Engine Mechanical: Other Suzuki Kizashi I

Cleaning

Blow off dust with compressed air from air outlet side of filter.

Scheme 146

Throttle Body Cleaning

Reference: THROTTLE BODY ASSEMBLY REMOVAL AND INSTALLATION

Clean throttle body assembly according to "Throttle Valve Visual Check" under ELECTRIC THROTTLE BODY ASSEMBLY ON-VEHICLE INSPECTION .

Cam Height

Use a micrometer to measure cam height "a". Replace camshaft if measured height is out of standard values.

Cam Height (IN)

Standard: 47.620 - 47.780 mm (1.8748 - 1.8811 in.)

Limit: 47.490 mm (1.8696 in.)

Cam Height (EX)

Standard: 46.543 - 46.703 mm (1.8324 - 1.8387 in.)

Limit: 46.420 mm (1.8275 in.)

Scheme 147

Camshaft Runout

Set camshaft between two "V" blocks and measure its runout using a dial gauge.

Replace camshaft if measured camshaft runout exceeds limit.

Camshaft runout limit

0.015 mm (0.00059 in.)

Scheme 148

Scheme 149

1. Check camshaft journals and camshaft housings for pitting, scratches, wear or damage. Replace camshaft or cylinder head with camshaft housings if any defective conditions are found. CAUTION: Do not attempt to fix faults in camshaft journal and camshaft housing for the purpose of reuse.

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Scheme 154

1. Clean camshaft housings and camshaft journals.
2. Remove all tappets.
3. Install lower bearing half and camshafts to cylinder head.
4. Place plastic gauge with the same width as the camshaft journal parallel to the camshaft, avoiding the oil hole.
5. Install camshaft housing. Refer to steps 5 ) to 6 ) in "Installation" under «CAMSHAFT AND TAPPET REMOVAL AND INSTALLATION»(ref-585578-S27345590882013111200000) . CAUTION: Do not rotate camshaft while gauging plastic is installed.
6. Remove housings, and use scale (2) on plastic gauge envelope to measure plastic gauge (1) width at the widest point. Camshaft journal clearance (intake side of camshaft housing No. 1) Standard: 0.020 - 0.072 mm (0.00078 - 0.00283 in.) Limit: 0.10 mm (0.0039 in.) Camshaft journal clearance (except intake side of camshaft housing No. 1) Standard: 0.020 - 0.062 mm (0.00078 - 0.00244 in.) Limit: 0.095 mm (0.00374 in.) If measured camshaft journal clearance exceeds limit, recheck camshaft journal clearance using the following procedures: Install camshaft upper bearing half and camshaft housings without camshafts to cylinder head. Tighten camshaft housing bolts. Refer to Step 6 ) in "Installation" under «CAMSHAFT AND TAPPET REMOVAL AND INSTALLATION»(ref-585578-S27345590882013111200000) . For intake camshaft journal No. 1, measure journal outside diameter at positions shown in figure. Replace camshaft and recheck camshaft journal clearance if measured diameter is out of standard values. Replace camshaft bearings and recheck camshaft journal clearance if measured diameter is within standard values. For all other camshaft journals, measure camshaft journal outside diameters and camshaft housing inside diameters. Replace corresponding camshaft or cylinder head and camshaft housings if measured diameters are out of standard values. Camshaft journal outside diameter CAMSHAFT JOURNAL OUTSIDE DIAMETER SPECIFICATION Item Standard Intake camshaft journal No. 1 "a" 28.959 - 28.980 mm (1.1402 - 1.1409 in.) Exhaust camshaft journal No. 1 26.959 - 26.980 mm (1.0614 - 1.0622 in.) Others 25.959 - 25.980 mm (1.0220 - 1.0228 in.) Camshaft housing inside diameter CAMSHAFT HOUSING INSIDE DIAMETER SPECIFICATION Item Camshaft housing No. 1 (intake) 32.000 - 32.025 mm (1.2599 - 1.2608 in.) Camshaft housing No. 1 (exhaust) 27.000 - 27.021 mm (1.0630 - 1.0638 in.) Others 26.000 - 26.021 mm (1.0237 - 1.0244 in.)
7. Install intake and exhaust camshaft without tappet, and then measure intake and exhaust camshaft housing thrust clearance using a dial gauge. Replace camshaft or cylinder head and camshaft housings if measured clearance exceeds limit. Camshaft housing thrust clearance Standard: 0.10 - 0.35 mm (0.0039 - 0.0137 in.) Limit: 0.50 mm (0.019 in.)

Wear of Tappet

Check tappet for pitting, scratches, or damage.

Replace tappet if any defective conditions are found.

Scheme 155

Measure tappet bore of cylinder head inside diameter, and tappet outside diameter, and then determine cylinder head-to-tappet clearance. Replace tappet or cylinder head if clearance exceeds limit.

Cylinder head to tappet clearance

Standard: 0.025 - 0.066 mm (0.0010 - 0.0025 in.)

Limit: 0.10 mm (0.0039 in.)

Tappet outside diameter

Standard: 32.459 - 32.475 mm (1.2780 - 1.2785 in.)

Cylinder head tappet bore

Standard: 32.500 - 32.525 mm (1.2796 - 1.2805 in.)

Scheme 156

Scheme 157

Scheme 158

1. Check CMP actuator for wear or damage. Replace CMP actuator if any defective conditions are found.
2. Install CMP actuator to intake camshaft and hold hexagonal section of intake camshaft stationary using wrench. Check that CMP actuator (1) cannot be turned by hand. Replace CMP actuator if it can be turned by hand.

Exhaust Camshaft Timing Sprocket

Check exhaust camshaft timing sprocket for wear and damage.

Replace exhaust camshaft timing sprocket if any defective conditions are found.

Scheme 159

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Scheme 173

1. Relieve fuel pressure, see «FUEL PRESSURE RELIEF PROCEDURE»(ref-585580-S41562041252013111200000) .
2. Disconnect negative (-) and positive (+) cables at battery.
3. Disconnect ECM connectors.
4. Remove ECM, battery, battery tray and battery bracket, see «BATTERY REMOVAL AND INSTALLATION»(ref-585571-S13362772662013111200000) .
5. Remove right and left side engine under covers.
6. Remove right and left side front fender lower linings.
7. Remove front bumper and front bumper lower cover, see «FRONT BUMPER REMOVAL AND INSTALLATION»(ref-585603-S29130228662013111200000) .
8. Remove engine cover.
9. Drain coolant, see «COOLING SYSTEM DRAINING»(ref-585577-S13391481082013111200000) .
10. Drain the following oils and fluid if necessary. Engine oil: «ENGINE OIL AND FILTER CHANGE»(ref-585579-S01068882562013111200000) Manual transaxle oil (M/T model): «MANUAL TRANSAXLE OIL CHANGE»(ref-585624-S34895448932013111200000) CVT fluid (CVT model): «CVT FLUID CHANGE»(ref-585587-S28544723892013111200000) Transfer oil (4WD model): «TRANSFER OIL CHANGE»(ref-585625-S30391754522013111200000)
11. Disconnect the following electric wires, connectors and clamp: Connector (1) in main fuse box Connector (2) in fuse box No. 1 Connector (3) in fuse box No. 2 Engine harness connector to main harness connector (4) (CVT model) Battery ground cable (5) Engine harness clamp (6) Front height sensor connector (7)
12. Disconnect the following hoses: Brake booster hose (1) Heater inlet and outlet hoses (2) Fuel hose (3) EVAP canister purge hose (4) Radiator inlet hose (5) CVT Fluid Cooler No. 1 Hose (6) (CVT model) CVT Fluid Cooler No. 2 Hose (7) (CVT model)
13. Remove radiator outlet hose, thermostat cap and thermostat, see «THERMOSTAT REMOVAL AND INSTALLATION»(ref-585577-S36494921282013111200000) .
14. Remove battery ground terminal bolt (1) after disconnecting the following cables: Gear select control cable (2) (M/T model): «MANUAL TRANSAXLE UNIT COMPONENTS»(ref-585624-S03633693932013111200000) Gear shift control cable (3) (M/T model): «MANUAL TRANSAXLE UNIT COMPONENTS»(ref-585624-S03633693932013111200000) Battery ground terminal bolt (M/T model): «MANUAL TRANSAXLE UNIT COMPONENTS»(ref-585624-S03633693932013111200000) Select cable (4) (CVT model): «SELECT CABLE COMPONENTS»(ref-585587-S18513163062013111200000)
15. Remove accessory drive belt, see «ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(ref-585571-S19141351432013111200000) .
16. With A/C hoses connected, remove A/C compressor from bracket, see «A/C COMPRESSOR ASSEMBLY REMOVAL AND INSTALLATION»(ref-585570-S34930290842013111200000) . CAUTION: The A/C compressor may be damaged if it hits against or interferes with other parts. Suspend the removed A/C compressor in a place where no damage will be caused during removal and installation of the engine assembly.
17. Remove front brake caliper and brake pads, see «FRONT BRAKE PAD REMOVAL AND INSTALLATION»(ref-585573-S38530280222013111200000) .
18. Remove front wheel speed sensor harness clamp bolt, and then detach front speed sensor harness from strut bracket, see «FRONT WHEEL SPEED SENSOR REMOVAL AND INSTALLATION»(ref-585576-S37738961872013111200000) .
19. Remove front strut nuts and bolts. Refer to steps 1) to 5) in "removal" under «FRONT STRUT ASSEMBLY REMOVAL AND INSTALLATION»(ref-585582-S17737411652013111200000) .
20. Remove floor tunnel front brace (1).
21. Remove exhaust pipe No. 1 and heat protector panel No. 1, see «EXHAUST SYSTEM COMPONENTS»(ref-585626-S07679347812013111200000) .
22. For 4WD model, remove propeller shaft assembly, see «PROPELLER SHAFT ASSEMBLY REMOVAL AND INSTALLATION»(ref-585627-S40086012832013111200000) .
23. Remove steering lower shaft. Refer to steps 4) to 7) in "removal" under «STEERING COLUMN REMOVAL AND INSTALLATION»(ref-585616-S28555238922013111200000) .
24. Remove P/S control module cover after turning over passenger side carpet, disconnect P/S control module connector (1) and remove ground bolt (2). Then, pull the harness (3) out to engine compartment.
25. Disconnect ground cable (1) from suspension frame rear mounting bracket and body.
26. Support suspension frame (1) and engine assembly (2) using engine lifter.
27. Remove suspension frame mounting brackets, see «FRONT SUSPENSION FRAME COMPONENTS»(ref-585582-S13441328602013111200000) .
28. Remove engine left mounting bracket (1).
29. Remove engine right mounting bracket nuts (1), then loosen engine right mounting bolts (2).
30. Before lowering engine, make sure that all hoses, electric wires and cables are disconnected from engine.
31. Lower engine assembly with transaxle, transfer (4WD model), front drive shafts and suspension frame all together. CAUTION: The A/C compressor may be damaged if there is not adequate clearance when the engine is lowered. Before lowering the engine, move the A/C compressor to vehicle body side to ensure that there is adequate clearance when the engine is lowered. NOTE: Prior to removing engine rear mounting bracket No. 1 on 4WD model, it is necessary to remove transfer and disconnect engine rear mounting bracket No. 2.
32. Remove front drive shaft assembly if necessary, see «FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION»(ref-585617-S17552051012013111200000) .
33. For 4WD model, remove transfer if necessary, see «TRANSFER DISMOUNTING AND REMOUNTING»(ref-585625-S01899617802013111200000) .
34. Remove engine mounting bracket from engine assembly if necessary, see «ENGINE MOUNTINGS COMPONENTS»(ref-585578-S18230687082013111200000) .
35. Remove transaxle if necessary. M/T model: «MANUAL TRANSAXLE UNIT DISMOUNTING AND REMOUNTING»(ref-585624-S15424779752013111200000) CVT model: «CVT ASSEMBLY DISMOUNTING AND REMOUNTING»(ref-585587-S29986396022013111200000)
36. For M/T model, remove clutch cover and clutch disc if necessary, see «CLUTCH COVER AND CLUTCH DISC REMOVAL AND INSTALLATION»(ref-585631-S28044271252013111200000) .
37. For M/T model, remove flywheel if necessary, see «FLYWHEEL/DRIVE PLATE REMOVAL AND INSTALLATION»(ref-585578-S07998687232013111200000) . For CVT model, remove drive plate if necessary, see «FLYWHEEL/DRIVE PLATE REMOVAL AND INSTALLATION»(ref-585578-S07998687232013111200000) .
38. Remove engine harness from engine assembly if necessary.

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1. Install engine harness to engine assembly if removed.
2. For M/T model, install flywheel if removed, see «FLYWHEEL/DRIVE PLATE REMOVAL AND INSTALLATION»(ref-585578-S07998687232013111200000) .
3. For CVT model, install drive plate if removed, see «FLYWHEEL/DRIVE PLATE REMOVAL AND INSTALLATION»(ref-585578-S07998687232013111200000) .
4. For M/T model, install clutch cover and clutch disc if removed, see «CLUTCH COVER AND CLUTCH DISC REMOVAL AND INSTALLATION»(ref-585631-S28044271252013111200000) .
5. Install transaxle to engine if removed. For M/T model: «MANUAL TRANSAXLE UNIT DISMOUNTING AND REMOUNTING»(ref-585624-S15424779752013111200000) For CVT model: «CVT ASSEMBLY DISMOUNTING AND REMOUNTING»(ref-585587-S29986396022013111200000)
6. Install engine mounting bracket to engine assembly if removed, see «ENGINE MOUNTINGS COMPONENTS»(ref-585578-S18230687082013111200000) .
7. For 4WD model, install transfer if removed, see «TRANSFER DISMOUNTING AND REMOUNTING»(ref-585625-S01899617802013111200000) .
8. Install front drive shaft assembly if removed, see «FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION»(ref-585617-S17552051012013111200000) .
9. Lift up engine assembly together with transaxle, transfer (4WD model), front drive shafts and suspension frame into engine compartment using engine lifter. NOTE: The A/C compressor may be damaged if there is not adequate clearance when the engine is raised. Before raising the engine, move the A/C compressor to vehicle body side to ensure that there is adequate clearance when the engine is raised.
10. Tighten engine right mounting bracket bolts and nuts to specified torque, see «ENGINE MOUNTINGS COMPONENTS»(ref-585578-S18230687082013111200000) .
11. Install left mounting bracket, then tighten left mounting bracket bolts and nuts to specified torque, see «ENGINE MOUNTINGS COMPONENTS»(ref-585578-S18230687082013111200000) .
12. Install suspension frame mounting brackets, then tighten suspension frame mounting bracket bolts to specified torque, see «FRONT SUSPENSION FRAME COMPONENTS»(ref-585582-S13441328602013111200000) .
13. Connect ground cable to suspension frame mounting bracket and body, then tighten ground cable bolts (1) to specified torque. Tightening torque Ground cable bolt (a): 9.0 N.m (0.92 kg-m, 7.0 lbf-ft)
14. Insert EPS harness (3) into cabin, connect P/S control module connector (1), tighten ground bolt (2) to specified torque, and then install P/S control module cover. Tightening torque P/S control module ground bolt (a): 9.0 N.m (0.92 kg-m, 7.0 lbf-ft)
15. Connect steering lower shaft to pinion shaft, then tighten lower joint bolt to specified torque, see «STEERING COLUMN REMOVAL AND INSTALLATION»(ref-585616-S28555238922013111200000) .
16. For 4WD model, install propeller shaft assembly, see «PROPELLER SHAFT ASSEMBLY REMOVAL AND INSTALLATION»(ref-585627-S40086012832013111200000) .
17. Install exhaust pipe No. 1 and heat protector panel No. 1, see «EXHAUST SYSTEM COMPONENTS»(ref-585626-S07679347812013111200000) .
18. Install floor tunnel front brace (1).
19. Tighten front strut bolts and nuts to specified torque, see «FRONT STRUT ASSEMBLY REMOVAL AND INSTALLATION»(ref-585582-S17737411652013111200000) .
20. Connect front wheel speed sensor harness to strut bracket, then tighten front wheel speed sensor harness clamp bolt, see «FRONT WHEEL SPEED SENSOR REMOVAL AND INSTALLATION»(ref-585576-S37738961872013111200000) .
21. Install brake pads and caliper, see «FRONT BRAKE PAD REMOVAL AND INSTALLATION»(ref-585573-S38530280222013111200000) .
22. Install A/C compressor to bracket, see «A/C COMPRESSOR ASSEMBLY REMOVAL AND INSTALLATION»(ref-585570-S34930290842013111200000) .
23. Install accessory drive belt, see «ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(ref-585571-S19141351432013111200000) .
24. For M/T model, connect gear select control cable, gear shift control cable, then tighten battery ground terminal bolt to specified torque, see «MANUAL TRANSAXLE UNIT COMPONENTS»(ref-585624-S03633693932013111200000) .
25. For CVT model, connect select cable, see «SELECT CABLE COMPONENTS»(ref-585587-S18513163062013111200000) .
26. Install thermostat, thermostat cap and radiator outlet hose, see «THERMOSTAT REMOVAL AND INSTALLATION»(ref-585577-S36494921282013111200000) .
27. Install engine harness clamps.
28. Install all other removed electric wires, connectors and hoses to original locations.
29. Tighten battery ground terminal bolts (1) to specified torque. Tightening torque Battery ground terminal bolts (a): 9.0 N.m (0.92 kg-m, 7.0 lbf-ft)
30. Install air cleaner assembly, see «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(ref-585578-S10930133882013111200000) .
31. Refill oils and fluid. Engine oil: «ENGINE OIL AND FILTER CHANGE»(ref-585579-S01068882562013111200000) . Manual transmission oil (M/T model): «MANUAL TRANSAXLE OIL CHANGE»(ref-585624-S34895448932013111200000) . CVT fluid (CVT model): «CVT FLUID CHANGE»(ref-585587-S28544723892013111200000) . Transfer oil (4WD model): «TRANSFER OIL CHANGE»(ref-585625-S30391754522013111200000) .
32. Refill cooling system with coolant, see «COOLING SYSTEM REFILLING»(ref-585577-S08150924882013111200000) .
33. Install right and left side engine under covers.
34. Install battery bracket, battery tray, battery and ECM, see «BATTERY REMOVAL AND INSTALLATION»(ref-585571-S13362772662013111200000) .
35. Connect ECM connectors.
36. Connect positive (+) cables and negative (-) at battery.
37. Check any leakage of fuel, coolant, oil and exhaust. Fuel leak: «FUEL LEAKAGE CHECK PROCEDURE»(ref-585580-S37613334522013111200000) Coolant leak: «ENGINE COOLING SYSTEM INSPECTION»(ref-585577-S39475297722013111200000)
38. Install engine cover.
39. Install front bumper and front bumper lower cover, see «FRONT BUMPER REMOVAL AND INSTALLATION»(ref-585603-S29130228662013111200000) .
40. Install right and left side front fender lower linings.

Scheme 178

Oil Seal

Check oil seal lip for any damage. Replace oil seal if any abnormalities are found.

Timing Chain Cover

Inspect oil passage (1) for driving CMP actuator and strainer (2).

Clean passage and strainer if clog or foreign matter exists.

Scheme 179

Flywheel/Drive Plate Face Runout

1. Check flywheel for M/T model or drive plate for CVT model for runout using dial gauge and "V" blocks. Replace flywheel for M/T model or drive plate for CVT model if measured runout exceeds the limit, see «FLYWHEEL/DRIVE PLATE REMOVAL AND INSTALLATION»(ref-585578-S07998687232013111200000) .

Flywheel/drive plate face runout

Limit: 0.2 mm (0.0078 in.)

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Timing Chain Guide

Check sliding surface of timing chain guide (1) for wear or damage.

Replace timing chain guide if any abnormalities are found.

Scheme 182

Timing Chain Tensioner

Check sliding surface of timing chain tensioner (1) for wear or damage.

Replace timing chain tensioner if any abnormalities are found.

Scheme 183

Crankshaft Timing Sprocket

Check sprocket teeth for wear or damage.

Replace crankshaft timing sprocket if any abnormalities are found.

Scheme 184

Timing Chain

Check timing chain for wear or damage.

Replace timing chain if any abnormalities are found.

Scheme 185

Timing Chain Tensioner Adjuster

Check that tooth surface (1) are free from damage.

Replace timing chain tensioner adjuster if any abnormalities are found.

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Valve Stem-To-Guide Clearance

1. Take diameter readings on valve stems and guides with a micrometer and bore gauge to check system-to-guide clearance.
2. Be sure to take reading at more than one place along the length of each stem and guide.
3. Replace valve and valve guide if clearance exceeds limit.

Valve stem outside diameter

IN: 5.465 - 5.480 mm (0.2152 - 0.2157 in.)

EX: 5.440 - 5.455 mm (0.2142 - 0.2147 in.)

Valve guide inside diameter

IN & EX: 5.500 - 5.512 mm (0.2166 - 0.2170 in.)

Stem-to-guide clearance

Standard

IN: 0.020 - 0.047 mm (0.0007 - 0.0018 in.)

EX: 0.045 - 0.072 mm (0.0017 - 0.0028 in.)

Limit

IN: 0.070 mm (0.0027 in.)

EX: 0.090 mm (0.0035 in.)

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Valve Stem End Deflection

Check valve stem end deflection using a dial gauge.

Move stem end in directions (1) and (2) to measure end deflection.

Replace valve and valve guide if deflection exceeds the limit.

Valve stem end deflection limit

In: 0.14 mm (0.0055 in.)

Ex: 0.18 mm (0.0070 in.)

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Scheme 191

1. Remove all carbon deposits from each valve (1).
2. Check each valve for wear, burn or distortion at its face and stem end and replace if necessary.
3. Measure valve protrusion length "a". Replace valve and/or cylinder head if measured length is out of standard value. Valve protrusion length "a" Standard IN: 44.00 - 44.60 mm (1.733 - 1.755 in.) EX: 42.85 - 43.45 mm (1.687 - 1.710 in.)

Valve Head Radial Runout

Check each valve for radial runout using a dial gauge and "V" block.

To check runout, rotate valve slowly.

Replace valve if runout exceeds the limit.

Valve head radial runout

Standard

IN: 0.000 - 0.045 mm (0.0000 - 0.0017 in.)

EX: 0.000 - 0.030 mm (0.0000 - 0.0011 in.)

Limit

IN: 0.090 mm (0.0035 in.)

EX: 0.060 mm (0.0023 in.)

Scheme 192

Seating Contact Width

Create contact pattern on each valve in the usual manner, i.e., by giving uniform coat of marking compound to valve seat and, by rotating and tapping seat with valve. Must use a valve lapper (tool used in valve lapping).

Pattern produced on seating surface of valve must be a continuous ring without any break, and the width of pattern must be within specified range.

Standard seating width "a" revealed by contact pattern on valve face

IN: 1.05 - 1.35 mm (0.0414 - 0.531 in.)

EX: 1.12 - 1.42 mm (0.0441 - 0.0559 in.)

Scheme 193

Valve Seat Repair

A valve seat not producing uniform contact with its valve or showing a seating surface width that is out of specified range must be repaired by regrinding or cutting and finished by lapping.

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1. Intake valve seat: Use valve seat cutters to make three cuts as illustrated in figure. Must use three separate cutters: the 1st for making 22° angle, the 2nd for making 60° angle, and 3rd for making 45° angle. The 3rd cut (45°) must be made to produce desired seat width. Seat width for intake valve seat "a": 1.05 - 1.35 mm (0.0414 - 0.0531 in.)
2. Exhaust valve seat: Use valve seat cutters to make three cuts as illustrated in the figure. Three cutters must be used: the 1st for making 22° angle, the 2nd for making 65° angle, and 3rd for making 45° angle. Must make the 3rd cut (45°) to produce desired seat width. Seat width for exhaust valve seat "b": 1.12 - 1.42 mm (0.0441 - 0.559 in.)
3. Valve lapping: Lap valve on seat in two steps, first with coarse size lapping compound applied to face and the second with fine-size compound, each time using valve lapper according to usual lapping method.

Combustion Chamber

1. Remove all carbon deposits from each combustion chamber. NOTE: Do not use any sharp-edged tools to scrape off carbon deposits. Be careful not to scuff or nick metal surfaces when removing carbon deposits. The same applies to valves and valve seats, too.
2. Check cylinder head for cracks on intake and exhaust ports, combustion chambers, and head surface.

Cylinder Head Flatness

Use a straightedge (1) and feeler gauge (2) to check flatness of gasket surface at a total of 6 locations. If any measured value exceeds its limit, correct gasket surface with a surface plate and abrasive paper #400 (Waterproof silicon carbide abrasive paper) by placing abrasive paper on and over surface plate and rubbing gasket surface against paper to grind off high spots.

Replace cylinder head if it is impossible to correct cylinder head distortion.

Note. Distorted mating surface of cylinder head and cylinder head gasket causes combustion gas and/or check cooling system for leakage, overheating and reduced power output.

Distortion of mating surface of cylinder head and cylinder head gasket

Limit: 0.03 mm (0.0011 in.)

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Manifold Seating Surface Flatness

Use straightedge (1) and feeler gauge (2) to check flatness of manifold seating surface.

Correct seating surface or replace cylinder head if measured value exceeds its limit.

Distortion of seating face of intake manifold and exhaust manifold on cylinder head

Limit: 0.05 mm (0.0019 in.)

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Scheme 199

Valve Spring Free Length and Preload

1. Check each valve spring for breakage or weakening.
2. Measure valve spring free length and preload. Replace valve spring if measured value is less than limit. NOTE: Weakened valve springs can cause chatter, not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure.

Valve spring free length "a"

Standard: 51.34 mm (2.021 in.)

Limit: 50.34 mm (1.981 in.)

Valve spring preload when compressed to 41.0 mm (1.61 in.)

Standard: 170 - 196 N (17.4 kgf - 19.9 kgf, 125.5 lbf - 144.0 lbf)

Limit: 165 N (16.9 kgf, 37.1 lbf)

Valve spring preload when compressed to 31.2 mm (1.22 in.)

Standard: 379 - 437 N (38.7 - 44.5 kgf, 279.5 - 322.0 lbf)

Limit: 375 N (38.2 kgf, 277.0 lbf)

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Scheme 201

Spring Squareness

Use a square surface plate to check each spring for squareness in terms of clearance between end of valve spring and square. Valve springs found to exhibit a larger clearance than limit must be replaced.

Valve spring squareness

Limit: 2.2 mm (0.086 in.)

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Cylinder Bore Diameter, Taper And Out-Of-Round

Use cylinder gauge to measure cylinder bore in thrust and axial direction.

Replace cylinder block if any of the following conditions are discovered

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Scheme 205

1. Cylinder bore exceeds limit.
2. Difference of measurements at two positions ([1] and [2]) exceeds taper limit.
3. Difference between thrust [4] and axial [3] measurements exceeds roundness limit. NOTE: There are two sizes for cylinder bore, to keep clearance between piston and cylinder properly. To distinguish standard value, refer to «PISTON, PISTON RING AND CONNECTING ROD DISASSEMBLY AND REASSEMBLY»(ref-585578-S31342883522013111200000) . CAUTION: Replace cylinder block if any abnormality is found on cylinder inside wall. Cylinder bore diameter Standard CYLINDER BORE DIAMETER SPECIFICATION Stamped number on lower crankcase 1 92.0101 - 92.0200 mm (3.62245 - 3.62283 in.) 2 92.0000 - 92.0100 mm (3.62205 - 3.62244 in.) Cylinder bore diameter Limit: 92.050 mm (3.6240 in.) Cylinder bore roundness ([3] - [4]) Limit: 0.020 mm (0.00078 in.) Cylinder bore taper ([1] - [2]) Limit: 0.013 mm (0.00051 in.)

Piston

Note. Two sizes of piston are available as standard size spare part so as to ensure proper piston-to-cylinder clearance.

Piston Diameter

As indicated in figure, piston diameter should be measured at specified position "a" 11.4 mm (0.448 in) from piston skirt end in the direction perpendicular to piston pin.

Replace piston if measured diameter is less than its limit.

New piston diameter standard size

PISTON DIAMETER SPECIFICATION

Piston diameter limit size

PISTON DIAMETER SIZE SPECIFICATION

Scheme 206

Piston Clearance

Measure cylinder bore diameter and piston diameter to find their difference called piston clearance. Piston clearance should be within its standard value.

Replace piston if it is out of limit.

Note. Cylinder bore diameters used here are measured in thrust direction at two positions.

Piston clearance

Limit: 0.12 mm (0.0047 in.)

Scheme 207

1. Before checking, piston grooves must be clean, dry and free from carbon deposits.
2. Fit new piston ring (1) into piston groove.
3. Use feeler gauge (2) to measure clearance between ring and ring land. Replace piston if clearance is out of limit. Ring groove clearance RING GROOVE CLEARANCE SPECIFICATION Standard Limit 1st ring 0.04 - 0.08 mm (0.0015 - 0.0031 in.) 0.13 mm (0.0051 in.) 2nd ring 0.03 - 0.07 mm (0.0011 - 0.0027 in.) 0.11 mm (0.0433 in.) Oil ring 0.035 - 0.175 mm (0.0014 - 0.0068 in.)

Piston Ring End Gap

To measure end gap, insert piston ring (1) into cylinder bore, and then measure the gap with feeler gauge (2).

Replace piston ring if measured gap exceeds limit.

Note. Remove carbon deposit from top of cylinder bore before inserting piston ring.

Piston ring end gap

PISTON RING END GAP SPECIFICATION

Scheme 208

Piston Pin Clearance

Check piston pin clearance in connecting rod small-end and piston. Replace connecting rod and/or piston if its small-end is badly worn or damaged or if measured clearance exceeds limit.

Piston pin clearance in connecting rod small-end

Standard: 0.003 - 0.017 mm (0.0002 - 0.0006 in.)

Limit: 0.040 mm (0.0015 in.)

Piston pin clearance in piston

Standard: 0.010 - 0.016 mm (0.00039 - 0.00062 in.)

Limit: 0.05 mm (0.0019 in.)

Small-end bore

21.003 - 21.011 mm (0.82689 - 0.83720 in.)

Piston pin outside diameter

20.994 - 21.000 mm (0.82654 - 0.82677 in.)

Diameter of piston pin hole in piston

21.007 - 21.013 mm (0.82705 - 0.82728 in.)

Scheme 209

Big-End Side Clearance

Check big-end side clearance of connecting rod, with rod fitted and connected to its crankshaft pin in the normal manner.

Replace connecting rod if measured clearance exceeds standard value.

Big-end side clearance

Standard: 0.25 - 0.40 mm (0.0098 - 0.0157 in.)

Scheme 210

Connecting Rod Bolt Deformation

Use micrometer (3) to measure each thread, diameter of connecting rod bolt (1) "A" at "a" and "B" at "b".

Calculate difference in diameters ("A" - "B").

Replace connected rod bolt if it exceeds limit.

Connecting rod bolt measurement points

"a": 28.5 mm (1.12 in.)

"b": 42.0 mm (1.65 in.)

Connecting rod bolt diameter difference

Limit ("A" - "B"): 0.05 mm (0.0019 in.)

Scheme 211

Crankshaft Pin Diameter

1. Use micrometer to measure crankshaft pin diameter at several points and calculate taper and out-of-round conditions. Replace crankshaft or regrind crankshaft pin to undersize and use undersize bearing if calculated taper and/or out-of-round is out of their service limit.

Crankshaft pin diameter

Standard: 49.982 - 50.000 mm (1.9678 - 1.9685 in.)

Crankshaft pin taper ([a] - [b]) and out-of-round ([1] -[2])

Limit: 0.01 mm (0.0003 in.)

Scheme 212

Scheme 213

1. Service connecting rod bearings are available in five standard sizes and 0.25 mm (0.0098 in) undersize bearing. The difference of those sizes is thickness.
2. Specified colors for identification of sizes are painted at specified location (1) as shown in figure. BEARING THICKNESS SPECIFICATION Painted color Bearing thickness Standard size Blue 1.494 - 1.497 mm (0.05882 - 0.05893 in.) Yellow 1.491 - 1.494 mm (0.05870 - 0.05881 in.) Colorless 1.488 - 1.491 mm (0.05859 - 0.05870 in.) Black 1.485 - 1.488 mm (0.05847 - 0.05858 in.) Green 1.482 - 1.485 mm (0.05835 - 0.05846 in.) 0.25 mm (0.0098 in) undersize Red 1.605 - 1.615 mm (0.06319 - 0.06358 in.)

Connecting Rod Bearing Clearance

Note. Do not rotate crankshaft while gauging plastic is installed.

Scheme 214

Scheme 215

1. Clean connecting rod bearings and crankshaft pin.
2. Place plastic gauge (1) with the same width as the crankshaft pin, so that it fits over the bearing, parallel to the crankshaft, avoiding the oil hole.
3. Install connecting rod bearings and its cap. Refer to «PISTON, PISTON RING AND CONNECTING ROD REMOVAL AND INSTALLATION»(ref-585578-S31019673882013111200000)
4. After three minutes elapsed, remove cap and use a scale (2) on plastic gauge envelope to measure plastic gauge (1) width at the widest point. Connecting rod bearing clearance Standard: 0.045 - 0.063 mm (0.0017 - 0.0024 in.) Limit: 0.065 mm (0.0025 in.) If measured oil clearance is less than standard value or more than service limit, replace connecting rod bearings with new ones. Refer to «SELECTION OF CONNECTING ROD BEARINGS»(ref-585578-S27708120032013111200000) , and recheck oil clearance. Depending on measured oil clearance with new bearing, select other bearings using the following procedures and recheck oil clearance: More than standard: Replace bearings with one size thicker or regrind crankshaft pin to under size and use 0.25 mm (0.0098 in) undersize bearings. Less than standard: Replace bearings with one size thinner or regrind crankshaft pin to under size and use 0.25 mm (0.0098 in) undersize bearings.

Scheme 216

Scheme 217

1. Check connecting rod big-end inside diameter using the following procedures: There is stamped number (any of "1", "2" or "3") on each connecting rod and it cap as shown in figure. That number represent connecting rod big-end inside diameter as follows. Connecting rod big-end inside diameter CONNECTING ROD BIG-END INSIDE DIAMETER SPECIFICATION Stamped number Connecting rod big-end inside diameter 1 53.0000 - 53.0060 mm (2.08662 - 2.08685 in.) 2 53.0061 - 53.0120 mm (2.08686 - 2.08708 in.) 3 53.0121 - 53.0180 mm (2.08709 - 2.08732 in.)
2. Check crankshaft pin diameter using the following procedures: There are four stamped alphabets (any of "A", "B" or "C") on crank web No. 5 as shown in figure. Those alphabets represent crankshaft pin diameter as follows: Crankshaft pin diameter CRANKSHAFT PIN DIAMETER SPECIFICATION Stamped alphabet Crankshaft pin diameter A 49.9940 - 50.0000 mm (1.96827 - 1.96850 in.) B 49.9880 - 49.9939 mm (1.96804 - 1.96826 in.) C 49.9820 - 49.9879 mm (1.96780 - 1.96802 in.)
3. Determine new standard bearings to be installed to connecting rod big-end from numbers stamped on connecting rods and the caps and alphabets stamped on crank web No. 5 using the following table: Connecting rod bearing cross-reference selection table CONNECTING ROD BEARING CROSS-REFERENCE SELECTION CHART Stamped number for connecting rod big-end inside diameter 1 or A 2 or B 3 or C Stamped alphabet for crankshaft pin outside diameter A Green Black Colorless B Black Colorless Yellow C Colorless Yellow Blue

Scheme 218

1. Determine target diameter of crankshaft pin for regrinding according to the following procedure. Assemble connecting rod, connecting rod cap and undersize bearings (0.25 mm (0.0098 in.)), refer to step 2 ) to 5 ) of "Installation" under «PISTON, PISTON RING AND CONNECTING ROD REMOVAL AND INSTALLATION»(ref-585578-S31019673882013111200000) . Use a bore gauge to measure connecting rod bearing inside diameter "a". Calculate target diameter using the following formula: Formula for target diameter of crankshaft pin A = B - 0.054 mm (0.0021 in.) A: Target diameter of crankshaft pin B: Measured connecting rod bearing inside diameter "a" .
2. Grind crankshaft pin to target diameter.
3. Check connecting rod bearing oil clearance. Refer to «CONNECTING ROD BEARING CLEARANCE»(ref-585578-S36356083922013111200000)

Scheme 219

Crankshaft Runout

Use dial gauge to measure runout at center journal. Rotate crankshaft slowly.

Replace crankshaft if runout exceeds the limit.

Crankshaft runout

Limit: 0.02 mm (0.0007 in.)

Scheme 220

Scheme 221

1. Assemble crankshaft, main bearings, thrust bearings and lower crankcase without applying sealant, see «MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION»(ref-585578-S05126976822013111200000) .
2. Use dial gauge (1) to measure crankshaft thrust play (2) as shown in figure below. Replace thrust bearing with new one (standard size or over size) to obtain standard thrust play if measured thrust play is out of standard value. Recheck crankshaft thrust play. Crankshaft thrust play Standard: 0.10 - 0.35 mm (0.0039 - 0.0137 in.) Thrust bearing thickness Standard size: 2.470 - 2.520 mm (0.973 - 0.9921 in.) Oversize (0.125 mm, 0.00492 in.): 2.533 - 2.583 mm (0.0998 - 0.1016 in.)

Out-of-Round and Taper (Uneven Wear) of Journals

An unevenly worn crankshaft journal shows up as a difference in diameter at a cross section or along its length (or both). This difference, if any, is determined by taking micrometer readings.

Regrind or replace crankshaft if any one of journals is badly damaged or uneven wear exceeds its limit.

Crankshaft journal outside diameter

Standard: 51.982- 52.000 mm (2.0466 - 2.0472 in)

Limit: 51.972 mm (2.0461 in.)

Crankshaft out-of-round (A - B) and taper (a - b)

Limit: 0.01 mm (0.0003 in.)

Scheme 222

Distortion of Gasket Surface

Use straightedge and feeler gauge to check gasket surface for distortion and repair it, if flatness exceeds the limit.

Replace cylinder block if repair is not possible.

Cylinder block flatness

Limit: 0.03 mm (0.001 in.)

Scheme 223

Scheme 224

Main Bearing Clearance

Note. Do not rotate crankshaft while gauging plastic is installed. After checking main bearing clearance, check crankcase bolt No. 1 for deformation, see MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION .

Scheme 225

Scheme 226

1. Remove lower crankcase.
2. Clean bearings and crankshaft journals.
3. Place plastic gauge (1) with the same width as the bearing, parallel to the crankshaft, avoiding oil hole.
4. Without applying sealant install lower crankcase, see «MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION»(ref-585578-S05126976822013111200000) .
5. After three minutes, remove lower crankcase and use scale (2) on plastic gauge envelope (1) to measure plastic gauge width at the widest point. NOTE: If either of the following conditions exists for the crankshaft journal and the cylinder block journal together, different standard values are applied. Stamped number for crankshaft journal diameter is "4", and stamped alphabet for cylinder block journal inside diameter is "A". Standard: 0.019 - 0.031 mm (0.00075 - 0.00122 in.) Stamped number for crankshaft journal diameter is "9", and stamped alphabet for cylinder block journal inside diameter is "F". Standard: 0.025 - 0.037 mm (0.0010 - 0.0014 in.) For more information about stamped number and stamped alphabet. Refer to «SELECTION OF MAIN BEARINGS»(ref-585578-S41686459312013111200000) Main bearing clearance Standard: 0.022 - 0.034 mm (0.00087 - 0.00133 in.) Limit: 0.050 mm (0.00196 in.) If measured clearance is less than standard or more than service limit, replace main bearings with new ones. Refer to «SELECTION OF MAIN BEARINGS»(ref-585578-S41686459312013111200000) and recheck main bearing clearance. If measured clearance with new bearings is out of standard, select other bearing using the following procedures and recheck main bearing clearance: More than standard: Replace bearing with one size thicker or regrind crankshaft journal to undersize and use 0.25 mm undersize bearing (0.0098 in). Less than standard: Replace bearing with one size thinner or regrind crankshaft journal to undersize and use 0.25 mm undersize bearing (0.0098 in).

Standard Size Bearing

If engine is under one of the following conditions, select a new standard bearings as follows, and install it.

1. Bearing is in defective condition.
2. Bearing clearance is out of specification.
3. Crankshaft or cylinder block is replaced.

Scheme 227

Scheme 228

Scheme 229

1. Check crankshaft journal diameter using the following procedures: There are five stamped numbers (any of "4" through "9") on crank web No. 4 as shown in figure. Those numbers represent crankshaft journal diameter as follows: Determine crankshaft journal diameter for journals No. 1 through No. 5 using stamped numbers and following table. Crankshaft journal diameter CRANKSHAFT JOURNAL DIAMETER SPECIFICATION Stamped numbers Journal diameter 4 51.997 - 52.000 mm (2.04712 - 2.04724 in.) 5 51.994 - 51.997 mm (2.04700 - 2.04712 in.) 6 51.991 - 51.994 mm (2.04688 - 2.04700 in.) 7 51.988 - 51.991 mm (2.04677 - 2.04688 in.) 8 51.985 - 51.988 mm (2.04665 - 2.04677 in.) 9 51.982 - 51.985 mm (2.04654 - 2.04665 in.)
2. Check cylinder block journal inside diameter using the following procedures: There are five stamped alphabets (6) (any of "A" through "F") on Lower crankcase as shown in figure. Those alphabets represent cylinder block journal inside diameter as follows: Determine cylinder block journal inside diameter for journals No. 1 through No. 5 using stamped alphabets and following table. CYLINDER BLOCK JOURNAL INSIDE DIAMETER SPECIFICATION Stamped number Cylinder block journal inside diameter A 56.000 - 56.003 mm (2.20473 - 2.20484 in.) B 56.003 - 56.006 mm (2.20484 - 2.20496 in.) C 56.006 - 56.009 mm (2.20496 - 2.20507 in.) D 56.009 - 56.012 mm (2.20507 - 2.20519 in.) E 56.012 - 56.015 mm (2.20519 - 2.20531 in.) F 56.015 - 56.018 mm (2.20531 - 2.20543 in.)
3. There are 5 kinds of standard bearings differing in thickness. To distinguish them, each bearing is painted in the following colors at the position as shown in figure. Each color represents the following thickness at the center of bearing: Standard size crankshaft main bearing thickness CRANKSHAFT MAIN BEARING THICKNESS SPECIFICATION Painted color Bearing thickness Blue 2.011 - 2.014 mm (0.07917 - 0.07929 in) Yellow 2.008 - 2.011 mm (0.07905 - 0.07917 in) Colorless 2.005 - 2.008 mm (0.07893 - 0.07905 in) Black 2.002 - 2.005 mm (0.07881 - 0.07893 in) Green 1.999 - 2.002 mm (0.07870 - 0.07881 in)
4. Select new standard crankshaft bearings using stamped numbers for crankshaft journal diameter, stamped alphabets for cylinder block journal inside diameter and following table: Main bearing cross - reference selection table (standard size) MAIN BEARING SPECIFICATION Stamped number on crank web No. 4 4 5 6 7 8 9 Stamped alphabets on lower crankcase A Upper Green Green Green Black Black Colorless Lower Green Green Black Black Colorless Colorless B Upper Green Green Black Black Colorless Colorless Lower Green Black Black Colorless Colorless Yellow C Upper Green Black Black Colorless Colorless Yellow Lower Black Black Colorless Colorless Yellow Yellow D Upper Black Black Colorless Colorless Yellow Yellow Lower Black Colorless Colorless Yellow Yellow Blue E Upper Black Colorless Colorless Yellow Yellow Blue Lower Colorless Colorless Yellow Yellow Blue Blue F Upper Colorless Colorless Yellow Yellow Blue Blue Lower Colorless Yellow Yellow Blue Blue Blue

Scheme 230

Scheme 231

1. 0.25 mm (0.0098 in.) undersize bearing is available, in five kinds varying in thickness. To distinguish them, each bearing is painted in the following colors at the position as shown in figure. Each color represents the following thickness at the center of bearing. Undersize of crankshaft main bearing thickness CRANKSHAFT MAIN BEARING THICKNESS SPECIFICATION Painted color Bearing thickness Red & Blue 2.136 - 2.139 mm (0.08409 - 0.08421 in.) Red & Yellow 2.133 - 2.136 mm (0.08397 - 0.08409 in.) Red 2.130 - 2.133 mm (0.08385 - 0.08397 in.) Red & Black 2.127 - 2.130 mm (0.08374 - 0.08385 in.) Red & Green 2.124 - 2.127 mm (0.08363 - 0.08374 in.)
2. If necessary, regrind crankshaft journal and select undersize bearing to use with it as follows. Regrind crankshaft journal to the following finished diameter: Finished crankshaft journal diameter 51.732 - 51.750 mm (2.0367 - 2.0374 in.) Use micrometer to measure reground journal diameter, see «CRANKSHAFT INSPECTION»(ref-585578-S24072490782013111200000) . Use measured journal diameter above and alphabets on cylinder block to select an undersize bearing by referring to the following table: Main bearing cross - reference table (under size) MAIN BEARING SPECIFICATION Measured journal diameter 51.7470 - 51.7499 mm (2.03728 - 2.03739 in.) 51.7440 - 51.7469 mm (2.03717 - 2.03727 in.) 51.7410 - 51.7439 mm (2.03705 - 2.03716 in.) 51.7380 - 51.7409 mm (2.03693 - 2.03704 in.) 51.7350 - 51.7379 mm (2.03682 - 2.03692 in.) 51.7320 - 51.7349 mm (2.03670 - 2.03680 in.) Stamped alphabet on lower crankcase A Upper Red & Green Red & Green Red & Green Red & Black Red & Black Red Lower Red & Green Red & Green Red & Black Red & Black Red Red B Upper Red & Green Red & Green Red & Black Red & Black Red Red Lower Red & Green Red & Black Red & Black Red Red Red & Yellow C Upper Red & Green Red & Black Red & Black Red Red Red & Yellow Lower Red & Black Red & Black Red Red Red & Yellow Red & Yellow D Upper Red & Black Red & Black Red Red Red & Yellow Red & Yellow Lower Red & Black Red Red Red & Yellow Red & Yellow Red & Blue E Upper Red & Black Red Red Red & Yellow Red & Yellow Red & Blue Lower Red Red Red & Yellow Red & Yellow Red & Blue Red & Blue F Upper Red Red Red & Yellow Red & Yellow Red & Blue Red & Blue Lower Red Red & Yellow Red & Yellow Red & Blue Red & Blue Red & Blue Install selected main bearings and measure bearing clearance. Refer to «MAIN BEARING CLEARANCE»(ref-585578-S17877984512013111200000) If measured clearance is more than standard, replace bearings with one size thicker and recheck bearing clearance. If measured clearance is less than standard, replace bearings with one size thinner and recheck bearing clearance.

Oil Pump Chain

Check oil pump chain for wear or any damage.

Replace oil pump chain if faulty condition is found.

Scheme 232

Oil Pump Chain Adjuster

Check oil pump chain adjuster according to the following procedures.

Scheme 233

Scheme 234

1. Check latch (1), teeth (2), plunger (3) or tensioner (4) for cracks, wear or any damage.
2. Check that plunger (3) moves in direction [b] and does not move in direction [a] when latch (1) engages with plunger teeth (2).
3. Check that plunger (2) moves in direction [b] freely and smoothly when latch (1) is raised up in direction [a].
4. Check that tensioner (3) moves in direction [c] freely and smoothly.

Replace oil pump chain adjuster if defective conditions are found.

Recommended Service Material

SPECIAL TOOLS SPECIFICATION

Note. Required service material is also described in the following: CYLINDER HEAD COVER COMPONENTS CAMSHAFT AND TAPPET COMPONENTS TIMING CHAIN COVER COMPONENTS TIMING CHAIN AND CHAIN TENSIONER COMPONENTS VALVE AND CYLINDER HEAD COMPONENTS PISTON, PISTON RING AND CONNECTING ROD COMPONENTS MAIN BEARING, CRANKSHAFT AND CYLINDER BLOCK COMPONENTS