Engine Mechanical: Other Nissan Versa 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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.

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

Scheme 201

Disconnecting Fuel Piping

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

Special Service Tools

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

Tool number (Kent-Moore No.) Tool name Description KV10111100 (J-37228) Seal cutter Removing oil pan (lower and upper) etc. KV10116200 (J-26336-B) Valve spring compressor KV10115900 (J-26336-20) Attachment KV10109220 (-) Adapter Disassembling and assembling valve mechanism Part (1) is a component of KV10116200, but Part (2) is not so. KV10112100 (BT-8653-A) Angle wrench Tightening bolts for main bearing cap, cylinder head, etc. KV10117100 (-) Heated oxygen sensor wrench Loosening or tightening heated oxygen sensor 1 For 22 mm (0.87 in) width hexagon nut KV10107902 (J-38959) Valve oil seal puller 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) 5 (0.20) Unit: mm (in) EM03470000 (J-8037) Piston ring compressor Installing piston assembly into cylinder bore ST16610001 (J-23907) Pulley puller Removing pilot converter KV11103000 (-) Pulley puller Removing crankshaft pulley KV11105210 (J-44716) Stopper plate Holding drive plate and flywheel static

Scheme 202

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Commercial Service Tools

Tool name Description Power tool Loosening nuts, screws and bolts Quick connector release Removing fuel tube quick connectors in engine room Spark plug wrench Removing and installing spark plug a: 14 mm (0.55 in) Pulley holder Crankshaft pulley removing and installing Valve seat cutter set Finishing valve seat dimensions Piston ring expander Removing and installing piston ring 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 air fuel ratio sensor (Use with anti-seize lubricant shown below.) [18 mm (0.71 in) dia.] for zirconia heated oxygen sensor [12 mm (0.47 in) dia.] for titania heated oxygen sensor Mating surface shave cylinder Flutes Acoustic tension gauge Checking drive belt tension Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907) Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads Manual lift table caddy Removing and installing engine Compression gauge Adapter Checking compression pressure Tube presser Pressing the tube of liquid gasket

Scheme 207

Scheme 208

Scheme 209

Scheme 210

Scheme 211

Electric Throttle Control Actuator

1. Tighten bolts of electric throttle control actuator equally and diagonally in several steps.
2. Perform "Throttle Valve Closed Position Learning" after repair when removing harness connector of the electric throttle control actuator. Refer to " «WORK PROCEDURE»(ref-605934-S19939682792014032500000) ".
3. Perform "Throttle Valve Closed Position Learning" and "Idle Air Volume Learning" after repair when replacing electric throttle control actuator. Refer to " «WORK PROCEDURE»(ref-605934-S15570644802014032500000) ".

Scheme 212

Scheme 213

Scheme 214

1. Remove air duct (inlet), air duct and air cleaner assembly. Refer to " «EXPLODED VIEW»(ref-605933-S38654093822014032500000) ".
2. Remove exhaust center tube and front tube. Refer to " «EXPLODED VIEW»(ref-605938-S29975867842014032500000) ".
3. Remove the air-fuel ratio sensor harness bracket from the cylinder head on the right rear side.
4. Remove exhaust manifold cover.
5. Disconnect the harness from air-fuel ratio sensor 1.
6. Remove exhaust manifold side bolt of exhaust manifold stay.
7. Remove exhaust manifold. Loosen nuts in reverse order as shown below.
8. Use Tool (A) to remove the air-fuel ratio sensor 1 (if necessary). Tool number: KV10117100 (-) CAUTION: Handle the air-fuel ratio sensor carefully and avoid impacts. Before installing a new air-fuel ratio sensor 1, clean the exhaust tube threads using suitable tool and approved anti-seize lubricant. If air-fuel ratio sensor is dropped onto a hard surface, such as a concrete floor, from a height of 0.5 m or more, discard the sensor and use a new one. Oxygen sensor thread cleaner: - (J-43897-12) Oxygen sensor thread cleaner: - (J-43897-18)
9. Remove exhaust manifold gasket and discard.
10. Remove stud bolt using suitable tool from cylinder head (if necessary).

Mounting Surface Distortion

1. Using suitable tools (A) and (B), check the surface distortion of the exhaust manifold mating surface as shown below. Limit: Refer to " «EXHAUST MANIFOLD»(ref-605933-S36591741462014032500000) ".
2. Replace exhaust manifold if it exceeds the limit.

Scheme 215

Check on Fuel Leaks

1. Turn ignition switch ON with the engine stopped. Ensure there are no fuel leaks at fuel pipe connection points. NOTE: Use mirrors for checking points out of clear sight.
2. Start the engine and increase engine speed. Check again that there are no fuel leaks. CAUTION: Do not touch the engine immediately after stopped, as the engine becomes extremely hot.

Scheme 216

Scheme 217

1. Disconnect the battery negative terminal.
2. Remove intake manifold. Refer to " «EXPLODED VIEW»(ref-605933-S32978347962014032500000) ".
3. Remove ignition coil. CAUTION: Do not drop or shock ignition coil. Do not disassemble ignition coil.
4. Remove fuel tube protector. Refer to " «EXPLODED VIEW»(ref-605933-S28131376412014032500000) ".
5. Remove PCV hose from rocker cover.
6. Remove PCV valve, if necessary.
7. Remove rocker cover. Loosen bolts in reverse order as shown below.
8. Remove rocker cover gasket from rocker cover.
9. Use scraper to remove all traces of liquid gasket from cylinder head and front cover. CAUTION: Do not scratch or damage the mating surface when cleaning off old liquid gasket.

Cylinder Head Distortion

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

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 engine coolant.
2. At each of several locations on bottom surface of cylinder head, measure the distortion in six directions.

Scheme 218

Limit: Refer to " CYLINDER HEAD ".

1. If it exceeds the limit, replace cylinder head.

VALVE DIMENSIONS

1. Check the dimensions of each valve. For the dimensions, refer to " «CYLINDER HEAD»(ref-605933-S38619464092014032500000) ".
2. If dimensions are out of the standard, replace valve and check valve seat contact. Refer to " «VALVE SEAT CONTACT»(ref-605933-S04753446432014032500000) ".

VALVE GUIDE CLEARANCE

Valve Stem Diameter

Scheme 219

1. Measure the diameter of valve stem with micrometer (A). Standard: Refer to " «CYLINDER HEAD»(ref-605933-S38619464092014032500000) ". Valve Guide Inner Diameter
2. Measure the inner diameter of valve guide with bore gauge. Standard: Refer to " «CYLINDER HEAD»(ref-605933-S38619464092014032500000) ". Valve Guide Clearance
3. (Valve guide clearance) = (Valve guide inner diameter) - (Valve stem diameter) Standard and Limit: Refer to " «CYLINDER HEAD»(ref-605933-S38619464092014032500000) ".
4. If the calculated value exceeds the limit, replace valve and/or valve guide. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-605933-S27718448432014032500000) ".

Preparation

1. Release fuel pressure. Refer to " «WORK PROCEDURE»(ref-605934-S17108709862014032500000) ".
2. Drain engine coolant from radiator. Refer to " «DRAINING ENGINE COOLANT»(ref-605935-S26294057612014032500000) ". CAUTION: Perform this step when the engine is cold. Do not spill engine coolant on drive belts.
3. Remove the following parts

1. Front road wheels and tires (RH/LH).
2. Front fender protector (RH/LH). Refer to " «EXPLODED VIEW»(ref-605937-S14789021672014032500000) ".
3. Drive belt: Refer to " «REMOVAL AND INSTALLATION»(ref-605933-S42764128112014032500000) ".
4. Battery and battery tray. Refer to " «EXPLODED VIEW»(ref-605945-S41182453182014032500000) ".
5. Air duct (inlet), air duct, and air cleaner case assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-605933-S28177087482014032500000) ".
6. Radiator hose (upper and lower). Refer to " «EXPLODED VIEW»(ref-605935-S31360684332014032500000) ".
7. Exhaust front tube. Refer to " «EXPLODED VIEW»(ref-605938-S29975867842014032500000) ".

Engine Room (LH)

1. Disconnect all connections of engine harness around the battery, and then temporarily secure the engine harness into the engine side. CAUTION: Protect connectors against foreign materials during the operation by wrapping in a plastic bag.
2. Disconnect heater hoses. Refer to " «EXPLODED VIEW»(ref-605935-S31360684332014032500000) ".
3. Disconnect fuel feed hose at engine side. Refer to " «REMOVAL AND INSTALLATION»(ref-605933-S01089251912014032500000) ".
4. Disconnect control linkage cable from transaxle. Refer to " «REMOVAL AND INSTALLATION»(ref-605942-S17299259912014032500000) " (M/T models), " «REMOVAL AND INSTALLATION»(ref-605946-S30132690292014032500000) " (A/T models), " «REMOVAL AND INSTALLATION»(ref-605943-S10142516982014032500000) " (CVT models).
5. Disconnect clutch tube on transaxle side from clutch damper. Refer to " «EXPLODED VIEW»(ref-605944-S31194786542014032500000) ".

Engine Room (RH)

1. Remove alternator. Refer to " «EXPLODED VIEW»(ref-605945-S41182453182014032500000) ".
2. Disconnect vacuum hose at engine side.
3. Remove EVAP hoses at engine side.
4. Remove air conditioner compressor from the engine with the piping connected. Temporarily position the air conditioner compressor on the vehicle side with a rope without placing a heavy load on the piping.

Scheme 220

1. Remove ground cable at transaxle side.
2. Remove drive shafts (RH/LH). Refer to " «EXPLODED VIEW»(ref-605947-S00069964422014032500000) ".
3. Remove rear torque rod (1).
4. Preparation for the work of transaxle is as follows: Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to " «EXPLODED VIEW»(ref-605933-S41359413582014032500000) ".

Scheme 221

Scheme 222

Scheme 223

1. When engine can be hoisted, install engine slinger to cylinder head front left side (A) and rear right side (B) and support the engine position with a suitable tool. Slinger (A) bolts: 65.0 N.m (6.6 kg-m, 48 ft-lb) Slinger (B) bolts: 25.0 N.m (2.6 kg-m, 18 ft-lb)
2. Use a suitable tool (A) to securely support the bottom of the engine and the transaxle assembly. CAUTION: Put a piece of wood or an equivalent as the supporting surface and secure in a stable condition.
3. Remove engine mounting insulator (RH) (1).
4. Remove engine through bolt-securing nut (C).
5. Carefully lower jack, or raise lift to remove the engine and the transaxle assembly. Observe the following cautions: CAUTION: Check that no part interferes with the vehicle side. Before and during lifting, always check if any harnesses are left connected. During removal, 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.

Separation

1. Remove starter motor. Refer to " «EXPLODED VIEW»(ref-605948-S25665400352014032500000) ".
2. Lift with a hoist and separate the engine from the transaxle assembly. Refer to " «EXPLODED VIEW»(ref-605942-S12702844602014032500000) " (M/T models), " «EXPLODED VIEW»(ref-605946-S36599912482014032500000) " (A/T models), " «EXPLODED VIEW»(ref-605943-S12757538122014032500000) " (CVT models).

Engine Mounting Insulator (RH)

1. Tighten bolts in the numerical order as shown below.

Scheme 224

Setting

Note. The following procedures explain how to disassemble the engine with the engine stand fastened to the bell housing. Some steps may be different if using a different type of engine stand.

Scheme 225

Scheme 226

Scheme 227

1. Install engine to engine stand: Remove flywheel or drive plate. Secure flywheel (1) (M/T models) or drive plate (A/T or CVT models) using tool (A), and remove bolts. Tool number: KV11105210 (J-44716) CAUTION: Do not disassemble flywheel. Do not place flywheel or drive plate with signal plate facing down. When handling signal plate, take care not to damage or scratch it. Handle signal plate in a manner that prevents it from becoming magnetized. Lift the engine with a hoist to install it onto a suitable tool. CAUTION: Use the engine stand that has a load capacity approximately 150 kg (331 lb) or more large enough for supporting the engine weight. If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the potential risk of overturning stand. Intake manifold. Refer to " «EXPLODED VIEW»(ref-605933-S32978347962014032500000) ". Exhaust manifold. Refer to " «REMOVAL AND INSTALLATION»(ref-605933-S27339664862014032500000) ". Rocker cover. Refer to " «EXPLODED VIEW»(ref-605933-S07534786442014032500000) ". NOTE: The figure shows an example of widely used engine stand (A) that can support the mating surface of transaxle with flywheel removed. CAUTION: Before removing the hanging chains, check the engine stand is stable and there is no risk of overturning.
2. Drain engine oil. Refer to " «DRAINING»(ref-605939-S05113950672014032500000) ". CAUTION: Be sure to clean drain plug and install with new drain plug washer. Do not reuse drain plug washer.
3. Drain engine coolant by removing water drain plug (1) from inside of the engine. Water drain plug tightening torque: Refer to " «EXPLODED VIEW»(ref-605933-S34097784992014032500000) ". Use Genuine Silicone RTV Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-605927-S20340231952014032500000) ".

Piston Pin Hole Diameter

Measure the inner diameter of piston pin hole with an suitable tool (A).

Standard: Refer to " CYLINDER BLOCK ".

Scheme 228

Piston to Piston Pin Oil Clearance

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

Standard: Refer to " CYLINDER BLOCK ".

1. If oil clearance is out of the standard, replace piston and piston pin assembly.
2. When replacing piston and piston pin assembly. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-605933-S21985235282014032500000) ".

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 factory. For service parts, no grades can be selected. Only grade "0" is available.

Scheme 229

1. Measure the side clearance of piston ring and piston ring groove with a suitable tool (A). Standard and Limit: Refer to " «CYLINDER BLOCK»(ref-605933-S18255715842014032500000) ".
2. If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, replace piston also.

Scheme 230

1. Check that cylinder bore inner diameter is within specification. Refer to " «PISTON TO CYLINDER BORE CLEARANCE»(ref-605933-S21494962572014032500000) ".
2. Lubricate piston (1) and piston ring (2) with new engine oil and then insert (A) piston ring until middle of cylinder (B) with piston, and measure piston ring end gap with a feeler gauge (C). Standard and Limit: Refer to " «CYLINDER BLOCK»(ref-605933-S18255715842014032500000) ".
3. If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, replace cylinder block.

Scheme 231

1. Check with a connecting rod aligner. Limit: Refer to " «CYLINDER BLOCK»(ref-605933-S18255715842014032500000) ".
2. If it exceeds the limit, replace connecting rod assembly.

Scheme 232

1. Install connecting rod cap (1) without connecting rod bearing installed, and tightening connecting rod cap bolts to the specified torque. Refer to " «EXPLODED VIEW»(ref-605933-S34097784992014032500000) ".
2. Measure the inner diameter (B) of connecting rod big end with a suitable tool. Standard: Refer to " «CYLINDER BLOCK»(ref-605933-S18255715842014032500000) ".
3. If out of the standard, replace connecting rod assembly.

Connecting Rod Bushing Inner Diameter

Measure the inner diameter of connecting rod bushing with a suitable tool (A).

Inner diameter (Standard): Refer to " CYLINDER BLOCK ".

Scheme 233

Connecting Rod Bushing Oil Clearance

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

Oil clearance (Standard and Limit): Refer to " CYLINDER BLOCK ".

1. If the measured value is out of the standard range, replace connecting rod assembly and/or piston and piston pin assembly.
2. If replacing piston and piston pin assembly. Refer to " «CYLINDER BLOCK»(ref-605933-S18255715842014032500000) ".
3. If replacing connecting rod assembly. Refer to " «CONNECTING ROD BEARING»(ref-605933-S29798662162014032500000) ".

CYLINDER BLOCK TOP SURFACE DISTORTION

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 particles to enter engine oil or engine coolant passages.

1. Measure the distortion on the cylinder block upper face at different points in six directions with a suitable tool (A) and (B). Limit: Refer to " «CYLINDER BLOCK»(ref-605933-S18255715842014032500000) ".
2. If it exceeds the limit, replace cylinder block.

Scheme 234

Scheme 235

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-605933-S21985235282014032500000) ".
2. Measure the inner diameter of main bearing housing with a suitable tool.
3. Measure the position shown [5 mm (0.20 in)] backward from main bearing housing front side in the 2 directions as shown below. The smaller one is the measured value. Standard: Refer to " «CYLINDER BLOCK»(ref-605933-S18255715842014032500000) ".
4. If out of the standard, replace cylinder block and main bearing caps assembly.

Note. Main bearing caps cannot be replaced individually, because they are machined together with cylinder block.

Scheme 236

1. Using a suitable tool, measure the cylinder bore for wear, out-of-round and taper at six different points on each cylinder. [(A) and (B) directions at (C), (D), and (E)] [(A) is in longitudinal direction of engine] NOTE: When determining cylinder bore grade, measure the cylinder bore (B) direction at (D) position. Standard: Cylinder bore inner diameter: Refer to " «CYLINDER BLOCK»(ref-605933-S18255715842014032500000) ". Limit: Out-of-round [Difference between (A) and (B)] Taper [Difference between (C) and (E)]: Refer to " «CYLINDER BLOCK»(ref-605933-S18255715842014032500000) ".
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 available.

Piston Skirt Diameter

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

Standard: Refer to " CYLINDER BLOCK ".

Scheme 237

Piston to Cylinder Bore Clearance

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

Scheme 238

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

Standard and Limit: Refer to " CYLINDER BLOCK ".

1. If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block. Refer to " «CYLINDER BLOCK»(ref-605933-S18255715842014032500000) ".

Scheme 239

1. Measure the outer diameter of crankshaft main journals with a suitable tool (A). Standard: Refer to " «CYLINDER BLOCK»(ref-605933-S18255715842014032500000) ".
2. If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to " «MAIN BEARING»(ref-605933-S31282837182014032500000) ".

CRANKSHAFT PIN JOURNAL DIAMETER

1. Measure the outer diameter of crankshaft pin journal with a suitable tool. Standard: Refer to " «CYLINDER BLOCK»(ref-605933-S18255715842014032500000) ".
2. If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer to " «CONNECTING ROD BEARING»(ref-605933-S29798662162014032500000) ".

Scheme 240

1. Measure the dimensions at four different points as shown on each main journal and pin journal with a suitable tool.
2. Out-of-round is indicated by the difference in dimensions between (a) and (b) at (c) and (d).
3. Taper is indicated by the difference in dimension between (c) and (d) at (a) and (b).
4. If the measured value exceeds the limit, correct or replace crankshaft. Limit: Out-of-round [Difference between (a) and (b)] Taper [Difference between (c) and (d)]: Refer to " «CYLINDER BLOCK»(ref-605933-S18255715842014032500000) ".
5. If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select main bearing and/or connecting rod bearing. Refer to " «CONNECTING ROD BEARING»(ref-605933-S29798662162014032500000) " and/or " «MAIN BEARING»(ref-605933-S31282837182014032500000) ".

Scheme 241

1. Place a V-block on a precise flat table to support the journals on both ends of the crankshaft.
2. Place a suitable tool (A) straight up on the No. 3 journal.
3. While rotating crankshaft, read the movement of the pointer on the suitable tool. (Total indicator reading) Standard and Limit: Refer to " «CYLINDER BLOCK»(ref-605933-S18255715842014032500000) ".
4. If it exceeds the limit, replace crankshaft.

Scheme 242

1. Install connecting rod bearings (2) to connecting rod (3) and connecting rod cap (1), and tighten connecting rod cap bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-605933-S21985235282014032500000) ".
2. Measure the inner diameter of connecting rod bearing with a suitable tool. (Bearing oil clearance) = (Connecting rod bearing inner diameter) - (Crankshaft pin journal diameter) Standard and Limit: Refer to " «CONNECTING ROD BEARING»(ref-605933-S29798662162014032500000) ".
3. If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to " «CONNECTING ROD BEARING»(ref-605933-S29798662162014032500000) ".

Method of Using Plastigage

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 cap bolts to the specified torque. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-605933-S21985235282014032500000) ". 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 243

Scheme 244

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-605933-S21985235282014032500000) ".
2. Measure the inner diameter (B) of main bearing (3) with a suitable tool. (Bearing oil clearance) = (Main bearing inner diameter) - (Crankshaft main journal diameter) Standard and Limit: Refer to " «MAIN BEARING»(ref-605933-S31282837182014032500000) ".
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 " «MAIN BEARING»(ref-605933-S31282837182014032500000) ".

Scheme 245

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-605933-S21985235282014032500000) ". CAUTION: Do not 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 246

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-605933-S21985235282014032500000) ". Standard: There must be crush height.
2. If the standard is not met, replace main bearings.

Scheme 247

1. When connecting rod cap is removed after being tightened to the specified torque with connecting rod bearings (1) installed, the tip end of bearing must protrude (B). Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-605933-S21985235282014032500000) ". Standard: There must be crush height.
2. If the standard is not met, replace connecting rod bearings.

Scheme 248

1. Measure the outer diameters (d1) and (d2) at two positions as shown below.
2. If reduction appears in places other than (B) range, regard it as (d2). Limit [(d1) - (d2)]: 0.2 mm (0.0078 in)
3. If it exceeds the limit (a large difference in dimensions), replace main bearing cap bolt with a new one.

CONNECTING ROD CAP BOLT OUTER DIAMETER

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

Scheme 249

Scheme 250

1. Measure the deflection of flywheel contact surface to torque with a suitable tool (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, clean it with sandpaper. CAUTION: When measuring, keep magnetic fields (such as dial indicator stand) away from signal plate of the rear end of crankshaft.

WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED

1. Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter individually. Refer to " «INSPECTION»(ref-605933-S26432153622014032500000) ".
2. Apply the measured dimension to the " «Connecting Rod Bearing Selection Table»(ref-605933-S42502039452014032500000) ".
3. Read the symbol at the cross point of selected row and column in the " «Connecting Rod Bearing Selection Table»(ref-605933-S42502039452014032500000) ".
4. Apply the symbol obtained to the " «Connecting Rod Bearing Grade Table»(ref-605933-S40372706652014032500000) " to select connecting rod bearing.

Scheme 251

Connecting Rod Bearing Grade Table

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

Undersize Bearings Usage Guide

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

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

Scheme 252

Scheme 253

Scheme 254

1. "Main Bearing Selection Table" rows correspond to main bearing housing grade on left side of cylinder block. If there is a corrected stamp mark (B) 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»(ref-605933-S35354036232014032500000) ".
3. Read the symbol at the cross point of selected row and column in the " «Main Bearing Selection Table»(ref-605933-S35354036232014032500000) ".
4. Apply the symbol obtained to the " «Main Bearing Grade Table»(ref-605933-S30108692302014032500000) " to select main bearing. NOTE: Service part is available as a set of both upper and lower.

When Cylinder Block and Crankshaft Are Reused

1. Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main journal diameter individually. Refer to " «INSPECTION»(ref-605933-S26432153622014032500000) ".
2. Apply the measured dimension to the " «Main Bearing Selection Table»(ref-605933-S35354036232014032500000) ".
3. Read the symbol at the cross point of selected row and column in the " «Main Bearing Selection Table»(ref-605933-S35354036232014032500000) ".
4. Apply the symbol obtained to the " «Main Bearing Grade Table»(ref-605933-S30108692302014032500000) " to select main bearing.

Scheme 255

Main Bearing Grade Table

Main Bearing Grade Table: Refer to " MAIN BEARING ".

Use Undersize Bearing Usage Guide

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

In grinding crankshaft main journal to use undersize bearings, keep fillet (A) [0.8 - 1.2 mm (0.031 - 0.047 in)].

Bearing undersize table: Refer to " MAIN BEARING ".

Scheme 256

Valve Timing

Unit: degree Valve timing White Arrow: Intake valve Black Arrow: Exhaust valve a b c d e f 216 228 11 (-27) ATDC 59 (-21) ABDC -1 (49) ATDC 37 (-13) BBDC (): Valve timing control "ON"

DRIVE BELT

BELT DEFLECTION

BELT TENSION AND FREQUENCY SPECIFICATION

SPARK PLUG (PLATINUM-TIPPED TYPE)

EXHAUST MANIFOLD

CAMSHAFT

Unit: degree Items Standard Limit Camshaft runout [TIR (1) ] 0.02 (0.0008) 0.1 (0.0039) Camshaft cam height "A" Intake 41.705 - 41.895 (1.6419 - 1.6494) 41.505 (1.6341) Exhaust 40.915 - 41.105 (1.6108 - 1.6183) 40.715 (1.6029) Camshaft journal outer diameter No. 1 27.935 - 27.955 (1.0998 - 1.1006) - No. 2, 3, 4, 5 24.950 - 24.970 (0.9822 - 0.9830) - Camshaft bracket inner diameter No. 1 28.000 - 28.021 (1.1024 - 1.1032) - No. 2, 3, 4, 5 25.000 - 25.021 (0.9842 - 0.9850) - Camshaft journal oil clearance No. 1 0.045 - 0.086 (0.0018 - 0.0034) - No. 2, 3, 4, 5 0.030 - 0.071 (0.0011 - 0.0027) - Camshaft end play 0.075 - 0.153 (0.0029 - 0.0060) 0.2 (0.0078) Camshaft sprocket runout [TIR (1) ] - 0.1 (0.0039) (1) Total indicator reading

Scheme 257

VALVE LIFTER

VALVE CLEARANCE

AVAILABLE VALVE LIFTER

Unit: degree Identification mark (A) Thickness (B) 300 3.00 (0.1181) 302 3.02 (0.1188) 304 3.04 (0.1196) 306 3.06 (0.1204) 308 3.08 (0.1212) 310 3.10 (0.1220) 312 3.12 (0.1228) 314 3.14 (0.1236) 316 3.16 (0.1244) 318 3.18 (0.1251) 320 3.20 (0.1259) 322 3.22 (0.1267) 324 3.24 (0.1275) 326 3.26 (0.1283) 328 3.28 (0.1291) 330 3.30 (0.1299) 332 3.32 (0.1307) 334 3.34 (0.1314) 336 3.36 (0.1322) 338 3.38 (0.1330) 340 3.40 (0.1338) 342 3.42 (0.1346) 344 3.44 (0.1354) 346 3.46 (0.1362) 348 3.48 (0.1370) 350 3.50 (0.1377)

CYLINDER HEAD

Unit: degree Valve head diameter "D" Intake 31.6 - 31.9 (1.244 - 1.256) Exhaust 25.3 - 25.6 (0.996 - 1.007) Valve length "a" Intake 101.73 (4.01) Exhaust 102.49 (4.04) "b" Intake 1.0 (0.0393) Exhaust 1.0 (0.0393) "c" Intake 2.1 - 2.8 (0.0826 - 0.1102) Exhaust 2.3 - 3.0 (0.0905 - 0.1181) "c" Intake 3.0 (0.1181) Exhaust -- "d" Intake 4.965 - 4.980 (0.1954 - 0.1960) Exhaust 4.955 - 4.970 (0.1950 - 0.1956) Valve seat angle "α" Intake 45°15' - 45°45' Exhaust

Scheme 258

VALVE GUIDE

Unit: degree Items Standard part Service part Valve guide Outer diameter 9.023 - 9.034 (0.3552 - 0.3556) 9.223 - 9.234 (0.3631 - 0.3635) Inner diameter (Finished size) 5.000 - 5.018 (0.1968 - 0.1975) Cylinder head valve guide hole diameter 8.975 - 9.001 (0.3533 - 0.3544) 9.175 - 9.201 (0.3612 - 0.3622) Interference fit of valve guide 0.022 - 0.059 (0.0009 - 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) 0.1 (0.004) Projection length "L" 11.4 - 11.8 (0.448 - 0.464)

Scheme 259

VALVE SEAT

Unit: degree Items Standard Oversize [0.5 (0.02)] (Service) Cylinder head seat recess diameter "D" Intake 32.000 - 32.027 (1.2598 - 1.2609) 32.500 - 32.527 (1.2795 - 1.2806) Exhaust 25.900 - 25.927 (1.0197 - 1.0207) 26.400 - 26.427 (1.0394 - 1.0404) Valve seat outer diameter "d" Intake 32.108 - 32.124 (1.2641 - 1.2647) 32.608 - 32.624 (1.2838 - 1.2844) Exhaust 25.991 - 26.007 (1.0233 - 1.0239) 26.491 - 26.507 (1.0430 - 1.0436) Valve seat interference fit Intake 0.081 - 0.124 (0.0032 - 0.0049) Exhaust 0.064 - 0.107 (0.0025 - 0.0042) Diameter "d1" (1) Intake 29.6 (1.165) Exhaust 23.0 (0.905) Diameter "d2" (2) Intake 31.2 - 31.4 (1.228 - 1.236) Exhaust 24.9 - 25.1 (0.980 - 0.988) Angle "α1" Intake 60° Exhaust 45° Angle "α2" Intake 88°45' - 90°15' Exhaust 88°45' - 90°15' Angle "α3" Intake 120° Exhaust 120° Contacting width "W" (3) Intake 1.05 - 1.35 (0.0413 - 0.0531) Exhaust 1.15 - 1.55 (0.0453 - 0.0610) Height "h" Intake 4.7 (0.185) 4.15 (0.163) Exhaust 6.0 (0.236) 5.43 (0.213) Depth "H" Intake 4.7 (0.185) Exhaust 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: degree Surface distortion Limit 0.1 (0.004) Cylinder bore Inner diameter Standard 78.000 - 78.015 (3.0708 - 3.0714) Wear limit - Out-of-round (Difference between "X" and "Y") Limit 0.015 (0.0006) Taper (Difference between "A" and "C") 0.010 (0.0004) Cylinder block main bearing housing inner diameter grade (1) Grade No. A 51.997 - 51.998 (2.0471 - 2.0472) Grade No. B 51.998 - 51.999 (2.0472 - 2.0472) Grade No. C 51.999 - 52.000 (2.0472 - 2.0472) Grade No. D 52.000 - 52.001 (2.0472 - 2.0472) Grade No. E 52.001 - 52.002 (2.0473 - 2.0473) Grade No. F 52.002 - 52.003 (2.0473 - 2.0473) Grade No. G 52.003 - 52.004 (2.0474 - 2.0474) Grade No. H 52.004 - 52.005 (2.0474 - 2.0474) Grade No. J 52.005 - 52.006 (2.0474 - 2.0474) Grade No. K 52.006 - 52.007 (2.0475 - 2.0475) Grade No. L 52.007 - 52.008 (2.0475 - 2.0475) Grade No. M 52.008 - 52.009 (2.0476 - 2.0476) Grade No. N 52.009 - 52.010 (2.0476 - 2.0476) Grade No. P 52.010 - 52.011 (2.0476 - 2.0476) Grade No. R 52.011 - 52.012 (2.0477 - 2.0477) Grade No. S 52.012 - 52.013 (2.0477 - 2.0477) Grade No. T 52.013 - 52.014 (2.0478 - 2.0478) Grade No. U 52.014 - 52.015 (2.0478 - 2.0478) Grade No. V 52.015 - 52.016 (2.0478 - 2.0478) Grade No. W 52.016 - 52.017 (2.0479 - 2.0479) Difference in inner diameter between cylinders Standard Less than 0.03 (0.0012) (1) Always check with the Parts Department for the latest parts information

AVAILABLE PISTON

Unit: degree Piston skirt diameter "A" 77.965 - 77.980 (3.0694 - 3.0700) Piston height "H" dimension 37.1 (1.460) Piston pin hole diameter 19.006 - 19.012 (0.7482 - 0.7485) Piston to cylinder bore clearance 0.020 - 0.050 (0.0007 - 0.0019)

Scheme 260

PISTON RING

PISTON PIN

CONNECTING ROD

CRANKSHAFT

Unit: degree Center distance "r" 41.68 - 41.76 (1.6409 - 1.6440) Out-of-round Limit 0.003 (0.0001) Taper Limit 0.004 (0.0002) Runout [TIR (1) ] Limit 0.10 (0.0039) Crankshaft end play Standard 0.098 - 0.260 (0.0039 - 0.0102) Limit 0.35 (0.0138) Crankshaft pin journal diameter grade. (2) "Dp" Grade No. A 39.971 - 39.970 (1.5737 - 1.5736) Grade No. B 39.970 - 39.969 (1.5736 - 1.5736) Grade No. C 39.969 - 39.968 (1.5736 - 1.5735) Grade No. D 39.968 - 39.967 (1.5735 - 1.5735) Grade No. E 39.967 - 39.966 (1.5735 - 1.5735) Grade No. F 39.966 - 39.965 (1.5735 - 1.5734) Grade No. G 39.965 - 39.964 (1.5734 - 1.5734) Grade No. H 39.964 - 39.963 (1.5734 - 1.5733) Grade No. J 39.963 - 39.962 (1.5733 - 1.5733) Grade No. K 39.962 - 39.961 (1.5733 - 1.5733) Grade No. L 39.961 - 39.960 (1.5733 - 1.5732) Grade No. M 39.960 - 39.959 (1.5732 - 1.5732) Grade No. N 39.959 - 39.958 (1.5732 - 1.5731) Grade No. P 39.958 - 39.957 (1.5731 - 1.5731) Grade No. R 39.957 - 39.956 (1.5731 - 1.5731) Grade No. S 39.956 - 39.955 (1.5731 - 1.5730) Grade No. T 39.955 - 39.954 (1.5730 - 1.5730) Grade No. U 39.954 - 39.953 (1.5730 - 1.5729) Crankshaft main journal diameter grade. (2) "Dm" Grade No. A 47.979 - 47.978 (1.8889 - 1.8889) Grade No. B 47.978 - 47.977 (1.8889 - 1.8889) Grade No. C 47.977 - 47.976 (1.8889 - 1.8888) Grade No. D 47.976 - 47.975 (1.8888 - 1.8888) Grade No. E 47.975 - 47.974 (1.8888 - 1.8887) Grade No. F 47.974 - 47.973 (1.8887 - 1.8887) Grade No. G 47.973 - 47.972 (1.8887 - 1.8887) Grade No. H 47.972 - 47.971 (1.8887 - 1.8886) Grade No. J 47.971 - 47.970 (1.8886 - 1.8886) Grade No. K 47.970 - 47.969 (1.8886 - 1.8885) Grade No. L 47.969 - 47.968 (1.8885 - 1.8885) Grade No. M 47.968 - 47.967 (1.8885 - 1.8885) Grade No. N 47.967 - 47.966 (1.8885 - 1.8884) Grade No. P 47.966 - 47.965 (1.8884 - 1.8884) Grade No. R 47.995 - 47.964 (1.8884 - 1.8883) Grade No. S 47.994 - 47.963 (1.8883 - 1.8883) Grade No. T 47.963 - 47.962 (1.8883 - 1.8883) Grade No. U 47.962 - 47.961 (1.8883 - 1.8882) Grade No. V 47.961 - 47.960 (1.8882 - 1.8882) Grade No. W 47.960 - 47.959 (1.8882 - 1.8881) (1) Total indicator reading (2) Always check with the Parts Department for the latest parts information

Scheme 261

MAIN BEARING

Unit: degree Grade number (1) Thickness Identification color Remarks 0 1.996 - 1.999 (0.0785 - 0.0787) Black Grade and color are the same for upper and lower bearings. 1 1.999 - 2.002 (0.0787 - 0.0788) Brown 2 2.002 - 2.005 (0.0788 - 0.0789) Green 3 2.005 - 2.008 (0.0789 - 0.0790) Yellow 4 2.008 - 2.011 (0.0790 - 0.0791) Blue 5 2.011 - 2.014 (0.0791 - 0.0792) Pink 01 UPR 1.996 - 1.999 (0.0785 - 0.0787) Black Grade and color are different for upper and lower bearings. LWR 1.999 - 2.002 (0.0787 - 0.0788) Brown 12 UPR 1.999 - 2.002 (0.0787 - 0.0788) Brown LWR 2.002 - 2.005 (0.0788 - 0.0789) Green 23 UPR 2.002 - 2.005 (0.0788 - 0.0789) Green LWR 2.005 - 2.008 (0.0789 - 0.0790) Yellow 34 UPR 2.005 - 2.008 (0.0789 - 0.0790) Yellow LWR 2.008 - 2.011 (0.0790 - 0.0791) Blue 45 UPR 2.008 - 2.011 (0.0790 - 0.0791) Blue LWR 2.011 - 2.014 (0.0791 - 0.0792) Pink (1) Always check with the Parts Department for the latest parts information

Scheme 262

Undersize

Bearing Oil Clearance

CONNECTING ROD BEARING