653-A) Step 1 Bolts 1-5: 42 N.m (4.3 kg-m, 31 ft-lb) Bolt 6: 36 N.m (3.7 kg-m, 27 ft-lb) Step 2 Bolts 1-5: 120° + 5° Bolt 6: 90° + 5° Step 3 Loosen in reverse order: 0 N.m (0 kg-m, 0 ft-lb) Step 4 Bolts 1-5: 42 N.m (4.3 kg-m, 31 ft-lb) Bolt 6: 36 N.m (3.7 kg-m, 27 ft-lb) Step 5 Bolts 1-5: 120° + 5° Bolt 6: 90° + 5°
3. Install the crankshaft sprocket (1) and timing chain (2) for the balancer unit. Make sure that the crankshaft sprocket (1) is positioned with mating marks (A) on the block and sprocket meeting at the top. Install it by lining up mating marks on each sprocket (A), (C) and timing chain (B), (D). (B): Pink link (D): Yellow link
4. Install timing chain tensioner for balancer unit (1). Compress the plunger, insert a stopper pin (A), and then install the tensioner for the balancer unit. Do not pull out (<==) the stopper pin until after installing the timing chain tensioner for balancer unit. Check matching mark position of balancer unit drive chain and each sprocket again.
5. Install camshaft sprockets. Install them by lining up the mating marks on each camshaft sprocket (B) with the ones painted on the timing chain (A) during removal. Before installation of chain tensioner, it is possible to re-match the marks on timing chain with the ones on each sprocket. CAUTION: Aligned mating marks could slip. Therefore, after matching them, hold the timing chain in place by hand. Before and after installing chain tensioner, check again to make sure that mating marks have not slipped.
6. Install chain tensioner using the following procedure: Install stopper pin (A) into the chain tensioner (1). Install the chain tensioner and pull the stopper pin out. CAUTION: After installation, pull the stopper pin out, and make sure that the tensioner is fully released.
7. Install timing chain (1) and related parts. Install by lining up mating marks on each sprocket and timing chain as shown below. Before and after installing chain tensioner (3), check to make sure the mating marks have not slipped. After installing timing chain tensioner (3), remove the stopper pin, and make sure that the tensioner moves freely. CAUTION: For the following note, after the mating marks are aligned, keep them aligned by holding them by hand. To avoid skipped teeth, do not move crankshaft and camshaft until front cover is installed. NOTE: Before installing chain tensioner (3) it is possible to slip the chain on the sprocket to align the chain timing mark with the sprocket timing mark. There may be two color variations of the link marks (link colors) on the timing chain. There are 26 links between the pink mating marks on the timing chain; and 64 links between the camshaft sprocket pink link and the crankshaft sprocket yellow link, on the timing chain side without the tensioner.
8. Install new front oil seal to front cover. Refer to " «FRONT OIL SEAL: REMOVAL AND INSTALLATION»(ref-616715-S34416416252014051900000) ".
9. Install front cover with the following procedure: Install O-rings to cylinder head and cylinder block. CAUTION: Do not reuse O-rings. Apply a continuous bead of liquid gasket to front cover as shown below. 35.7 mm (1.406 in) 6.0 - 7.0 mm (0.236 - 0.276 in) 3.4 - 4.4 mm (0.134 - 0.173 in) 179.6 mm (7.07 in) 35.5 mm (1.398 in) 31.3 mm (1.232 in) (G): Dowel pin hole Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-616709-S30035767112014051900000) ". CAUTION: Be sure sealant surfaces are free from grease, dirt, water, and engine oil. Be sure to apply sealant without breaks or overlap. Installation should be done within 5 minutes after application of liquid gasket. Do not fill the engine with engine oil for at least 30 minutes after the components are installed to allow the liquid gasket to cure. Make sure the mating marks on the timing chain and each sprocket are still aligned. Then install the front cover. CAUTION: Do not damage the front oil seal during installation. Tighten front cover bolts in the numerical order shown below. After all bolts are tightened, retighten them to the specified torque. Front cover bolts Bolts 6, 10, 12: 49 N.m (5.0 kg-m, 36 ft-lb) Bolts (all remaining): 12.8 N.m (1.3 kg-m, 9 ft-lb) (A): Dowel pin CAUTION: Wipe off excess sealant leaking at the surface for installing the oil pan.
10. Install the chain guide between the camshaft sprockets.
11. Install valve timing control cover. Refer to " «VALVE TIMING CONTROL COVER»(ref-616715-S00987182682014051900000) ".
12. Insert crankshaft pulley by aligning with crankshaft key. Tap its center with a plastic hammer to insert. CAUTION: Do not hit belt mounting section with hammer to avoid breaking belt guide. Be sure not to damage front oil seal while installing crankshaft pulley.
13. Install crankshaft pulley bolt (1) and tighten to specification. CAUTION: Apply anti-corrosive engine oil to threads of crankshaft pulley bolt (1) and bolt bearing surface prior to installation. Secure crankshaft pulley (2) with suitable tool to tighten the bolt. Step 1: Crankshaft bolt (1): 42.1 N.m (4.3 kg-m, 31 ft-lb) Step 2: Crankshaft bolt (1): 60° + 6°
14. Apply a paint mark (A) on the front cover, mating with any one of six easy to recognize stamp marks on bolt flange (B).
15. Installation of the remaining components is in the reverse order of removal.

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Scheme 127

1. Remove the timing chain. Refer to " «REMOVAL AND INSTALLATION»(ref-616715-S01424716332014051900000) ".
2. Remove the camshafts. Refer to " «EXPLODED VIEW»(ref-616715-S36134938302014051900000) ".
3. Remove spark plugs. Refer to " «REMOVAL AND INSTALLATION»(ref-616715-S21266772742014051900000) ".
4. Remove the intake manifold. Refer to " «REMOVAL AND INSTALLATION»(ref-616715-S27343873462014051900000) ".
5. Remove the exhaust manifold and three way catalyst. Refer to " «REMOVAL AND INSTALLATION»(ref-616715-S12011755722014051900000) ".
6. Loosen the cylinder head bolts in the reverse order shown below, using power tool.
7. Remove cylinder head.
8. Remove cylinder head gasket.

Scheme 128

1. Replace the cylinder head bolts with new ones if the size difference between d1 and d2 exceeds the limit. Limit (d1 - d2): 0.23 mm (0.0091 in) or more
2. If reduction of outer diameter appears in a position other than d2, use it as d2 point.

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1. Clean surfaces of cylinder head and cylinder block.
2. Install a new cylinder head gasket. CAUTION: Do not reuse cylinder head gasket.
3. Install the cylinder head.
4. Follow the steps below to tighten the cylinder head bolts in the numerical order as shown below. Clean threads and seating surfaces of bolts. Apply new engine oil to the threads and the seating surfaces of bolts. CAUTION: If cylinder head bolts are re-used, check their outer diameters before installation. Follow the Outer Diameter of Cylinder Head Bolts measurement procedure. Check and confirm the tightening angle by using angle wrench or protractor. Do not judge angle by visual inspection. Tool number (A): KV10112100 (BT-8653-A) Step a: 50 N.m (5.1 kg-m, 37 ft-lb) in order Step b: 60° clockwise in order Step c: Loosen to 0 N.m in order Step d: 39.2 N.m (4.0 kg-m, 29 ft-lb) in order Step e: 75° clockwise in order Step f: 75° clockwise in order
5. Installation of the remaining components is in the reverse order of removal.

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1. Remove the valve lifter. NOTE: Confirm installation point to return valve lifter to original location during assembly.
2. Remove valve collet, valve spring retainer, and valve spring using suitable tool (A). Remove valve collet with magnetic hand. CAUTION: Be careful not to damage valve lifter holes. Install suitable tool (A) in the center of valve spring retainer (1) to install it.
3. Remove valve spring retainer and valve spring (with valve spring seat). CAUTION: Do not remove valve spring seat from valve spring.
4. Push valve stem to combustion chamber side, and remove valve. Inspect valve guide clearance before removal. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-616715-S03321339012014051900000) ". Confirm installation point to return valve to original location during assembly.
5. Remove valve oil seal using suitable tool (A).
6. Remove valve seat, if necessary. 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-616715-S30472501152014051900000) ". CAUTION: Do not bore excessively to prevent damage to cylinder head.
7. Remove valve guide, if necessary. To remove valve guide, heat cylinder head to 110°C to 130°C (230°F to 266°F) by soaking in heated engine oil (A). WARNING: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned. Drive out valve guide using suitable tool.
8. Remove spark plugs. Refer to " «REMOVAL AND INSTALLATION»(ref-616715-S21266772742014051900000) "
9. Remove spark plug tubes, if necessary, using suitable tool. CAUTION: Be careful not to damage cylinder head. Do not remove spark plug tube if not necessary. Once removed, the spark plug tube cannot be reused because of deformation during removal.

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1. Install valve guide, if removed. Ream cylinder head valve guide hole using suitable tool (A). Refer to " «CYLINDER HEAD»(ref-616715-S30472501152014051900000) ". Heat cylinder head to 110°C to 130°C (230°F to 266°F) by soaking in heated engine oil (A). WARNING: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned. Press valve guide (1) into cylinder head (2) from camshaft side to dimension as shown below. Projection (H): Refer to " «CYLINDER HEAD»(ref-616715-S30472501152014051900000) " Apply reamer finish to valve guide using suitable tool (A). Standard: Refer to " «CYLINDER HEAD»(ref-616715-S30472501152014051900000) "
2. Install valve seat, if removed. Ream cylinder head (1) recess diameter for service valve seat (2). Heat cylinder head to 110°C to 130°C (230°F to 266°F) by soaking in heated engine oil (A). WARNING: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned. Allow valve seats to cool with dry ice. Press-fit valve seat into cylinder head. CAUTION: Do not touch cold valve seats directly. Finish valve seat to the specified dimension using suitable tool. Refer to " «CYLINDER HEAD»(ref-616715-S30472501152014051900000) ". 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 the cutter or cutting many different times may result in stage valve seat. Using compound, grind to adjust valve. Check again for normal contact. Refer to " «CYLINDER HEAD»(ref-616715-S30472501152014051900000) ". (A): OK (B): NG
3. Apply new engine oil to new valve oil seal joint surface and seal lip.
4. Install new valve oil seal using suitable tool (A) as shown below. NOTE: Dimension is height measured before installing valve spring (with valve spring seat). Projection (H): Refer to " «CYLINDER HEAD»(ref-616715-S30472501152014051900000) "
5. Install valve. Install larger diameter to intake side.
6. Install valve spring with valve spring seat (1). Install valve spring so that the identification color faces upward (A). Install smaller pitch to cylinder head side (B). Confirm the identification color of the valve spring. Intake: White Exhaust: Light blue
7. Install valve spring retainer.
8. Install valve collet. Compress valve spring using suitable tool (A). Install valve collet with a magnet hand. CAUTION: When working do not damage valve lifter holes. Tap valve stem edge lightly with a plastic hammer after installation to check its installed condition.
9. Install valve lifter.
10. Install spark plug. Refer to " «REMOVAL AND INSTALLATION»(ref-616715-S21266772742014051900000) "

Scheme 144

1. Wipe off engine oil and remove water scale deposits, old gasket, old sealer, and carbon using a suitable tool. CAUTION: Use care not to allow gasket debris to enter passages for engine oil or engine coolant.
2. At each of several locations on bottom surface of cylinder head, measure distortion in six directions using suitable tools (A, B). Limit: Refer to " «CYLINDER HEAD»(ref-616715-S30472501152014051900000) " If measurements exceed the limit, replace cylinder head.

VALVE DIMENSIONS

1. Check dimensions of each valve. Refer to " «CYLINDER HEAD»(ref-616715-S30472501152014051900000) ".
2. If dimensions are out of the standard, replace valve and check valve seat contact.

VALVE SEAT CONTACT

Note. After confirming that the dimensions of valve guides and valves are within specifications, perform this procedure: Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the vavle contact on the seat surface. Ensure that the contact area band is continuous all around the circumference. (A): OK (B): NG If the contact area is not continuous, grind to adjust valve fitting and check again. If the contacting surface still has NG conditions even after the re-check, replace the valve seat.

Scheme 145

1. Measure diameter of valve stem using suitable tool (A) as shown below. Standard: Refer to " «CYLINDER HEAD»(ref-616715-S30472501152014051900000) "
2. Measure inner diameter of valve guide using suitable tool. Standard: Refer to " «CYLINDER HEAD»(ref-616715-S30472501152014051900000) "
3. Valve guide clearance = (Valve guide inner diameter) - (Valve stem diameter) Standard and Limit: Refer to " «CYLINDER HEAD»(ref-616715-S30472501152014051900000) "
4. 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-616715-S05628286472014051900000) "

VALVE SPRING SQUARENESS

Scheme 146

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-616715-S30472501152014051900000) ".
2. If the valve spring exceeds the limit, replace the valve spring with the valve spring seat.

VALVE SPRING PRESSURE LOAD

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1. Check valve spring pressure with valve spring seat installed at the specified spring height. Standard: Refer to " «CYLINDER HEAD»(ref-616715-S30472501152014051900000) ".
2. If the installation load or load with valve open is out of the standard, replace valve spring with valve spring seat.

Camshaft Journal Clearance

Outer Diameter of Camshaft Journal

Scheme 148

1. Measure the outer diameter of the camshaft journal using suitable tool (A). Standard No. 1 outer diameter: Refer to " «CAMSHAFT»(ref-616715-S28504132322014051900000) " Standard No. 2, 3, 4, 5, outer diameter: Refer to " «CAMSHAFT»(ref-616715-S28504132322014051900000) "

Inner Diameter of Camshaft Bracket

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1. Tighten the camshaft bracket bolts to the specified torque following the tightening pattern as shown below. Step 1 (bolts 9 - 11): 1.96 N.m (0.20 kg-m, 17 in-lb) Step 2 (bolts 1 - 8): 1.96 N.m (0.20 kg-m, 17 in-lb) Step 3 (bolts 1 - 11): 5.88 N.m (0.60 kg-m, 52 in-lb) Step 4 (bolts 1 - 11): 10.41 N.m (1.1 kg-m, 8 ft-lb)
2. Using suitable tool (A), measure inner diameter of camshaft bracket (1). Standard No. 1: Refer to " «CAMSHAFT»(ref-616715-S28504132322014051900000) " Standard No. 2, 3, 4, 5: Refer to " «CAMSHAFT»(ref-616715-S28504132322014051900000) "

Calculation of Camshaft Journal Clearance

1. (Journal clearance) = (inner diameter of camshaft bracket) - (outer diameter of camshaft journal) Standard: Refer to " «CAMSHAFT»(ref-616715-S28504132322014051900000) "
2. When out of the specified range above, replace either or both the camshaft and the cylinder head assembly. NOTE: Inner diameter of the camshaft bracket is manufactured together with the cylinder head. If the camshaft bracket is out of specification, replace the whole cylinder head assembly.

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1. Install suitable tool (A) in the thrust direction on the front end of the camshaft. Measure the end play with the dial gauge while moving the camshaft forward and backward (in direction to axis). Standard end play: Refer to " «CAMSHAFT»(ref-616715-S28504132322014051900000) " Measure the following parts if out of the standard. Dimension (A) for camshaft No. 1 journal Standard: Refer to " «CAMSHAFT»(ref-616715-S28504132322014051900000) " Dimension (B) for cylinder head No. 1 journal Standard: Refer to " «CAMSHAFT»(ref-616715-S28504132322014051900000) " Refer to the standards above, and then replace camshaft and/or cylinder head.

Scheme 153

1. Install the camshaft in the cylinder head.
2. Install the camshaft sprocket on the camshaft.
3. Measure camshaft sprocket runout while turning the camshaft by hand using suitable tool (A). Runout: Refer to " «CAMSHAFT»(ref-616715-S28504132322014051900000) "
4. If it exceeds the specification, replace camshaft sprocket.

Scheme 154

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

Valve Lifter Clearance

Outer Diameter of Valve Lifter

Scheme 155

1. Measure the outer diameter of the valve lifter using suitable tool (A). Valve lifter outer diameter: Refer to " «CAMSHAFT»(ref-616715-S28504132322014051900000) "
2. If out of the specified range, replace the valve lifter.

Valve Lifter Bore Inner Diameter

Scheme 156

1. Measure diameter of valve lifter bore of cylinder head using suitable tool (A). Standard: Refer to " «CAMSHAFT»(ref-616715-S28504132322014051900000) "
2. If out of the specified range, replace the cylinder head assembly.

Calculation of Valve Lifter Clearance

1. (Valve lifter clearance) = (hole diameter for valve lifter) - (outer diameter of valve lifter) Standard: Refer to " «CAMSHAFT»(ref-616715-S28504132322014051900000) "
2. If out of specified range, replace either or both valve lifter and cylinder head assembly.

Scheme 157

Scheme 158

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

1. Install the valve lifter. Install them in the same position from which they were removed.
2. Install the camshafts. NOTE: The distinction between the intake and exhaust camshafts is the difference in the shape of the rear. Install camshafts so that the dowel pins (A) on the front side are positioned as shown below.
3. Install camshaft brackets. Install by referring to identification mark on upper surface mark. Install so that identification mark can be correctly read when viewed from the exhaust side. Install camshaft bracket (No. 1) as follows. Apply liquid gasket to camshaft bracket (No. 1) as shown below (A), (B). Refer to " «LIQUID GASKET»(ref-616715-S33237835822014051900000) ". Apply liquid gasket to camshaft bracket (No. 1) contact surface on the front cover backside. Refer to " «LIQUID GASKET»(ref-616715-S33237835822014051900000) " (a): 3.4 - 4.4 mm (0.134-0.173 in) Apply liquid gasket to the outside of bolt hole on front cover. Refer to " «LIQUID GASKET»(ref-616715-S33237835822014051900000) " Position the camshaft bracket (No. 1) near the installation position, and install it without disturbing the liquid gasket applied to the surfaces.
4. Tighten camshaft bracket bolts in four steps in the order as shown. Step 1 (bolts 9 - 11): 1.96 N.m (0.20 kg-m, 17 in-lb) Step 2 (bolts 1 - 8): 1.96 N.m (0.20 kg-m, 17 in-lb) Step 3 (bolts 1 - 11): 5.88 N.m (0.60 kg-m, 52 in-lb) Step 4 (bolts 1 - 11): 10.41 N.m (1.1 kg-m, 8 ft-lb) CAUTION: After tightening camshaft bracket bolts, be sure to wipe off excessive liquid gasket from the parts listed below. Mating surface of rocker cover. Mating surface of front cover, when installed without the front cover.
5. Install camshaft sprockets. Install them by lining up the mating marks (outer groove) (B) on each camshaft sprocket with the painted marks (A) on the timing chain during removal. Before installation of chain tensioner, it is possible to re-match the painted marks (A) on timing chain with the mating marks (B) on each sprocket. CAUTION: Aligned mating marks could slip. Therefore, after matching them, hold the timing chain in place by hand. Before and after installing chain tensioner, check again to make sure that mating marks have not slipped.
6. Install timing chain tension guide.
7. Install chain tensioner using the following procedure: Install stopper pin (A) into the chain tensioner (1). Install the chain tensioner and pull the stopper pin out. CAUTION: After installation, pull the stopper pin out, and make sure that the tensioner is fully released.
8. Install intake valve timing control cover with the following procedure. Install intake valve timing intermediate lock control solenoid valve, intake valve timing control solenoid valve, and exhaust valve timing control solenoid valve to valve timing control cover. CAUTION: Do not reuse O-ring. Install O-ring to front cover side. CAUTION: Do not reuse O-ring. Apply liquid gasket to the positions shown. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-616709-S30035767112014051900000) ". Diameter (A): 3.4 - 4.4 mm (0.134 - 0.173 in) Install valve timing control cover. Tighten the bolts to specification in the numerical order as shown.
9. Check and adjust valve clearances. Refer to " «CAMSHAFT VALVE CLEARANCE»(ref-616715-S04804767462014051900000) ".
10. Install camshaft position sensor bracket. Apply liquid gasket to camshaft position sensor bracket as shown. (A): 2.0 - 3.0 mm (0.079-0.118) (B): 10.5 mm (0.413 in) CAUTION: Use Genuine Silicone RTV Sealant, or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-616709-S30035767112014051900000) ". After installation be sure to wipe off excessive liquid gasket leaking from part (B). Installation should be done within 5 minutes after applying liquid gasket. Do not fill the engine with engine oil for at least 30 minutes after the components are installed to allow the liquid gasket to cure. Tighten bolts to specification in numerical order shown. Camshaft position sensor bracket bolts: 10.41 N.m (1.1 kg-m, 8 ft-lb)
11. Install the camshaft position sensors. Refer to " «EXPLODED VIEW»(ref-616715-S36134938302014051900000) ".
12. Installation of the remaining components is in the reverse order of removal.

Setting

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

Scheme 168

Scheme 169

Scheme 170

1. Remove engine and transaxle assembly from vehicle, and separate transaxle from engine. Refer to " «EXPLODED VIEW»(ref-616715-S15867975302014051900000) ".
2. Install engine to engine stand with the following procedure: Remove drive plate. Secure drive plate (1) using suitable tool (A) and remove bolts using suitable tool. Remove pilot converter (1) from the rear end of the crankshaft. Use suitable tool (A), if necessary. Lift the engine with a hoist to install it onto widely used 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 " «REMOVAL AND INSTALLATION»(ref-616715-S27343873462014051900000) ". Exhaust manifold: Refer to " «REMOVAL AND INSTALLATION»(ref-616715-S12011755722014051900000) ". Rocker cover: Refer to " «REMOVAL AND INSTALLATION»(ref-616715-S27518389342014051900000) ". 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.

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

1. Mount the engine on a suitable engine stand. Refer to " «SETTING»(ref-616715-S27575000752014051900000) ".
2. Drain any remaining engine oil and engine coolant, (if necessary).
3. Remove drain plugs from cylinder block.
4. Remove cylinder block heater (if equipped).
5. Remove cylinder head. Refer to " «EXPLODED VIEW»(ref-616715-S09508362672014051900000) ".
6. Remove knock sensor. CAUTION: Carefully handle knock sensor avoiding shocks.
7. Remove crankshaft position sensor (POS) (2). CAUTION: Avoid impacts such as dropping. Do not disassemble. Keep crankshaft position sensor (POS) away from metal particles. Do not place crankshaft position sensor (POS) in a location where it is exposed to magnetism.
8. Remove oil temperature sensor. CAUTION: Do not reuse O-ring.
9. 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-616715-S25977263412014051900000) ". Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center. Remove connecting rod cap. Number connecting rod caps so they can be assembled in the same position and direction. Using a hammer handle or similar tool, push piston and connecting rod assembly out to cylinder head side. CAUTION: Do not damage matching surface with connecting rod cap. Do not damage cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end. NOTE: Number the pistons and rods so they can be installed in the same position.
10. Remove connecting rod bearings. CAUTION: When removing them note the installation position. Keep them in the correct order.
11. Remove piston rings from piston. Before removing piston rings check the piston ring side clearance. Refer to " «INSPECTION»(ref-616715-S25977263412014051900000) ". Remove piston rings using suitable tool (A). CAUTION: When removing piston rings, be careful not to damage the piston. Do not damage piston rings by expanding them excessively.
12. Remove piston from connecting rod using the following procedure: Remove snap rings using snap ring pliers (A). Heat piston to 60°C to 70°C (140°F to 158°F) with a heat gun (A). Push out piston pin using a suitable tool.
13. Remove lower cylinder block using the following procedure: Measure crankshaft end play before loosening lower cylinder block bolts. Refer to " «INSPECTION»(ref-616715-S25977263412014051900000) ". Loosen and remove lower cylinder block bolts in reverse order as shown. Remove the lower cylinder block using Tool (A). CAUTION: Be careful not to damage the mating surfaces. NOTE: In areas where the cutter is difficult to use, use a plastic hammer to lightly tap (1) the cutter where the liquid gasket is applied. Use a plastic hammer to slide (2) the cutter by tapping on the side. Tool number: KV10111100 (J-37228) Remove the lower cylinder block while tapping lightly with a plastic hammer.
14. Remove crankshaft (2). CAUTION: Do not damage or deform signal plate (1) mounted on crankshaft. When setting crankshaft on a flat floor surface, use a block of wood to avoid contact between signal plate and floor surface. Do not remove signal plate unless it is necessary.
15. Remove rear oil seal from rear end of crankshaft. CAUTION: Do not damage the crankshaft or cylinder block when removing the rear main seal.
16. Remove main bearing (upper and lower) and thrust bearings from cylinder block and lower cylinder block. CAUTION: When removing bearings note the installation position. Keep them in the correct order. NOTE: When removing the rear oil seal without removing the cylinder block, use a suitable tool to pull it out between the crankshaft and block.
17. Remove oil jets (1) from cylinder block. CAUTION: When removing oil jet assemblies note the installation position. Keep them in the correct order.

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to remove any foreign material. CAUTION: Use goggles to protect your eyes.
2. Install drain plugs to cylinder block as shown. CAUTION: Do not reuse washer (1). Apply liquid gasket to the threads of drain plug (3). Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-616709-S30035767112014051900000) ". NOTE: Do not apply liquid gasket to the thread of plug (2). Tighten each plug as specified below. Part Washer Tightening torque 2 Yes 53.9 N.m (5.5 kg-m, 40 ft-lb) 3 No 9.8 N.m (1.00 kg-m, 17 in-lb)
3. Install oil jets (1). Oil jets (1): 23 N.m (2.3 kg-m, 17 ft-lb)
4. Install main bearings and thrust bearings using following procedure: Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block and lower cylinder block. Install thrust bearings (1) to both sides of the No. 3 journal (A) housing on cylinder block. Install thrust bearings with the oil groove (B) facing crankshaft arm (outside). Install the main bearings paying attention to the direction. Main bearing with an oil hole and groove (E) goes on cylinder block. The one without them (C) goes on lower cylinder block. Only main bearing (on cylinder block) for No. 3 journal (2) has different specifications. Before installing main bearings, apply new engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it. When installing, align main bearing stopper (B) to the notch. Ensure the oil holes (A) on cylinder block and those on the corresponding bearing are aligned.
5. Install signal plate to crankshaft (if removed). Set the signal plate with flange facing toward the counterweight side (engine front side). After positioning crankshaft (2) and signal plate (1) with positioning dowl pin (A), tighten bolts. Remove dowel pin. CAUTION: Be sure to remove dowel pin.
6. Install crankshaft to cylinder block. While turning crankshaft by hand, check that it turns smoothly. CAUTION: Do not install rear oil seal yet.
7. Install lower cylinder block with the following procedure: Apply liquid gasket with a suitable tool to lower cylinder block. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-616709-S30035767112014051900000) ". (B): Apply liquid gasket to an end (a): 4.0 - 5.0 mm (0.157 - 0.197 in) NOTE: Lower cylinder block cannot be replaced as a single part because it is machined together with cylinder block. Apply new engine oil to threads and seat surfaces of the bolts. Tighten lower cylinder block bolts to specification in the numerical order as shown. Tighten bolts to specification using suitable tool and Tool (A). CAUTION: Check tightening angle. Do not judge angle by visual inspection. Step 1, bolts 11 - 22 only: 25.1 N.m (2.6 kg-m, 19 ft-lb) Step 2, bolts 1 - 10 only: 39.2 N.m (4.0 kg-m, 29 ft-lb) Step 3, bolts 1 - 10 only: 60° degrees rotation Tool number (A): KV10112100 (BT-8653-A) Install rear oil seal. Refer to " «REAR OIL SEAL: REMOVAL AND INSTALLATION»(ref-616715-S40250988062014051900000) ". After installing 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-616715-S25977263412014051900000) ".
8. Install piston to connecting rod with the following procedure: Install new snap ring to the groove of the piston rear side using snap ring pliers. Insert it fully into groove to install. CAUTION: Do not reuse snap rings. Assemble piston to connecting rod. Using a heat gun, heat piston until piston pin can be pushed in by hand without excess force [approximately 60°C to 70°C (140°F to 158°F)]. From the front to the rear, insert piston pin into piston and connecting rod. Set so that the front mark (A) on the piston head, the oil splash (B) and the cylinder number (C) on connecting rod are positioned as shown. 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. Install piston rings using suitable tool. Position each ring with the gap as shown referring to the piston front mark (B). Install second ring with the stamped surface (E) facing upward. CAUTION: Do not damage piston. Do not damage piston rings by expanding them excessively. Do not contact rail end gap under oil ring with oil drain cast groove of piston.
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 engine oil to the back surface, but thoroughly clean it. When installing, align the connecting rod bearing stopper protrusion (A) with the cutout (B) 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 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: Tighten the connecting rod bolts using Tool (A) as follows: Apply engine oil to the threads and seats of the connecting rod bolts. CAUTION: Check tightening angle. Do not judge angle by visual inspection. Step 1: 27.4 N.m (2.8 kg-m, 20 ft-lb) Step 2: 0 N.m Step 3: 19.6 N.m (2.0 kg-m, 14 lb-ft) Step 4: Rotate bolts 90° + 0.5° Tool number: KV10112100 (BT-8653-A) After tightening connecting rod bolts, check that crankshaft rotates smoothly. Check the connecting rod side clearance. Refer to " «INSPECTION»(ref-616715-S25977263412014051900000) ".
14. Install knock sensor (1). Install knock sensor with connector facing 180° +/- 15° (a) as shown. CAUTION: Do not tighten bolts while holding 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.
15. Install crankshaft position sensor (POS).
16. Assembly of remaining components is in the reverse order of disassembly.

Scheme 195

1. Measure clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward using suitable tool (A). Standard and Limit: Refer to " «CYLINDER BLOCK»(ref-616715-S34677629682014051900000) ".
2. If measured value exceeds limit replace thrust bearings and measure again. If it still exceeds limit replace crankshaft.

Scheme 196

1. Measure side clearance between connecting rod and crankshaft arm using suitable tool (A). Standard and Limit: Refer to " «CYLINDER BLOCK»(ref-616715-S34677629682014051900000) ".
2. If measured value exceeds limit replace connecting rod and measure again. If it still exceeds limit replace crankshaft.

Scheme 197

1. Measure inner diameter of piston pin hole using suitable tool (A). Standard: Refer to " «CYLINDER BLOCK»(ref-616715-S34677629682014051900000) ".

Scheme 198

1. Measure outer diameter of piston pin using suitable tool (A). Standard: Refer to " «CYLINDER BLOCK»(ref-616715-S34677629682014051900000) ".

Piston to Piston Pin Oil Clearance

1. (Piston to piston pin oil clearance) = (Piston pin hole diameter) - (Piston pin outer diameter) Standard: Refer to " «CYLINDER BLOCK»(ref-616715-S34677629682014051900000) ".
2. If oil clearance value exceeds the limit replace piston and piston pin assembly.

Note. Piston is available together with piston pin as assembly.

Scheme 199

1. Measure side clearance of piston ring and piston ring groove using suitable tool (A). Standard and Limit: Refer to " «CYLINDER BLOCK»(ref-616715-S34677629682014051900000) ".
2. If measured value exceeds limit replace piston ring and measure again. If value still exceeds the limit replace piston.

Scheme 200

1. Check with a connecting rod aligner. Limit: Refer to " «CYLINDER BLOCK»(ref-616715-S34677629682014051900000) ".
2. If measured value exceeds limit replace connecting rod assembly.

Scheme 201

1. Install connecting rod cap (1) without connecting rod bearing installed and tighten connecting rod bolts. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-616715-S20184845032014051900000) ".
2. Measure inner diameter of connecting rod big end using suitable tool. Standard: Refer to " «CYLINDER BLOCK»(ref-616715-S34677629682014051900000) ".
3. If measured value exceeds standard replace connecting rod assembly.

Scheme 202

1. Measure inner diameter of connecting rod bushing using suitable tool (A). Standard: Refer to " «CYLINDER BLOCK»(ref-616715-S34677629682014051900000) ".

Connecting Rod Bushing Oil Clearance

1. (Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) - (Piston pin outer diameter) Standard: Refer to " «CYLINDER BLOCK»(ref-616715-S34677629682014051900000) ".
2. If measured value exceeds standard replace connecting rod assembly and/or piston and piston pin assembly.

Scheme 203

1. Remove gasket on the cylinder block surface and also remove engine oil, scale, carbon and other contamination using suitable tool. CAUTION: Do not allow gasket flakes to enter engine oil or engine coolant passages.
2. Measure distortion on cylinder block upper face at some different points in six directions using suitable tools (A/B). Limit: Refer to " «CYLINDER BLOCK»(ref-616715-S34677629682014051900000) ".
3. If measured value exceeds standard replace cylinder block.

Scheme 204

1. Install lower cylinder block without main bearings installed and tighten lower cylinder block bolts. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-616715-S20184845032014051900000) ".
2. Measure inner diameter of main bearing housing using suitable tool. Standard: Refer to " «CYLINDER BLOCK»(ref-616715-S34677629682014051900000) ".
3. If measured value exceeds standard replace cylinder block (1) and lower cylinder block (2) assembly. NOTE: Lower cylinder block cannot be replaced as a single unit because it is machined together with cylinder block.

Scheme 205

1. Measure cylinder bore for wear, out-of-round and taper at six different points on each cylinder using suitable tool. [(A) and (B) directions at (C), (D), and (E)] [(A) 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 ".

Limit: Out-of-round [Difference between (A) and (B)]

Taper [Difference between (C) and (D)]: Refer to " CYLINDER BLOCK ".

1. If measured value exceeds limit or if there are scratches and/or seizure on the cylinder inner wall hone or re-bore the cylinder inner wall.

Scheme 206

1. Measure outer diameter of piston skirt with suitable tool (A). Standard: Refer to " «CYLINDER BLOCK»(ref-616715-S34677629682014051900000) ".

Piston to Cylinder Bore Clearance

1. (Piston to cylinder bore clearance) = (Cylinder bore inner diameter) - (Piston skirt diameter) Standard and Limit: Refer to " «CYLINDER BLOCK»(ref-616715-S34677629682014051900000) ".
2. If measured value exceeds limit replace piston and piston pin assembly.

Scheme 207

1. Check that cylinder bore inner diameter is within standards.
2. Lubricate with new engine oil to piston (1) and piston ring (2), and then insert (A) piston ring to middle of cylinder (B) with piston and measure piston ring end gap using suitable tool (C). Standard and Limit: Refer to " «CYLINDER BLOCK»(ref-616715-S34677629682014051900000) ".
3. If measured value exceeds limit replace piston ring and measure again. If it still exceeds the limit replace cylinder block.

Scheme 208

1. Measure outer diameter of crankshaft main journals using suitable tool (A). Standard: Refer to " «CYLINDER BLOCK»(ref-616715-S34677629682014051900000) ".
2. If measured value exceeds limit measure the main bearing oil clearance and use undersize bearing.

CRANKSHAFT PIN JOURNAL DIAMETER

1. Measure outer diameter of crankshaft pin journal using suitable tool. Standard: Refer to " «CYLINDER BLOCK»(ref-616715-S34677629682014051900000) ".
2. If measured value exceeds limit measure connecting rod bearing oil clearance and use undersize bearing.

Scheme 209

1. Measure dimensions at four different points as shown on each main journal and pin journal using suitable tool.
2. Out-of-round is indicated by the difference in dimension between (a) and (b) at (c) and (d).
3. Taper is indicated by difference in dimension between (c) and (d) at (a) and (b). Limit: Out-of-round [Difference between (a) and (b)] Taper [Difference between (c) and (d)]: Refer to " «CYLINDER BLOCK»(ref-616715-S34677629682014051900000) ".
4. If measured value exceeds limit correct or replace crankshaft.
5. If corrected, measure bearing oil clearance of corrected main journal and/or pin journal. Then select main bearing and/or connecting rod bearing.

Scheme 210

1. Place V-block on precise flat table to support the journals on both ends of crankshaft.
2. Place suitable tool (A) straight up on No. 3 journal.
3. While rotating crankshaft, read movement of pointer on suitable tool. (Total indicator reading) Limit: Refer to " «CYLINDER BLOCK»(ref-616715-S34677629682014051900000) ".
4. If measured value exceeds limit replace crankshaft.

Scheme 211

1. Install connecting rod bearings (2) to connecting rod (3) and connecting rod bearings cap (1) and tighten connecting rod bolts. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-616715-S20184845032014051900000) ".
2. Measure inner diameter (B) of connecting rod bearing using suitable tool.
3. (Bearing oil clearance) = (Connecting rod bearing inner diameter) - (Crankshaft pin journal diameter) Standard and Limit: Refer to " «CONNECTING ROD BEARING»(ref-616715-S30570159902014051900000) ".
4. If measured value exceeds limit select proper connecting rod bearing. Use connecting rod big end diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance.

Scheme 212

1. Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.
2. Cut plastigage slightly shorter than 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. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-616715-S20184845032014051900000) ". CAUTION: Do not rotate crankshaft.
4. Remove connecting rod cap and bearing and using the scale (A) 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 213

1. Install main bearings (3) to cylinder block (1) and lower cylinder block (2) and tighten lower cylinder block bolts. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-616715-S20184845032014051900000) ".
2. Measure the inner diameter (B) of main bearing with bore gauge.
3. (Bearing oil clearance) = (Main bearing inner diameter) - (Crankshaft main journal diameter) Standard and Limit: Refer to " «MAIN BEARING»(ref-616715-S21238528162014051900000) ".
4. If measured value exceeds limit select proper main bearing. Use main bearing inner diameter and crankshaft main journal diameter to obtain specified bearing oil clearance. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-616715-S20184845032014051900000) ".

Scheme 214

1. Remove engine oil and dust on crankshaft main journal and surfaces of each bearing completely.
2. Cut plastigage slightly shorter than bearing width and place it in crankshaft axial direction avoiding oil holes.
3. Install main bearings on cylinder block and lower cylinder block and tighten lower cylinder block bolts. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-616715-S20184845032014051900000) ". CAUTION: Do not rotate crankshaft.
4. Remove lower cylinder block and bearings and using the scale (A) on the plastigage bag measure the plastigage width. NOTE: The procedure when measured value exceeds the limit is same as that described in "Method by Calculation".

Scheme 215

1. When lower cylinder block is removed after being tightened to specified torque with main bearings (1) installed, tip end of bearing must protrude (B). Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-616715-S20184845032014051900000) ". Standard: There must be crush height.
2. If standard is not met, replace main bearings.

Scheme 216

1. When connecting rod bearing cap is removed after being tightened to specified torque with connecting rod bearings (1) installed, tip end of bearing must protrude (B). Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-616715-S20184845032014051900000) ". Standard: There must be crush height.
2. If standard is not met, replace connecting rod bearings.

Scheme 217

1. Measure outer diameters (d1) and (d2) at two positions as shown.
2. If reduction appears in (B) range, regard it as (d2). Limit [(d1) - (d2)]: 0.13 mm (0.0051 in)
3. If measured value exceeds limit (a large difference in dimensions) replace lower cylinder block bolt with new one.

Scheme 218

1. Measure outer diameter (d) at position as shown.
2. If reduction appears in position other than (d), regard it as (d). Limit: 7.75 mm (0.3051 in)
3. If measured value exceeds limit (large difference in dimensions) replace connecting rod bolt with new one.

When a Cylinder Block is Reused

1. Measure the cylinder block bore inner diameter.
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner diameter of the "Piston Selection Table". Select the piston of the same grade.

Piston Selection Table

1. For the piston selection table, refer to " «CYLINDER BLOCK»(ref-616715-S34677629682014051900000) ".

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

Scheme 219

Scheme 220

1. Apply big end inside diameter grade stamped on connecting rod side face to the row in the "Connecting Rod Bearing Selection Table".
2. Apply pin diameter grade (B) stamped on crankshaft front side to the column in the "Connecting Rod Bearing Selection Table". Journal diameter grade (A)
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 connecting rod bearing grade table to select.

When Crankshaft and Connecting Rod are Reused

1. Measure dimensions of the big end inner diameter of connecting rod and outer diameter of crankshaft pin individually.
2. Apply the dimension measured to the "Connecting Rod Bearing Selection Table" below.

Scheme 221

Connecting Rod Bearing Grade Table. Refer to " CONNECTING ROD BEARING ".

Undersize Bearing Usage Guide

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

Bearing Undersize Table

Scheme 222

Scheme 223

1. "Main Bearing Selection Table" rows correspond to bearing housing grade on rear left side of cylinder block. If there is a corrected stamp mark on the cylinder block, use it as a correct reference.
2. Apply journal diameter grade (A) stamped on crankshaft front side to column in "Main Bearing Selection Table".
3. Find value at crossing of row and column in "Main Bearing Selection Table". CAUTION: There are two main bearing selection tables. One is for odd-numbered journals (1, 3, and 5) and the other is for even-numbered journals (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 "Main Bearing Grade Table" to select. NOTE: Service parts are available as a set of both upper and lower.

When Cylinder Block and Crankshaft are Reused

1. Measure inner diameter of cylinder block main bearing housing and outer diameter of crankshaft journal.
2. Apply measurement in above step 1 to the "Main Bearing Selection Table".
3. Follow steps 3 and 4 in "When New Cylinder Block and Crankshaft are Used".

Scheme 224

Scheme 225

Main Bearing Grade Table (All Journals) Refer to " MAIN BEARING ".

Use Undersize Bearing Usage Guide

1. Use undersize (U.S.) bearing when oil clearance with standard size main bearing is not within specification.
2. When using undersize (U.S.) bearing, measure the bearing inner diameter with the bearing installed and grind journal until oil clearance falls within specification.

DRIVE BELT

SPARK PLUG

CAMSHAFT

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 45.865 - 46.055 (1.8057 - 1.8132) 0.2 (0.008) (1) Exhaust 44.175 - 44.365 (1.7392 - 1.7467) 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 CLEARANCE

AVAILABLE VALVE LIFTER

Unit: mm (in) Thickness Identification (stamped) mark 3.00 (0.1181) 300H 3.02 (0.1189) 302H 3.04 (0.1197) 304H 3.06 (0.1205) 306H 3.08 (0.1213) 308H 3.10 (0.1220) 310H 3.12 (0.1228) 312H 3.14 (0.1236) 314H 3.16 (0.1244) 316H 3.18 (0.1252) 318H 3.20 (0.1260) 320H 3.22 (0.1268) 322H 3.24 (0.1276) 324H 3.26 (0.1283) 326H 3.28 (0.1291) 328H 3.30 (0.1299) 330H 3.32 (0.1307) 332H 3.34 (0.1315) 334H 3.36 (0.1323) 336H 3.38 (0.1331) 338H 3.40 (0.1339) 340H 3.42 (0.1346) 342H 3.44 (0.1354) 344H 3.46 (0.1362) 346H 3.48 (0.1370) 348H 3.50 (0.1378) 350H

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" 129.3 - 129.5 (5.09 - 5.10)

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 101.72 (4.005) Exhaust 102.78 (4.046) 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 44°15' - 44°45' Exhaust Valve margin "T" Intake 1.15 - 1.45 (0.0453 - 0.0571) Exhaust 1.45 - 1.75 (0.0571 - 0.0689) Valve stem end surface grinding limit 0.2 (0.008)

Scheme 226

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 - 0.063 (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

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 30.85 - 31.15 (1.2146 - 1.2264) Exhaust 25.05 - 25.35 (0.9862 - 0.9980) Diameter "d2" (2) Intake 34.35 - 34.65 (1.3524 - 1.3642) Exhaust 29.35 - 29.65 (1.1555 - 1.1673) 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

CYLINDER BLOCK

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

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 48.95 (1.9272) 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 PIN

CONNECTING ROD

CRANKSHAFT

Unit: mm (in) Center distance "r" 50.52 - 51.00 (1.9890 - 2.0079) 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 44.973 - 44.974 (1.7706 - 1.7706) Grade No. B 44.972 - 44.973 (1.7705 - 1.7706) Grade No. C 44.971 - 44.972 (1.7705 - 1.7705) Grade No. D 44.970 - 44.971 (1.7705 - 1.7705) Grade No. E 44.969 - 44.970 (1.7704 - 1.7705) Grade No. F 44.968 - 44.969 (1.7704 - 1.7704) Grade No. G 44.967 - 44.968 (1.7704 - 1.7704) Grade No. H 44.966 - 44.967 (1.7703 - 1.7704) Grade No. J 44.965 - 44.966 (1.7703 - 1.7703) Grade No. K 44.964 - 44.965 (1.7702 - 1.7703) Grade No. L 44.963 - 44.964 (1.7702 - 1.7702) Grade No. M 44.962 - 44.963 (1.7702 - 1.7702) Grade No. N 44.961 - 44.962 (1.7701 - 1.7702) Grade No. P 44.960 - 44.961 (1.7701 - 1.7701) Grade No. R 44.959 - 44.960 (1.7700 - 1.7701) Grade No. S 44.958 - 44.959 (1.7700 - 1.7700) Grade No. T 44.957 - 44.958 (1.7700 - 1.7700) Grade No. U 44.956 - 44.957 (1.7699 - 1.7700) Main journal diameter grade. "Dm" Grade No. A 54.978 - 54.979 (2.1645 - 2.1645) Grade No. B 54.977 - 54.978 (2.1644 - 2.1645) Grade No. C 54.967 - 54.977 (2.1644 - 2.1644) Grade No. D 54.975 - 54.976 (2.1644 - 2.1644) Grade No. E 54.974 - 54.975 (2.1643 - 2.1644) Grade No. F 54.973 - 54.974 (2.1643 - 2.1643) Grade No. G 54.972 - 54.973 (2.1642 - 2.1643) Grade No. H 54.971 - 54.972 (2.1642 - 2.1642) Grade No. J 54.970 - 54.971 (2.1642 - 2.1642) Grade No. K 54.969 - 54.970 (2.1641 - 2.1642) Grade No. L 54.968 - 54.969 (2.1641 - 2.1641) Grade No. M 54.967 - 54.968 (2.1641 - 2.1641) Grade No. N 54.966 - 54.967 (2.1640 - 2.1641) Grade No. P 54.965 - 54.966 (2.1640 - 2.1640) Grade No. R 54.964 - 54.965 (2.1639 - 2.1640) Grade No. S 54.963 - 54.964 (2.1639 - 2.1639) Grade No. T 54.962 - 54.963 (2.1639 - 2.1639) Grade No. U 54.961 - 54.962 (2.1638 - 2.1639) Grade No. V 54.960 - 54.961 (2.1638 - 2.1638) Grade No. W 54.959 - 54.960 (2.1637 - 2.1638) Grade No. X 54.958 - 54.959 (2.1637 - 2.1637) Grade No. Y 54.957 - 54.958 (2.1637 - 2.1637) Grade No. 4 54.956 - 54.957 (2.1636 - 2.1637) Grade No. 7 54.955 - 54.956 (2.1636 - 2.1636) (1) Total indicator reading

Scheme 227

MAIN BEARING

Unit: mm (in) Grade number Thickness Identification color Remarks -1 1.970 - 1.973 (0.0776 - 0.0777) Red Grade and color are the same upper and lower bearings 0 1.973 - 1.976 (0.0777 - 0.0778) Black 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 -10 UPR 1.970 - 1.973 (0.0776 - 0.0777) Red Grade and color are different for upper and lower bearings LWR 1.973 - 1.976 (0.0777 - 0.0778) Black 01 UPR 1.973 - 1.976 (0.0777 - 0.0778) Black 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

MAIN BEARING OIL CLEARANCE

CONNECTING ROD BEARING

CONNECTING ROD BEARING OIL CLEARANCE