Engine Mechanical (MR20DE): Other Nissan Sentra B16 рестайлинг

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 SUPPLEMENTAL RESTRAINT SYSTEM and SEAT BELTS articles.

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

Precaution Necessary for Steering Wheel Rotation After Battery Disconnect

Note. This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT SYSTEM). 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 NATS, 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.

Precaution for Procedure without Cowl Top Cover

When performing the procedure after removing cowl top cover, cover the lower end of windshield.

Scheme 152

Precaution for Disconnecting Fuel Piping

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

Special Service Tool

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

SPECIAL SERVICE TOOL DESCRIPTION CHART Tool number (Kent-Moore No.) Tool name Description KV10111100 (J-37228) Seal cutter Removing steel oil pan and rear timing chain case KV10112100 (BT-8653-A) Angle wrench Tightening bolts for bearing cap, cylinder head, etc. KV10107902 (J-38959) Valve oil seal puller Removing valve oil seal EM03470000 (J-8037) Piston ring compressor Installing piston assembly into cylinder bore KV101092S0 (J-26336-B) Valve spring compressor KV10109210 (J-26336-20) Attachment KV10109220 (-) KV10109230 Adapter (M8) Disassembling and assembling valve mechanism WS39930000 (-) Tube presser Pressing the tube of liquid gasket ST16610001 (J-23907) Pilot bushing puller Removing crankshaft pilot bushing KV11103000 (-) Pulley puller Removing crankshaft pulley KV991J0050 (J-44626) Air fuel sensor Socket Loosening or tightening air fuel ratio A/F sensor 22 mm (0.87 in) KV10114400 (J-38365) Heated oxygen sensor wrench Loosening or tightening rear heated oxygen sensor 22 mm (0.87 in) KV11105210 (J-44716) Stopper plate Securing diveplate and flywheel 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) 5 (0.20) KV10115801 (-) Oil filter wrench Removing and installing oil filter 64.3 mm (2.531 in)

Scheme 153

Scheme 154

Scheme 155

Scheme 156

Scheme 157

Scheme 158

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Commercial Service Tool

COMMERCIAL SERVICE TOOL DESCRIPTION CHART (Kent-Moore No.) Tool name Description Power tool Loosening bolts and nuts Spark plug wrench Removing and installing spark plug Valve seat cutter set Finishing valve seat dimensions Piston ring expander Removing and installing piston ring KV10109300 (-) Pulley holder Removing and installing crankshaft pulley KV10111800 Valve guide drift Removing and installing valve guide Valve guide reamer Reaming valve guide inner hole Reaming hole for oversize valve guide (J-43897-18) (J-43897-12) Oxygen sensor thread cleaner Reconditioning the exhaust system threads before installing a new oxygen sensor and Air Fuel ratio sensor (Use with anti-seize lubricant shown below.) J-43897-18 (18 mm dia.) Air Fuel ratio sensors J-43897-12 (12 mm dia.) Air Fuel ratio sensors Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907) Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads E20 Torx® Socket (J-45816) Removing and installing drive plate and flywheel bolts

Scheme 166

Scheme 167

Scheme 168

Scheme 169

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Checking Drive Belts

Note. On vehicles not equipped with A/C, there is an idler pulley in the position for the drive belt routing.

1. Make sure that the indicator (notch on fixed side) of drive belt auto-tensioner is within the possible use range. NOTE: Check the drive belt auto-tensioner indicator (notch) when the engine is cold. When the new drive belt is installed, the range of possible use should be as shown in illustration. Visually check entire belt for wear, damage or cracks. If the indicator is out of allowable use range or belt is damaged, replace the drive belt.

Camshaft Journal Oil Clearance

CAMSHAFT JOURNAL OUTER DIAMETER

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

Standard

No. 1 : 27.935 - 27.955 mm (1.0998 - 1.1006 in)

No. 2, 3, 4, 5 : 24.950 - 24.970 mm (0.9823 - 0.9831 in)

Scheme 176

CAMSHAFT BRACKET INNER DIAMETER

Scheme 177

1. Tighten camshaft bracket bolts with specified torque. Follow the "INSTALLATION" tightening procedure.
2. Measure the inner diameter of camshaft bracket with a bore gauge (A). Standard: No. 1 : 28.000 - 28.021 mm (1.1024 - 1.1032 in) No. 2, 3, 4, 5 : 25.000 - 25.021 mm (0.9843 - 0.9851 in)

CAMSHAFT JOURNAL OIL CLEARANCE

1. (Oil clearance) = (Camshaft bracket inner diameter) - (Camshaft journal diameter) Standard: No. 1 : 0.045 - 0.086 mm (0.0018 - 0.0034 in) No. 2, 3, 4, 5 : 0.030 - 0.071 mm (0.0012 - 0.0028 in) Limit: : 0.15 mm (0.0059 in)
2. If it exceeds the limit, replace camshaft or cylinder head, or both. NOTE: Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head. Replace whole cylinder head assembly.

Scheme 178

Scheme 179

1. Install camshaft in cylinder head. Follow the "INSTALLATION" tightening procedure.
2. Install dial indicator in thrust direction on front end of camshaft. Read the end play of dial indicator (A) when camshaft is moved forward/backward (in direction to axis). Standard : 0.075 - 0.153 mm (0.0030 - 0.0060 in) Limit : 0.24 mm (0.0094 in) Measure the following parts if out of the standard. Dimension "A" for groove of cylinder head No. 1 journal Standard : 4.000 - 4.030 mm (0.1575 - 0.1587 in) Dimension "B" for camshaft flange Standard : 3.877 - 3.925 mm (0.1526 - 0.1545 in) Use the standards above, and then replace camshaft and/or cylinder head.

Scheme 180

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 (A). (Total indicator reading) Limit : 0.15 mm (0.0059 in) If it exceeds the limit, replace camshaft sprocket.

Valve Lifter

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

Scheme 181

1. If anything above is found, replace valve lifter. Refer to " «VALVE CLEARANCE»(ref-367306-S09052462272010072700000) ".

Valve Lifter Clearance

VALVE LIFTER OUTER DIAMETER

Scheme 182

1. Measure the outer diameter of valve lifter with a micrometer (A). Standard: Intake : 33.977 - 33.987 mm (1.3377 - 1.3381 in) Exhaust : 29.977 - 29.987 mm (1.1802 - 1.1806 in)

VALVE LIFTER HOLE DIAMETER

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

Standard

Intake : 34.000 - 34.021 mm (1.3386 - 1.3394 in)

Exhaust : 30.000 - 30.021 mm (1.1811 - 1.1819 in)

Scheme 183

VALVE LIFTER CLEARANCE

1. (Valve lifter clearance) = (Valve lifter hole diameter) - (Valve lifter outer diameter) Standard: 0.013 - 0.044 mm (0.0005 - 0.0017 in)
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.

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

1. Install valve lifters. Install them in the original positions.
2. Install camshafts. Clean camshaft journal to remove any foreign material. Distinguish between the intake and the exhaust by looking at the different shapes of the front and rear ends of the camshaft or using the identification colors (A) and (B). CAMSHAFT COLORS REFERENCE CHART Identification color A B Camshaft (EXH) - Yellow Camshaft (INT) Yellow - Install camshafts so that camshaft dowel pins (A) on the front side are positioned as shown in illustration. NOTE: Though camshaft does not stop at the positions as shown in illustration, for the placement of cam nose, it is generally accepted camshaft is placed for the same direction as shown in illustration.
3. Remove foreign material completely from camshaft bracket backside and from cylinder head installation face.
4. Apply liquid gasket (A) to camshaft bracket as shown in illustration. Use Genuine Silicone RTV Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCT AND SEALANT»(ref-367300-S11705964442010072700000) ". Tool number WS39930000 (-)
5. Install camshaft bracket bolts in three stage in numerical order as shown in illustration. There are two types of bolts. Use the following to locate bolts. M6 bolts [thread length: 57.5 mm (2.264 in)] : 13, 14 and 15 M6 bolts [thread length: 35.00 mm (1.378 in)] : Except the above
6. Tighten all bolts in numerical order in three steps. Step 1 : 1.96 N.m (0.20 kg-m, 17 in-lb) Step 2 : 5.88 N.m (0.60 kg-m, 52 in-lb) Step 3 : 9.5 N.m (0.97 kg-m, 84 in-lb)
7. Install the camshaft sprocket (INT) to the camshaft (INT). NOTE: When the camshaft sprocket (INT) (2) is removed, align the paint mark (A) put according to step "8". Securely align the knock pin and the pin hole, and then install them.
8. Tighten camshaft (INT) sprocket bolt. Camshaft sprocket bolt (INT) : 35.0 N.m (3.6 kg-m, 26 ft-lb) NOTE: Secure the hexagonal part of camshaft (INT) using wrench to tighten bolt.
9. Turn 67 degrees clockwise (angle tightening) using Tool (B). CAUTION: Never judge by visual inspection without an angle wrench. Tool number : KV10112100 (BT-8653-A)
10. Install camshaft sprocket (EXH) (2). Camshaft sprocket bolt (EXH) : 88.2 N.m (9.0 kg-m, 65 ft-lb) NOTE: Secure the hexagonal part (A) of camshaft (EXH) using wrench to tighten bolt.
11. Install timing chain and related parts. Refer to «TIMING CHAIN»(ref-367306-S10053709172010072700000) .
12. Inspect and adjust valve clearance. Refer to " «VALVE CLEARANCE»(ref-367306-S09052462272010072700000) ".
13. Installation of the remaining components is in the reverse order of removal.

Cylinder Head Distortion

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

Scheme 191

1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper. CAUTION: Use utmost care not to allow gasket debris to enter passages for engine oil or water.
2. At each of several locations on bottom surface of cylinder head, measure the distortion in six directions using straightedge (A) and feeler gauge (B). Limit: 0.1 mm (0.004 in) If it exceeds the limit, replace cylinder head.

Scheme 192

Scheme 193

1. Install cylinder head gasket.
2. Apply new engine oil to threads and seating surface of bolts. CAUTION: If cylinder head bolts re-used, check their outer diameters before installation. Follow the "Cylinder Head Bolts Outer Diameter" procedure.
3. Install cylinder head, follow the steps below to tighten cylinder head bolts in numerical order as shown in illustration. Step a : 40 N.m (4.1 kg-m, 30 ft-lb) Step b : 100° clockwise Step c : Loosen to 0 N.m in the reverse order of tightening. Step d : 40 N.m (4.1 kg-m, 30 ft-lb) Step e : 100° clockwise Step f : 100° clockwise CAUTION: Check and confirm the tightening angle by using Tool (A) or protractor. Never judge by visual inspection without the tool. Tool number : KV10112100 (BT-8653-A)
4. Installation of the remaining components is in the reverse order of removal.

Scheme 194

Scheme 195

Scheme 196

1. Remove spark plug using suitable tool.
2. Remove valve lifter. Identify installation positions, and store them without mixing them up.
3. Remove valve collet. Compress valve spring using Tool, attachment and adapter (A). Remove valve collet using a suitable magnet hand. CAUTION: When working, be careful not to damage valve lifter holes. Tool number : KV101092S0 (J-26336-B)
4. Remove valve spring retainer and valve spring (with valve spring seat). CAUTION: Never remove valve spring seat from valve spring.
5. Push valve stem to combustion chamber side, and remove valve. NOTE: Identify installed positions, and store them without mixing them up.
6. Remove valve oil seal using Tool (A). Tool number : KV10107902 (J-38959)
7. When valve seat must be replaced, refer to " «INSPECTION AFTER DISASSEMBLY»(ref-367306-S29554130182010072700000) " to removal.
8. When valve guide must be replaced, refer to " «INSPECTION AFTER DISASSEMBLY»(ref-367306-S29554130182010072700000) " to removal.

Scheme 197

1. Install valve guide if removed. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-367306-S29554130182010072700000) ".
2. Install valve seat if removed. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-367306-S29554130182010072700000) ".
3. Install valve oil seal. Install with a valve oil seal using Tool (A) to match dimension as shown in illustration. Tool number : KV10115600 (J-38958) NOTE: Dimension "H" is height that measured before installing valve spring (with valve spring seat). Height "H" : 15.1 - 15.7 mm (0.594 - 0.618 in)
4. Install valve. Install larger diameter to intake side.
5. Install valve spring (with valve spring seat). Install smaller pitch (valve spring seat side) to cylinder head side (B). Confirm identification color (A) of valve spring. Intake : White Exhaust : Orange
6. Install valve spring retainer.
7. Install valve collet. Compress valve spring using Tool (A). Install valve collet with a magnet hand. Tool number : KV101092S0 (J-26336 B) CAUTION: When working, be careful not to damage valve lifter holes. Tap valve stem edge lightly with a plastic hammer after installation to check its installed condition.
8. Install valve lifter. Install it in the original position.
9. Install spark plug using suitable tool.

VALVE DIMENSIONS

1. Check dimensions of each valve. For dimensions, refer to " «STANDARD AND LIMIT»(ref-367306-S20208098092010072700000) ".
2. If dimensions are out of the standard, replace valve.

Valve Stem Diameter

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

Standard

Intake : 5.465 - 5.480 mm (0.2152 - 0.2157 in)

Exhaust : 5.455 - 5.470 mm (0.2148 - 0.2154 in)

Scheme 198

Valve Guide Inner Diameter

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

Standard

5.500 - 5.518 mm (0.2165 - 0.2172 in)

Valve Guide Clearance

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

Valve guide clearance

Standard

Intake : 0.020 - 0.053 mm (0.0008 - 0.0021 in)

Exhaust : 0.030 - 0.063 mm (0.0012 - 0.0025 in)

Limit

0.1 mm (0.004 in)

1. If it exceeds the limit, replace valve guide and/or valve.

Outline

Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the transaxle.

Scheme 199

Scheme 200

Scheme 201

1. Remove engine under cover. Refer to " «REMOVAL AND INSTALLATION»(ref-367309-S07728457182010072700000) ".
2. Drain engine coolant from radiator. Refer to " «CHANGING ENGINE COOLANT»(ref-367308-S12677316052010072700000) ". CAUTION: Perform this step when the engine is cold. Do not spill engine coolant on drive belt.
3. Drain clutch fluid (M/T models). Refer to " «AIR BLEEDING PROCEDURE»(ref-367318-S07473296302010072700000) ".
4. Drain M/T oil (M/T models). Refer to " «CHANGING M/T OIL»(ref-367316-S35012713212010072700000) ".
5. Partially drain CVT fluid (CVT models). Refer to " «CHANGING CVT FLUID»(ref-367317-S22253310682010072700000) ".
6. Remove front fender protector (RH and LH). Refer to " «REMOVAL AND INSTALLATION»(ref-367309-S17675621432010072700000) ".
7. Remove exhaust front tube. Refer to «EXHAUST SYSTEM»(ref-367311-S04754663352010072700000) .
8. Remove drive shafts (LH and RH) from steering knuckle. Refer to " «REMOVAL AND INSTALLATION (LEFT SIDE)»(ref-367319-S15232641032010072700000) " and " «REMOVAL AND INSTALLATION (RIGHT SIDE)»(ref-367319-S02270596312010072700000) ".
9. Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to " «REMOVAL AND INSTALLATION (MR20DE)»(ref-367317-S05305200852010072700000) " (CVT models) or " «REMOVAL AND INSTALLATION»(ref-367316-S31143347862010072700000) " (M/T models).
10. Remove front suspension member. Refer to " «REMOVAL AND INSTALLATION»(ref-367320-S02438788112010072700000) ".
11. Remove hood assembly. Refer to «HOOD»(ref-367321-S34377663402010072700000) .
12. Remove cowl top cover and cowl top extension assembly. Refer to «COWL TOP»(ref-367309-S28238712702010072700000) .
13. Release fuel pressure. Refer to " «FUEL PRESSURE CHECK»(ref-367313-S41722281122010072700000) " (for California) or " «FUEL PRESSURE CHECK»(ref-367314-S00696232202010072700000) " (except for California).
14. Remove battery and battery tray. Refer to " «REMOVAL AND INSTALLATION (MR20DE BATTERY)»(ref-367310-S21928351492010072700000) ".
15. Remove drive belt. Refer to " «COMPONENT»(ref-367306-S34285767602010072700000) ".
16. Remove engine room cover.
17. Disconnect transmission control module (TCM) (CVT models).
18. Disconnect ECM and brake fluid level sensor.
19. Remove ECM.
20. Remove air duct and air cleaner case assembly. Refer to «AIR CLEANER AND AIR DUCT»(ref-367306-S15222089282010072700000) .
21. Remove cooling fan assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-367308-S37408325662010072700000) ".
22. Remove radiator hose (upper and lower). Refer to «RADIATOR»(ref-367308-S16346757022010072700000) .
23. Disconnect CVT fluid cooler hoses (CVT models). Refer to «RADIATOR»(ref-367308-S16346757022010072700000) .
24. Disconnect all connections of engine harness around the engine mounting insulator (LH), and then temporarily secure the engine harness into the engine side. CAUTION: Protect connectors using a resin bag to protect against foreign materials during the operation.
25. Disconnect fuel feed hose at engine side. Refer to " «COMPONENT»(ref-367306-S17697476492010072700000) ".
26. Disconnect heater hoses, and install plugs them to prevent engine coolant from draining. Refer to " «COMPONENT»(ref-367308-S24804451432010072700000) ".
27. Disconnect control cables from transaxle. Refer to «SHIFT CONTROL SYSTEM»(ref-367317-S22009448952010072700000) (CVT models), " «REMOVAL AND INSTALLATION»(ref-367316-S38474937922010072700000) " (M/T models).
28. Remove ground cable at transaxle side.
29. Remove ground cable between front cover and vehicle.
30. Remove generator, if necessary. Refer to «CHARGING SYSTEM»(ref-367310-S01375274422010072700000) .
31. Remove A/C compressor with piping connected from the engine, if equipped. Temporarily secure it on the vehicle side with a rope to avoid putting load on it. Refer to " «REMOVAL AND INSTALLATION FOR COMPRESSOR - MR20DE»(ref-367302-S37655888582010072700000) ".
32. Remove the intake manifold to prevent the hanging chain from interfering. Refer to " «COMPONENT»(ref-367306-S29517871822010072700000) ".
33. Install engine slinger to cylinder head front left side (A) and rear right side (B) and support the engine position with a hoist. Slinger bolts (front) : 32.9 N.m (3.3 kg-m, 24.2 ft-lb) Slinger bolts (rear) : 25.0 N.m (2.5 kg-m, 18.4 ft-lb)
34. Support engine and transaxle assembly with a hoist and secure the engine in appropriate position.
35. Use a manual lift table caddy (A) or equivalently rigid tool such as a transmission jack. Securely support bottom of the engine and the transaxle, and simultaneously adjust hoist tension. CAUTION: Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.
36. Remove torque rod (RH) (1), engine mounting insulator (RH) (2) and engine mounting bracket (3).
37. Remove pull down rod (RH) (CVT models).
38. Remove pull down rod (LH) (CVT models).
39. Remove engine through bolt-securing nut (C).
40. Remove the engine and the transaxle assembly from the vehicle downward by carefully operating supporting tools. CAUTION: During the operation, make sure that no part interferes with the vehicle side. Before and during this lifting, always check if any harnesses are left connected. During the removal operation, always be careful to prevent the vehicle from falling off the lift due to changes in the center of gravity. If necessary, support the vehicle by setting jack or suitable tool at the rear. During operation, securely support the engine by placing a piece of wood under the engine oil pan and transaxle oil pan. Securely support the engine slingers with a hoist.
41. When the engine hoisting is not performed simultaneously, install engine slinger to cylinder head front left side and rear right side.
42. Remove starter motor. Refer to «STARTING SYSTEM»(ref-367310-S31645863242010072700000) .
43. Lift with a hoist and position above engine.
44. Separate the engine and the transaxle. Refer to " «REMOVAL AND INSTALLATION (MR20DE)»(ref-367317-S05305200852010072700000) " (CVT models) or " «REMOVAL AND INSTALLATION»(ref-367316-S31143347862010072700000) " (M/T models).

HOW TO SELECT PISTON

When New Cylinder Block is Used

Scheme 202

1. Check the cylinder bore grade on rear left side of cylinder block (L), and select piston of the same grade.
2. If there is a correction stamp mark on the cylinder block, use it as a correct reference.

When Cylinder Block is Reused

Scheme 203

1. Measure the cylinder bore inner diameter. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-367306-S19075358502010072700000) ".
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner diameter of the "Piston Selection Table".
3. Select piston of the same grade. PISTON SELECTION CHART Unit: mm (in) Grade number (Mark) 1 2 [or no mark (piston only)] Cylinder bore Inner diameter 84.000 - 84.010 (3.3071 - 3.3075) 84.010 - 84.020 (3.3075 - 3.3079) Piston skirt diameter 83.970 - 83.980 (3.3059 - 3.3063) 83.980 - 83.990 (3.3063 - 3.3067) NOTE: Piston is available together with piston pin as an assembly. There is no piston pin (piston pin hole) grade.

HOW TO SELECT CONNECTING ROD BEARING

When New Connecting Rod and Crankshaft are Used

Scheme 204

Scheme 205

1. Apply connecting rod big end diameter grade stamped (C) 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 AFTER DISASSEMBLY»(ref-367306-S19075358502010072700000) " and " «INSPECTION AFTER DISASSEMBLY»(ref-367306-S19075358502010072700000) ".
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.

Connecting Rod Bearing Selection Table

Scheme 206

CONNECTING ROD BEARING GRADE CHART

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.

Scheme 207

BEARING UNDERSIZE CHART

HOW TO SELECT MAIN BEARING

When New Cylinder Block and Crankshaft are Used

Scheme 208

Scheme 209

1. "Main Bearing Selection Table" rows correspond to main bearing housing grade on rear left side of cylinder block (L). If there is a correction 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 No. 1, 4 and 5 journals and the other is for No. 2 and 3 journals. 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 AFTER DISASSEMBLY»(ref-367306-S19075358502010072700000) " and " «INSPECTION AFTER DISASSEMBLY»(ref-367306-S19075358502010072700000) ".
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 No. 1, 4 and 5 journals and the other is for No. 2 and 3 journals. 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.

Main Bearing Selection Table (No. 1, 4 and 5 journals)

Scheme 210

Main Bearing Selection Table (No. 2 and 3 journals)

Scheme 211

Main Bearing Grade Table (All Journals)

MAIN BEARING GRADE CHART (ALL JOURNALS)

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 CHART

Scheme 212

1. Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with a dial indicator (A). Standard : 0.10 - 0.26 mm (0.0039 - 0.0102 in) Limit : 0.30 mm (0.012 in)
2. If the measured value exceeds the limit, replace thrust bearings, and measure again. If it still exceeds the limit, replace crankshaft also.

Scheme 213

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

Piston Pin Hole Diameter

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

Standard: 19.993 - 19.999 mm (0.7871 - 0.7874 in)

Scheme 214

Piston to Piston Pin Oil Clearance

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

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

1. If oil clearance is out of the standard, replace piston and piston pin assembly.
2. When replacing piston and piston pin assembly, follow the "Piston to Cylinder Bore Clearance" procedure. 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 215

1. Measure the side clearance of piston ring and piston ring groove with a feeler gauge (A). Standard: Top ring : 0.04 - 0.08 mm (0.002 - 0.003 in) 2nd ring : 0.03 - 0.07 mm (0.001 - 0.003 in) Oil ring : 0.015 - 0.185 mm (0.001 - 0.007 in) Limit: Top ring : 0.11 mm (0.0043 in) 2nd ring : 0.10 mm (0.0039 in)
2. If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, replace piston also.

Scheme 216

1. Make sure that cylinder bore inner diameter is within specification. Follow the "Cylinder Bore Inner Diameter" procedure.
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: Top ring : 0.20 - 0.30 mm (0.008 - 0.012 in) 2nd ring : 0.50 - 0.65 mm (0.020 - 0.026 in) Oil ring (rail ring) : 0.15 - 0.45 mm (0.006 - 0.018 in) Limit: Top ring : 0.51 mm (0.020 in) 2nd ring : 0.83 mm (0.033 in) Oil ring (rail ring) : 0.78 mm (0.031 in)
3. If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, replace the cylinder block.

Scheme 217

1. Check with a connecting rod aligner. Bend (A): Limit: 0.15 mm (0.0059 in) per 100 mm (3.94 in) length Torsion (B): Limit: 0.30 mm (0.0118 in) per 100 mm (3.94 in) length
2. If it exceeds the limit, replace connecting rod assembly.

Scheme 218

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-367306-S35826402092010072700000) " for the tightening procedure.
2. Measure the inner diameter of connecting rod big end with an inside micrometer. Standard: 47.000 - 47.013 mm (1.8504 - 1.8509 in)
3. If out of the standard, replace connecting rod assembly.

Connecting Rod Bushing Inner Diameter

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

Standard: 20.000 - 20.012 mm (0.7874 - 0.7879 in)

Scheme 219

Connecting Rod Bushing Oil Clearance

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

Standard : 0.005 - 0.023 mm (0.0002 - 0.0009 in)

Limit : 0.03 mm (0.0012 in)

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, follow the "PISTON TO PISTON PIN OIL CLEARANCE" procedure.
3. If replacing connecting rod assembly, follow the "Connecting Rod Bushing Oil Clearance" procedure to select connecting rod bearing.

Scheme 220

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: 0.1 mm (0.004 in)
3. If it exceeds the limit, replace cylinder block.

Scheme 221

1. Install main bearing cap without main bearings installed, and tighten main bearing cap bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-367306-S35826402092010072700000) " for the tightening procedure.
2. Measure the inner diameter of main bearing housing with a bore gauge.
3. Measure the position shown in illustration [5 mm (0.20 in)] backward from main bearing housing front side in the 2 directions as shown in illustration. The smaller one is the measured value. Standard: 55.997 - 56.017 mm (2.2046 - 2.2054 in)
4. If out of the standard, replace cylinder block and main bearing caps assembly. NOTE: Main bearing caps cannot be replaced as a single, because it is machined together with cylinder block.

Scheme 222

1. Using a bore gauge (A), 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 "X" direction at "B" position. Standard inner diameter: 84.000 - 84.020 mm (3.3071 - 3.3079 in) Out-of-round (Difference between "X" and "Y"): 0.015 mm (0.0006 in) Taper limit (Difference between "A" and "C"): 0.01 mm (0.0004 in)
2. If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, replace cylinder block. NOTE: Oversize piston is not provided.

Piston Skirt Diameter

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

Measure point

Distance from the top 39.9 mm (1.571 in)

Standard

83.970 - 83.990 mm (3.3059 - 3.3067 in)

Scheme 223

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 : 0.020 - 0.040 mm (0.0008 - 0.0016 in)

Limit : 0.08 mm (0.0031 in)

1. If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block. Refer to " «HOW TO SELECT PISTON AND BEARING»(ref-367306-S07333379452010072700000) ".

Scheme 224

1. Measure the outer diameter of crankshaft main journals with a micrometer (A). Standard: 51.959 - 51.979 mm (2.0456 - 2.0464 in) dia.
2. If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Follow the "MAIN BEARING OIL CLEARANCE" procedure.

CRANKSHAFT PIN JOURNAL DIAMETER

1. Measure the outer diameter of crankshaft pin journal with a micrometer. Standard: 43.953 - 43.971 mm (1.7304-1.7311 in) dia.
2. If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Follow the "CONNECTING ROD BEARING OIL CLEARANCE" procedure.

Scheme 225

1. Measure the dimensions at four different points as shown in illustration 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") : 0.0035 mm (0.0001 in) Taper (Difference between "A" and "B") : 0.0035 mm (0.0001 in)
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. Follow the "MAIN BEARING OIL CLEARANCE" and/or "CONNECTING ROD BEARING OIL CLEARANCE" procedures.

Scheme 226

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 (A) straight up on the No. 3 journal.
3. While rotating crankshaft, read the movement of the pointer on the dial indicator. (Total indicator reading) Standard : 0.05 mm (0.0020 in) Limit : 0.10 mm (0.0040 in)
4. If it exceeds the limit, replace crankshaft.

Scheme 227

1. Install connecting rod bearings (2) to connecting rod (3) and connecting rod bearing cap (1), and tighten connecting rod bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-367306-S35826402092010072700000) " 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 : 0.037 - 0.047 mm (0.0015 - 0.0019 in) Limit : 0.07 mm (0.0028 in)
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 " «HOW TO SELECT PISTON AND BEARING»(ref-367306-S07333379452010072700000) ".

Scheme 228

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-367306-S35826402092010072700000) " for the tightening procedure. CAUTION: Never 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 229

1. Install main bearings (3) to cylinder block (1) and main bearing cap (2), and tighten main bearing cap bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-367306-S35826402092010072700000) " 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: No. 1, 4 and 5 journals : 0.024 - 0.034 mm (0.0009 - 0.0013 in) No. 2 and 3 journals : 0.012 - 0.022 mm (0.0005 - 0.0009 in) Limit : 0.065 mm (0.0026 in)
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 " «HOW TO SELECT PISTON AND BEARING»(ref-367306-S07333379452010072700000) ".

Scheme 230

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 main bearing cap, and tighten main bearing cap bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-367306-S35826402092010072700000) " for the tightening procedure. CAUTION: Never rotate crankshaft.
4. Remove main bearing cap and bearings, 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 231

1. When main bearing cap is removed after being tightened to the specified torque with main bearings (1) installed, the tip end of bearing must protrude (B). Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-367306-S35826402092010072700000) " for the tightening procedure. Standard : There must be crush height.
2. If the standard is not met, replace main bearings.

Scheme 232

1. When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings (1) installed, the tip end of bearing must protrude. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-367306-S35826402092010072700000) " for the tightening procedure (B). Standard : There must be crush height.
2. If the standard is not met, replace connecting rod bearings.

Scheme 233

1. Measure the outer diameters ("d1", "d2") at two positions as shown in illustration.
2. If reduction appears in places other than "B" range, regard it as "d2". Limit ("d1" - "d2"): 0.15 mm (0.0059 in)
3. If it exceeds the limit (a large difference in dimensions), replace main bearing cap bolt with a new one.

Scheme 234

1. Measure the outer diameter "d" at position as shown in illustration.
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.

Scheme 235

1. Make sure that there is no foreign material on the oil filter and check it for clogging. Clean it if necessary.
2. Check the oil filter for damage. Replace it if necessary.

Scheme 236

1. Measure the deflection of flywheel contact surface to clutch with a dial indicator (A).
2. Measure the deflection at 210 mm (8.27 in) diameter. Limit : 0.45 mm (0.0177 in) or less.
3. If measured value is out of the standard, replace flywheel.
4. If a trace of burn or discoloration is found on the surface, repair it with sandpaper.

MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS)

Movement Amount of Thrust (Fore-and-Aft) Direction

1. Measure the movement amount of thrust (fore-and-aft) direction when 100 N (10.2 kg, 22 lb) force is added at the portion of 125 mm (4.92 in) radius from the center of flywheel. Standard : 1.8 mm (0.071 in) or less
2. If measured value is out of the standard, replace flywheel.

Movement Amount in Radial (Rotation) Direction

Check the movement amount of radial (rotation) direction with the following procedure

Scheme 237

1. Install clutch cover bolt (1) to clutch cover mating hole, and place a torque wrench (A) on the extended line of the flywheel (2) center line. Tighten bolt at a force of 9.8 N.m (1.0 kg-m, 87 in-lb) to keep it from loosening.
2. Put a mating mark on circumferences of the two flywheel masses without applying any load (Measurement standard points).
3. Apply a force of 9.8 N.m (1.0 kg-m, 87 in-lb) in each direction, and mark the movement amount on the mass on the transaxle side.
4. Measure the dimensions of movement amounts "A" and "B" on circumference of the flywheel on the transaxle side. Limit: 33.2 mm (1.307 in) or less. If measured value is out of the standard, replace flywheel.

DRIVE BELT

DRIVE BELT SPECIFICATIONS

WATER CONTROL VALVE

WATER CONTROL VALVE SPECIFICATIONS

EXHAUST MANIFOLD

EXHAUST MANIFOLD SPECIFICATIONS

THERMOSTAT

THERMOSTAT SPECIFICATIONS

SPARK PLUG

SPARK PLUG SPECIFICATIONS

CYLINDER HEAD

CYLINDER HEAD SPECIFICATIONS Unit: mm (in) Items Standard Limit Head surface distortion - 0.1 (0.004) Normal cylinder head height "H" 130.9 (5.15)

VALVE

Valve Timing

VALVE TIMING SPECIFICATIONS Unit: degree Valve timing a b c d e f 212 224 -8 (32) 52 (12) 7 25 (): Valve timing control "ON"

Scheme 238

Valve Dimensions

VALVE DIMENSIONS Unit: mm (in) Valve head diameter "D" Intake 33.8 - 34.1 (1.331 - 1.343) Exhaust 27.6 - 27.9 (1.087 - 1.098) Valve length "L" Intake 106.27 (4.18) Exhaust 105.26 (4.144) Valve stem diameter "d" Intake 5.465 - 5.480 (0.2152 - 0.2157) Exhaust 5.455 - 5.470 (0.2148 - 0.2154) Valve seat angle "α" 45°15' - 45°45' Valve margin "T" Intake 1.1 (0.043) Exhaust 1.2 (0.047)

Valve Clearance

VALVE CLEARANCE

Available Valve Lifter

VALVE LIFTER THICKNESS Thickness mm (in) Identification mark (1) 3.00 (0.1181) 300 3.02 (0.1189) 302 3.04 (0.1197) 304 3.06 (0.1205) 306 3.08 (0.1213) 308 3.10 (0.1220) 310 3.12 (0.1228) 312 3.14 (0.1236) 314 3.16 (0.1244) 316 3.18 (0.1252) 318 3.20 (0.1260) 320 3.22 (0.1268) 322 3.24 (0.1276) 324 3.26 (0.1283) 326 3.28 (0.1291) 328 3.30 (0.1299) 330 3.32 (0.1307) 332 3.34 (0.1315) 334 3.36 (0.1323) 336 3.38 (0.1331) 338 3.40 (0.1339) 340 3.42 (0.1346) 342 3.44 (0.1354) 344 3.46 (0.1362) 346 3.48 (0.1370) 348 3.50 (0.1378) 350 (1) Always check with the Parts Department for the latest parts information

Valve Spring

VALVE SPRING SPECIFICATIONS

Valve Lifter

VALVE LIFTER SPECIFICATIONS

Valve Guide

VALVE GUIDE SPECIFICATIONS Unit: mm (in) Items Standard part Service part Valve guide Outer diameter 9.523 - 9.534 (0.3749 - 0.3754) 9.723 - 9.734 (0.3828 - 0.3832) Inner diameter (Finished size) 5.500 - 5.518 (0.2165 - 0.2172) Cylinder head valve guide hole diameter 9.475 - 9.496 (0.3730 - 0.3739) 9.675 - 9.696 (0.3809 - 0.3817) 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) 0.1 (0.004) Exhaust 0.030 - 0.063 (0.0012 - 0.0025) Projection length "L" 13.35 - 13.65 (0.526 - 0.537)

Valve Seat

VALVE SEAT SPECIFICATIONS Unit: mm (in) Items Standard Oversize [0.5 (0.02)] (Service) Cylinder head seat recess diameter "D" Intake 34.700 - 34.727 (1.3661 - 1.3672) 35.200 - 35.227 (1.3858 - 1.3869) Exhaust 28.700 - 28.727 (1.1299 - 1.1310) 29.200 - 29.227 (1.1496 - 1.1507) Valve seat outer diameter "d" Intake 34.808 - 34.824 (1.3704 - 1.3710) 35.308 - 35.324 (1.3901 - 1.3907) Exhaust 28.808 - 28.824 (1.1342 - 1.1348) 29.308 - 29.324 (1.1539 - 1.1545) Valve seat interference fit 0.081 - 0.124 (0.0032 - 0.0049) Diameter "d1" (1) Intake 31.8 (1.252) Exhaust 25.3 (0.996) Diameter "d2" (2) Intake 33.1 - 33.6 (1.303 - 1.323) Exhaust 26.9 - 27.4 (1.059 - 1.079) Angle "α1" Intake 60° Exhaust 45° Angle "α2" 88°45' - 90°15' Angle "α3" 120° Contacting width "W" (3) Intake 1.0 - 1.4 (0.039 - 0.055) Exhaust 1.2 - 1.6 (0.047 - 0.063) Height "h" Intake 5.9 - 6.0 (0.232 - 0.236) 5.03 - 5.13 (0.1980 - 0.2020) Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.95 - 5.05 (0.1949 - 0.1988) Depth "H" Intake 6.04 (0.2378) Exhaust 6.05 (0.2382) (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

CAMSHAFT AND CAMSHAFT BEARING

CAMSHAFT AND CAMSHAFT BEARING SPECIFICATIONS Unit: mm (in) Items Standard Limit Camshaft journal oil clearance No. 1 0.045 - 0.086 (0.0018 - 0.0034) 0.15 (0.0059) No. 2, 3, 4, 5 0.030 - 0.071 (0.0012 - 0.0028) Camshaft bracket inner diameter No. 1 28.000 - 28.021 (1.1024 - 1.1032) - No. 2, 3, 4, 5 25.000 - 25.021 (0.9843 - 0.9851) - Camshaft journal diameter No. 1 27.935 - 27.955 (1.0998 - 1.1006) - No. 2, 3, 4, 5 24.950 - 24.970 (0.9823 - 0.9381) - Camshaft end play 0.075 - 0.153 (0.0030 - 0.0060) 0.24 (0.0094) Camshaft cam height "A" Intake 44.605 - 44.795 (1.7560 - 1.7635) 44.405 (1.7482) Exhaust 43.175 - 43.365 (1.6997 - 1.7072) 42.975 (1.6919) Camshaft runout [TIR (1) ] Less than 0.02 (0.0008) 0.05 (0.0020) Camshaft sprocket runout [TIR (1) ] - 0.15 (0.0059) (1) Total indicator reading

CYLINDER BLOCK

CYLINDER BLOCK SPECIFICATIONS Unit: mm (in) Top surface distortion Limit 0.1 (0.004) Cylinder bore Inner diameter Standard Grade No. 1 84.000 - 84.010 (3.3071 - 3.3075) Grade No. 2 84.010 - 84.020 (3.3075 - 3.3079) 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 55.997 - 55.998 (2.2046 - 2.2046) Grade No. B 55.998 - 55.999 (2.2046 - 2.2047) Grade No. C 55.999 - 56.000 (2.2047 - 2.2047) Grade No. D 56.000 - 56.001 (2.2047 - 2.2048) Grade No. E 56.001 - 56.002 (2.2048 - 2.2048) Grade No. F 56.002 - 56.003 (2.2048 - 2.2048) Grade No. G 56.003 - 56.004 (2.2048 - 2.2049) Grade No. H 56.004 - 56.005 (2.2049 - 2.2049) Grade No. J 56.005 - 56.006 (2.2049 - 2.2050) Grade No. K 56.006 - 56.007 (2.2050 - 2.2050) Grade No. L 56.007 - 56.008 (2.2050 - 2.2050) Grade No. M 56.008 - 56.009 (2.2050 - 2.2051) Grade No. N 56.009 - 56.010 (2.2051 - 2.2051) Grade No. P 56.010 - 56.011 (2.2051 - 2.2052) Grade No. R 56.011 - 56.012 (2.2052 - 2.2052) Grade No. S 56.012 - 56.013 (2.2052 - 2.2052) Grade No. T 56.013 - 56.014 (2.2052 - 2.2053) Grade No. U 56.014 - 56.015 (2.2053 - 2.2053) Grade No. V 56.015 - 56.016 (2.2053 - 2.2053) Grade No. W 56.016 - 56.017 (2.2053 - 2.2054)

Scheme 239

PISTON, PISTON RING AND PISTON PIN

Available Piston

PISTON SPECIFICATIONS Unit: mm (in) Grade (1) Dimension Piston skirt diameter "A" Standard Grade No. 1 83.970 - 83.980 (3.3059 - 3.3063) Grade No. 2 83.980 - 83.990 (3.3063 - 3.3067) Piston height "H" dimension 39.9 (1.571) Piston pin hole diameter 19.993 - 19.999 (0.7871 - 0.7874) Piston to cylinder bore clearance Standard 0.020 - 0.040 (0.0008 - 0.0016) Limit 0.08 (0.0031) (1) Always check with the Parts Department for the latest parts information

Piston Ring

PISTON RING SPECIFICATIONS

Piston Pin

PISTON PIN SPECIFICATIONS

CONNECTING ROD

CONNECTING ROD SPECIFICATIONS

CRANKSHAFT

CRANKSHAFT SPECIFICATIONS Unit: mm (in) Center distance "r" 40.41 - 40.49 (1.5909 - 1.5940) Out-of-round (Difference between "X" and "Y") Limit 0.0035 (0.0001) Taper (Difference between "A" and "B") Limit 0.0035 (0.0001) Runout [TIR (1) ] Standard 0.05 (0.0020) Limit 0.10 (0.0040) Crankshaft end play Standard 0.10 - 0.26 (0.0039 - 0.0102) Limit 0.30 (0.012) Grade (2) Pin journal diameter grade. "Dp" Grade No. A 43.970 - 43.971 (1.7311 - 1.7311) Grade No. B 43.969 - 43.970 (1.7311 - 1.7311) Grade No. C 43.968 - 43.969 (1.7310 - 1.7311) Grade No. D 43.967 - 43.968 (1.7310 - 1.7310) Grade No. E 43.966 - 43.967 (1.7309 - 1.7310) Grade No. F 43.965 - 43.966 (1.7309 - 1.7309) Grade No. G 43.964 - 43.965 (1.7309 - 1.7309) Grade No. H 43.963 - 43.964 (1.7308 - 1.7309) Grade No. J 43.962 - 43.963 (1.7308 - 1.7308) Grade No. K 43.961 - 43.962 (1.7307 - 1.7308) Grade No. L 43.960 - 43.961 (1.7307 - 1.7307) Grade No. M 43.959 - 43.960 (1.7307 - 1.7307) Grade No. N 43.958 - 43.959 (1.7306 - 1.7307) Grade No. P 43.957 - 43.958 (1.7306 - 1.7306) Grade No. R 43.956 - 43.957 (1.7305 - 1.7306) Grade No. S 43.955 - 43.956 (1.7305 - 1.7305) Grade No. T 43.954 - 43.955 (1.7305 - 1.7305) Grade No. U 43.953 - 43.954 (1.7304 - 1.7305) Main journal diameter grade. "Dm" Grade No. A 51.978 - 51.979 (2.0464 - 2.0464) Grade No. B 51.977 - 51.978 (2.0463 - 2.0464) Grade No. C 51.976 - 51.977 (2.0463 - 2.0463) Grade No. D 51.975 - 51.976 (2.0463 - 2.0463) Grade No. E 51.974 - 51.975 (2.0462 - 2.0463) Grade No. F 51.973 - 51.974 (2.0462 - 2.0462) Grade No. G 51.972 - 51.973 (2.0461 - 2.0462) Grade No. H 51.971 - 51.972 (2.0461 - 2.0461) Grade No. J 51.970 - 51.971 (2.0461 - 2.0461) Grade No. K 51.969 - 51.970 (2.0460 - 2.0461) Grade No. L 51.968 - 51.969 (2.0460 - 2.0460) Grade No. M 51.967 - 51.968 (2.0459 - 2.0460) Grade No. N 51.966 - 51.967 (2.0459 - 2.0459) Grade No. P 51.965 - 51.966 (2.0459 - 2.0459) Grade No. R 51.964 - 51.965 (2.0458 - 2.0459) Grade No. S 51.963 - 51.964 (2.0458 - 2.0458) Grade No. T 51.962 - 51.963 (2.0457 - 2.0458) Grade No. U 51.961 - 51.962 (2.0457 - 2.0457) Grade No. V 51.960 - 51.961 (2.0457 - 2.0457) Grade No. W 51.959 - 51.960 (2.0456 - 2.0457) (1) Total indicator reading (2) Always check with the Parts Department for the latest parts information

Scheme 240

MAIN BEARING

MAIN BEARING SPECIFICATIONS

Undersize

UNDERSIZE SPECIFICATIONS

Bearing Oil Clearance

BEARING OIL CLEARANCE SPECIFICATIONS

CONNECTING ROD BEARING

CONNECTING ROD BEARING SPECIFICATIONS

Undersize

UNDERSIZE SPECIFICATIONS

Bearing Oil Clearance

BEARING OIL CLEARANCE SPECIFICATIONS