EM Nissan Yd 2008 PDF
EM Nissan Yd 2008 PDF
EM Nissan Yd 2008 PDF
SECTION
ENGINE MECHANICAL
EM EM
E
CONTENTS
KA24DE Installation ...............................................................22 F
SERVICE INFORMATION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT EM
PRE-TENSIONER" INFOID:0000000005779649
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING: D
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer. E
• Improper maintenance, including incorrect removal and installation of the SRS can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SRS section.
F
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
G
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni- H
tion ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a
hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the I
battery, and wait at least 3 minutes before performing any service.
Precaution for Draining Engine Coolant INFOID:0000000005472899
J
Drain engine coolant when engine is cooled.
Precaution for Disconnecting Fuel Piping INFOID:0000000005472900
K
• Before starting work, make sure no fire or spark producing items are in the work area.
• After disconnecting pipes, plug openings to stop fuel leakage.
L
Precaution for Removal and Disassembly INFOID:0000000005472901
• When instructed to use SST, use the specified tools. Always be careful to work safely, avoid forceful or unin-
structed operations. M
• Exercise maximum care to avoid damage to mating or sliding surfaces.
• Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly. N
• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precaution for Inspection, Repair and Replacement INFOID:0000000005472902 O
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
P
Precaution for Assembly and Installation INFOID:0000000005472903
• Use an angle wrench for the final tightening of the following engine parts:
- Cylinder head bolts
- Connecting rod cap nuts
• Do not use a torque value for final tightening.
• The torque value for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid Gasket INFOID:0000000005472905
PBIC0003E
2. Thoroughly clean the gasket application surface and the mating surface and remove adhering moisture,
grease and foreign materials.
3. Attach the sealant tube to the tube presser.
EMA0622D
The actual shapes of Kent-Moore tools may differ from those of the special service tools illustrated here.
Tool number
(Kent-Moore No.) Description
Tool name
ST0501S000 Disassembling and assembling
( — )
Engine stand assembly
1 ST05011000
( — )
Engine stand
2 ST05012000
( — )
Base NT042
KV10105001
( — )
Engine attachment
NT031
5 KV10110340
( — )
Drift
6 KV10110320
( — )
Center shaft
NT044
NT045 F
KV10111100 Removing oil pan
(J-37228)
Seal cutter G
H
NT046
NT052
K
KV101151S0 Changing valve lifter shims
(J-38972)
Lifter stopper set
1 KV10115110 L
(J-38972-1)
Camshaft pliers
2 KV10115120
(J-38972-2) M
Lifter stopper S-NT041
ZZA0023D
LBIA0362E
Tool name
Description
(Kent-Moore No.)
Spark plug wrench Removing and installing spark plug
NT047
NT035
NT048
NT030
NT015
C
NT049
WEM152
F
Thread repair tool for oxygen sensor a: 18 mm (0.71 in)
a: (J-43897-18) b: 12 mm (0.47 in)
b: (J-43897-12)
G
H
AEM488
AEM489
PBIC0887E M
AEM466
AWBIA0616GB
1. Throttle body 2. EGR temperature sensor (if equipped) 3. EGR valve (if equipped)
4. EGR tube (if equipped) 5. Oil dipstick 6. Exhaust manifold
7. Heated oxygen sensor 1 8. Exhaust manifold cover 9. TWC (manifold)
J
WBIA0180E
AWBIA0617GB
EM
AMA150
J
1. Inspect belt for cracks, fraying, wear and oil. If necessary, replace.
2. Inspect drive belt deflection or tension at a point on the belt midway between pulleys using Tool.
K
Tool number : BT-3373-F
NOTE:
• Inspect drive belt deflection or tension when engine is cold. L
• Adjust if belt deflections exceed the limit or if belt tension is not within specifications.
• Drive belt tension can be checked at other points on the belt, if necessary.
DRIVE BELT DEFLECTION AND TENSION M
REMOVAL
1. Loosen generator adjusting bar and release belt tension on generator belt. Refer to EM-12, "Removal and
Installation".
2. Loosen idler pulley and release belt tension on power steering belt, if equipped. Refer to EM-15, "Check-
ing Drive Belts".
3. Loosen idler pulley and release belt tension on A/C compressor belt, if equipped. Refer to EM-15, "Check-
ing Drive Belts".
4. Remove belts as necessary.
INSTALLATION
Installation is in the reverse order of removal.
• Adjust drive belt deflection and tension to specification. Refer to EM-15, "Checking Drive Belts".
EM
I
ALBIA0588GB
1. Air cleaner assembly support 2. Drain tube 3. Air cleaner case (upper) J
4. Wing nut 5. PCV valve 6. Air cleaner filter
7. Air duct bolts 8. Air duct 9. Intake air temperature sensor
10. Air cleaner case (lower) 11. Clip 12. Air cleaner case bolt (lower) K
Front
REMOVAL
1. Disconnect intake air temperature sensor harness connector. M
2. Disconnect vacuum hoses from air duct.
3. Remove air duct bolts and air duct.
4. Remove air cleaner case bolt (lower). N
5. Disconnect PCV hose from air cleaner case (lower).
6. Remove wing nuts and air cleaner assembly.
O
INSTALLATION
Installation is in the reverse order of removal.
CAUTION: P
If intake air temperature sensor is dropped, do not reuse it.
CHANGING AIR CLEANER FILTER
Removal
SMA243C
Installation
Installation is in the reverse order of removal.
REMOVAL EM
1. Disconnect ignition wires from spark plugs at boot.
CAUTION:
Do not pull on the wire. C
E
SMA356CA
SMA581C I
Spark Plug
Make NGK
J
Standard type BKR5E-11
N
SMA673B
SMA806C
EM
WBIA0174E
G
Removal INFOID:0000000005472916
L
AEM497
PBIC0002E
P
6. Pull the oil pan out from the front side.
1. Use a scraper to remove the old liquid gasket from the mating
surface of the oil pan.
• Remove all traces of the liquid gasket from the mating surface
of the cylinder block.
AEM299
AEM300
SEM015E
AEM301
AEM498
D
4. Install the remaining parts in the reverse order of removal.
WBIA0214E
EM
AWBIA0620GB F
AEM479 O
Removal INFOID:0000000005472919
CAUTION: P
• After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike
piston heads.
• When installing chain tensioners or other sliding parts, lubricate contacting surfaces with new
engine oil.
• Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprockets and
crankshaft pulley.
• Do not spill engine coolant on drive belts.
WEM067
4. Remove the vacuum hoses, electrical harness connectors, and harness clamps.
5. Remove the power steering belt, if equipped. Refer to EM-16, "Removal and Installation".
6. Remove the power steering pump, if equipped, and position it to one side. Remove the idler pulley and
bracket.
7. Remove the rocker cover, loosen and remove the rocker cover
bolts in the numerical order as shown.
AEM356
AEM374
9. Wipe off the links of the timing chain next to the timing marks on
the sprockets. Put paint marks on the timing chain, matching
them with the timing marks on the cam sprockets and idler
sprocket.
JEM547G
10. Remove cam sprocket bolts, cam sprockets and upper timing chain.
IDLER SPROCKET
AEM480
O
WEM067
LBIA0364E
LEM115
SEM796E
G
AEM482
17. Remove the lower timing chain, crankshaft sprocket, and idler sprocket.
H
Inspection INFOID:0000000005472920
Check for cracks and excessive wear at the roller links. Replace the
chain if necessary. I
AEM403
L
Installation INFOID:0000000005472921
P
SEM205C
2. Install the idler sprocket and lower timing chain using the mating marks and the paint marks made during
the removal process.
CAUTION:
Be careful not to tear or damage the cylinder head gasket.
SEM796E
4. Install the lower chain tensioner and remove the pin securing the piston in the tensioner body.
5. Install the front cover and oil seal.
• Using a scraper or other suitable tool remove all traces of liq-
uid gasket from the cylinder block and front cover mating sur-
faces.
• Install a new crankshaft seal in the front cover.
• Apply a continuous bead of Genuine Silicone RTV Sealant or
equivalent, to the front cover. Refer to GI-43, "Recommended
Chemical Product and Sealant".
SEM715A
• Install a new front oil seal using a suitable tool. Refer to EM-
33, "Replacement".
SEM292D
• Apply Genuine Silicone RTV Sealant on the head gasket surface. Refer to GI-43.
• Install the front engine cover.
6. Install oil strainer and oil pan. Refer to EM-22, "Installation".
7. Install the oil pump and distributor drive shaft.
• Make sure the flat side of the distributor drive shaft is facing
the engine. Failure to do so will result in the distributor being
out of time.
8. Install the crankshaft pulley and crankshaft pulley bolt. Refer to
EM-12, "Removal and Installation".
AEM391
EM
LBIA0364E
D
10. Install the rear plate.
G
LBIA0363E
11. Install the A/C compressor and idler pulley bracket, if equipped. Refer to MTC-68, "Removal and Installa-
tion for Compressor". H
12. Install the radiator shroud and cooling fan with coupling. Refer to CO-12, "Removal and Installation".
13. Install the A/C compressor, generator, and power steering pump drive belts, if equipped. Refer to EM-15,
"Checking Drive Belts". I
14. Install the intake air duct.
IDLER SPROCKET
J
Install the lower timing chain.
UPPER TIMING CHAIN
1. Install the lower timing chain and idler sprocket. K
SEM548G N
2. Install the upper timing chain and sprockets, aligning the paint
marks made during removal as shown. O
SEM549G
JEM547G
AEM357
WEM067
8. Install the vacuum hoses, electrical harnesses, connectors, and harness clamps.
I
SEM289D
• The valve oil seal must be installed to specification over the valve J
stem opening as shown.
SEM290D M
LBIA0364E
LEM115
AEM385
Installation
1. Apply engine oil to new oil seal and install it using a suitable tool.
SEM292D
EM
SEM715A
D
2. Install the crankshaft pulley. Refer to EM-12, "Removal and Installation".
3. If installed, remove Tool.
E
Tool number : — (J-45499)
LBIA0364E
H
4. Install the rear plate.
K
LBIA0363E
SEM895A
Installation
SEM897A
SEM715A
Rear oil seal re- : 6.4 - 7.5 N·m (0.65 - 0.76 kg-m,
tainer bolts 56 - 66 in-lb)
a. Before installing rear oil seal retainer, remove all traces of liquid
gasket from mating surface using a scraper as shown. Also
remove all traces of the old liquid gasket from the mating sur-
face of the cylinder block.
SEM896A
AEM404
H
SEM486D
WBIA0447E
Removal INFOID:0000000005472925
CAUTION:
• When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
surfaces with new engine oil.
• Apply new engine oil to threads and seat surfaces when installing cylinder head, camshaft sprocket,
crankshaft pulley, and camshaft bracket.
• Attach tags to valve lifters so as not to mix them up.
Revision: September 2009 EM-38 2010 D22 LCV
CYLINDER HEAD
< SERVICE INFORMATION > [KA24DE]
• Before removing camshaft and idler sprockets, apply paint marks to them for re-timing.
1. Remove upper timing chain and idler sprocket. Refer to EM-25, "Removal" and EM-25, "Removal". A
• For re-timing during cylinder head removal and installation, apply paint marks to the camshaft sprockets,
upper timing chain, lower timing chain, and idler sprocket.
2. Remove camshaft brackets and camshafts. Remove the bolts in EM
the reverse order as shown.
• Mark the part with their original position and direction for cor-
rect placement for installation.
C
AEM352 E
SEM274D
I
4. Remove the cylinder head and cylinder head gasket.
Disassembly INFOID:0000000005472926
J
1. Remove the intake manifold and exhaust manifold. Refer to EM-12, "Removal and Installation".
2. Remove the valve components using Tool as shown.
K
Valve spring compressor : KV101092S0 (J26336-B)
SEM692D
N
3. Remove the valve oil seals using a suitable tool.
Inspection INFOID:0000000005472927
O
CYLINDER HEAD DISTORTION
1. Clean the sealing surface of the cylinder head.
P
SEM294D
SEM926C
SEM295D
D
3. Measure outer diameter of camshaft journal.
G
SEM012A
AEM328
SEM297D
2. If the valve exceeds the deflection limit, check the valve to valve
guide clearance:
a. Measure valve stem diameter and valve guide inner diameter.
b. Check that clearance is within specification.
Valve to valve guide clearance = valve guide inner diameter
- valve stem diameter.
Unit: mm (in)
c. If the clearance exceeds the limit, replace the valve and remea-
sure the clearance.
d. If the clearance still exceeds the limit after replacing the valve,
replace the valve guide.
SEM298D
SEM008A
SEM299D
SEM300D
D
4. Heat cylinder head to 120° - 140°C (248° - 284°F) in heated oil
and press the replacement valve guide into the valve guide hole
in the cylinder head. Press the valve guide in to the specified
E
height "L" as shown.
G
SEM301D
SEM300D
K
VALVE SEATS
Check valve seats for pitting at contact surface. Resurface or
replace if excessively worn. L
• Before repairing the valve seats, check the valves and valve
guides for wear as shown. If they are worn, replace them. Then
resurface the valve seat as necessary. M
SBIA0322E
SEM302D
SEM795A
SEM008A
4. Press fit valve seat until it seats on the bottom of the recess.
SEM892B
D
6. After cutting, lap valve seat with abrasive compound.
7. Check the valve seat dimensions. Refer to EM-68, "Valve".
8. Use a depth gauge to measure the distance between the mount- E
ing surface of the cylinder head spring seat and the valve stem
end. If the distance is shorter than specified, repeat step 5
through 7 above, to adjust it. If it is longer, replace the valve seat
with a new one. F
VALVE DIMENSIONS
Check dimensions of each valve. Refer to EM-68, "Valve". When
I
valve head has been worn down to less than the margin thickness
"T", replace the valve. Do not grind the valve stem more than the
grinding limit specification.
J
Margin thickness "T" : 0.5 mm (0.020 in)
Valve stem tip grinding limit : 0.2 mm (0.008 in)
K
SEM188A
L
VALVE SPRING
Squareness
M
1. Measure the spring out-of-square dimension “S” as shown.
P
SEM288A
Pressure
EM113
AEM499
AEM502
SEM303D
4. If the measurements exceed the standard diameter or clearance, replace valve lifter or cylinder head as
necessary.
A
1. Install valve component parts.
• Always use new valve oil seal. Refer to EM-33, "Replace-
ment". EM
• Before installing valve oil seal, install valve spring seat.
• Install outer valve spring (uneven pitch type) with its narrow
pitch side toward cylinder head side.
C
2. After installing the valve component parts, tap valve stem tip
with a plastic hammer to assure a proper fit.
D
SEM638B
Installation INFOID:0000000005472929
E
SEM275D
AEM352
4. Install upper timing chain and idler sprocket. Refer to EM-29, "Installation", EM-29, "Installation".
CHECKING
Check valve clearance while engine is warm but not running.
1. Remove the following parts:
• Rocker cover
• All spark plugs
2. Set No. 1 cylinder at TDC on its compression stroke.
• Align pointer with TDC mark on crankshaft pulley.
• Check that valve lifters on No. 1 cylinder are loose and valve
lifters on No. 4 are tight.
If not, turn crankshaft one revolution (360°) and align as
above.
WEM068
AEM382
5. Turn crankshaft one revolution (360° degrees) and align mark on crankshaft pulley with pointer.
6. Check only those valves as shown.
• Use the same procedure as described in step 4.
AEM383
7. If all of the valve clearances are within specification, install the following parts:
• Rocker cover
• All spark plugs
Revision: September 2009 EM-48 2010 D22 LCV
CYLINDER HEAD
< SERVICE INFORMATION > [KA24DE]
ADJUSTING
CAUTION: A
Adjust the valve clearance while engine is cold.
1. Turn the crankshaft to position the camshaft lobe on the valve that must be adjusted upward.
2. Place Tool (A) around camshaft as shown. EM
CAUTION:
Before placing Tool (A), rotate notch toward the center of
the cylinder head as shown, to simplify the shim removal. C
3. Rotate Tool (A) so that lifter is pushed down.
CAUTION:
Be careful not to damage the cam surface with Tool (A).
D
SEM515EA
E
4. Place Tool (B) between camshaft and the edge of the valve lifter
to retain valve lifter. F
CAUTION:
• Tool (B) must be placed as close to camshaft bracket as
possible.
• Be careful not to damage cam surface with Tool (B). G
5. Remove Tool (A).
SEM516EA
I
6. Rotate the adjusting shim until a hole is visible. Blow air into the
hole to separate the adjusting shim from the valve lifter.
J
L
AEM447
SEM517EA
P
SEM145D
b. Calculate the thickness of the new adjusting shim so that the valve clearance comes within the specified
values.
N = Thickness of new shim
R = Thickness of removed shim
M = Measured valve clearance
SEM308D
SEM518EA
EM
P
WEM055
WARNING:
• Position vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels.
• Do not remove engine until exhaust system has completely cooled off. Otherwise, you may burn
yourself and/or fire may break out in fuel line.
• Before disconnecting fuel hose, release fuel pressure. Refer to EC-34, "Fuel Pressure Check".
Revision: September 2009 EM-51 2010 D22 LCV
ENGINE ASSEMBLY
< SERVICE INFORMATION > [KA24DE]
• Be sure to hoist engine and transmission in a safe manner.
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS
CATALOG.
CAUTION:
• When lifting engine, be sure to clear surrounding parts. Take special care near accelerator wire cas-
ing, brake lines and brake master cylinder.
• In hoisting the engine, always use engine slingers in a safe manner.
• Before separating engine and transmission, remove the crankshaft position sensor (OBD) from the
assembly.
• Always take extra care not to damage edge of crankshaft position sensor (OBD) or ring gear teeth.
REMOVAL
1. Drain the coolant from engine block and radiator. Refer to CO-10, "Changing Engine Coolant".
2. Release the fuel pressure. Refer to EC-34, "Fuel Pressure Check".
3. Disconnect the fuel hose.
4. Remove the negative battery cable.
5. Remove the hood. Refer to BL-11, "Removal and Installation of Hood Assembly".
6. Remove the air cleaner. Refer to EM-17, "Removal and Installation".
7. Remove the power steering drive belt, generator drive belt and A/C compressor drive belt, if equipped.
Refer to EM-16, "Removal and Installation".
8. Remove the radiator. Refer to CO-12, "Removal and Installation".
9. Remove the exhaust manifold heat shield. Refer to EM-12, "Removal and Installation".
10. Disconnect the exhaust system at rear of TWC (manifold).
11. Remove the A/C compressor from bracket, if equipped. Refer to MTC-68, "Removal and Installation for
Compressor".
12. Disconnect the accelerator wire, vacuum hoses, electrical connectors, heater hoses and vacuum booster
hose.
13. Remove the power steering pump, if equipped and position aside.
14. Remove the transmission. Refer to MT-12, "Removal and Installation".
15. Install the engine slingers and attach engine lift hooks as shown.
16. Remove the LH and RH engine mounts.
17. Lift and remove the engine.
WBIA0111E
INSTALLATION
Installation is in the reverse order of removal.
EM
AWBIA0621GB
1. To remove the cylinder block for disassembly, remove the engine. Refer to EM-51, "Removal and Installa-
tion".
CAUTION:
• When installing sliding parts, lubricate the contacting surfaces with new engine oil.
• Place removed parts such as bearings and bearing caps in their proper order and direction.
• When installing connecting rod nuts and main bearing cap bolts, apply new engine oil to the
threads and seating surfaces.
• Do not allow any magnetic materials to contact the ring gear teeth of the flywheel.
2. Installation is in the reverse order of removal.
Disassembly INFOID:0000000005472934
EEM118
b. Using the main bearing cap bolts, remove the main bearing cap
while shaking it right and left as shown.
• Remove the No. 3 and No. 5 main bearing caps using Tool.
EMI0552D
F
AEM023
AEM024 J
3. Calculate the piston pin clearance.
Side Clearance
N
Top ring : 0.04 - 0.08 mm (0.0016 - 0.0031 in)
2nd ring : 0.03 - 0.07 mm (0.0012 - 0.0028 in)
Oil ring : 0.065 - 0.135 mm (0.0026 - 0.0053 in) O
Limit (Top, 2nd) : 0.1 mm (0.004 in) SEM249CA
SEM250C
2. When replacing the piston, check cylinder block surface for scratches or seizure. If scratches or seizure
are found, hone or replace the cylinder block.
SEM038F
SEM003F
G
SEM255CB
3. If the block distortion exceeds specification, resurface the block. Replace the block if necessary.
The limit for cylinder block resurfacing is determined by cylinder head resurfacing. H
Amount of cylinder head resurfacing is “A”
Amount of cylinder block resurfacing is “B”
I
The maximum limit is as follows : A + B = 0.2 mm (0.008 in)
Nominal block height at crankshaft center : 246.95 - 247.05 mm (9.7224 - 9.7264 in)
Max. block distortion limit = A + B : 0.2 mm (0.008 in) J
4. If necessary, replace cylinder block.
PISTON-TO-CYLINDER BORE CLEARANCE K
1. Using a bore gauge, measure cylinder bore for wear, out-of-
round and taper.
If it exceeds the limit, rebore all cylinders. Replace cylinder block L
if necessary.
SEM257C
SEM258C
Out-of-round (X − Y)
Main journal : less than 0.01 mm (0.0004 in)
Crankshaft pin : less than 0.005 mm (0.0002 in)
Taper (A − B)
Main journal : less than 0.01 mm (0.0004 in)
Crankshaft pin : less than 0.005 mm (0.0002 in)
SEM316A
SEM254C
D
4. If the crankshaft is out of specification, replace the crankshaft.
BEARING CLEARANCE
E
Method A (using a bore gauge and micrometer)
Use Method A or Method B. Method A is preferred because it is more accurate.
NOTE:
Use the following procedures to inspect the bearing clearance using Method A (bore gauge and micrometer). F
Main bearing
1. Set main bearings in their proper positions on the cylinder block
and main bearing caps. Follow the position numbering as G
shown.
SEM448C
J
2. Install the main bearing caps on the cylinder block.
• Tighten the main bearing cap bolts in two or three steps to specification.
K
Main bearing cap bolts : 51 N·m (5.2 kg-m, 38 ft-lb)
3. Measure the inner diameter “A” of each main bearing as shown.
L
EEM119
O
AEM026
SEM964
EEM120
SEM272C
c. Select the main bearing with a suitable thickness according to the following example and table.
Example:
AEM027
J
AEM028
N
5. Calculate connecting rod bearing clearance.
2 or II 2
EM142
AEM332
SEM062A
D
2. Ream the bushing until clearance with piston pin is within specification.
FLYWHEEL
Using a dial gauge, rotate the flywheel and measure the runout by
the total dial gauge indicator reading as shown F
PISTON J
1. Completely remove any foreign material from the cylinder block, inside the crankshaft case, and cylinder
bores by blowing compressed air in the passages and oil passages.
2. Install the oil jets. K
• Oil jets for the No. 1 and No. 3 cylinders are a different shape
from those for the No. 2 and No. 4 cylinders, as shown.
L
WBIA0219E
N
• Insert the oil jet knock pin into the cylinder block knock pin
hole, and tighten the knock pin bolt to specification. O
PBIC0478E
SEM215E
SEM262C
LEM069
SEM160B
CRANKSHAFT
SEM448C
D
2. Install the crankshaft and main bearing caps and tighten the
bolts in numerical order as shown, to specification.
• Apply new engine oil to the bolt threads and seat surface.
E
• Prior to tightening the bearing cap bolts, place bearing cap in
its proper position by shifting crankshaft in the axial direction.
• Tighten the bearing cap bolts gradually in two or three stages
to specification. Tighten the bearing cap bolts in the numerical F
order as shown.
smoothly by hand.
H
3. Measure the crankshaft end play as shown.
K
EEM122
SEM159B
O
EEM124
SEM916AA
EM
AWBIA0664ZZ
COMPRESSION PRESSURE
Unit: kPa (kg/cm2, psi)/300 rpm
Unit: mm (in)
SEM519E
Limit
Cylinder head surface distortion 0.1 (0.004)
Valve INFOID:0000000005472939
VALVE
Unit: mm (in)
SEM188
VALVE SPRING
E
Free height mm (in) 50.3 (1.9831)
K
SEM301D
Standard Service
Valve guide
Intake 11.023 - 11.034 (0.4340 - 0.4344) 11.223 - 11.234 (0.4418 - 0.4423)
L
Outer diameter
Exhaust 11.023 - 11.034 (0.4340 - 0.4344) 11.223 - 11.234 (0.4418 - 0.4423)
Cylinder head valve guide hole Intake 10.975 - 10.996 (0.4321 - 0.4329) 11.175 - 11.196 (0.4400 - 0.4408)
diameter
N
Exhaust 10.975 - 10.996 (0.4321 - 0.4329) 11.175 - 11.196 (0.4400 - 0.4408)
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Standard Limit O
Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031)
Stem to guide clearance
Exhaust 0.040 - 0.073 (0.0016 - 0.0029) 0.1 (0.004)
Valve deflection limit 0.2 (0.008)
P
VALVE LIFTER
Unit: mm (in)
AVAILABLE SHIMS
SEM308D
*: Always check with the Parts Department for the latest parts information
VALVE SEAT
EM
AEM456
SEM621F L
Standard Service
Cylinder head seat recess diameter Intake 37.500 - 37.516 (1.4764 - 1.4770) 38.000 - 38.016 (1.4961 - 1.4967)
(D) M
Exhaust 32.200 - 32.216 (1.2677 - 1.2683) 32.700 - 32.716 (1.2874 - 1.2880)
Intake 0.064 - 0.096 (0.0025 - 0.0038)
Valve seat interference fit
Exhaust 0.064 - 0.096 (0.0025 - 0.0038) N
Intake 37.580 - 37.596 (1.4795 - 1.4802) 38.080 - 38.096 (1.4992 - 1.4998)
Valve seat outer diameter (d)
Exhaust 32.280 - 32.296 (1.2709 - 1.2715) 32.780 - 32.796 (1.2905 - 1.2912)
Intake 6.1 - 6.3 (0.240 - 0.248) O
Depth (H)
Exhaust 6.1 - 6.3 (0.240 - 0.248)
Intake 5.8 - 6.0 (0.228 - 0.236)
5.9 - 6.0 (0.232 - 0.236)
5.3 - 5.5 (0.209 - 0.217) P
Height (h1)
Exhaust 5.9 - 6.0 (0.232 - 0.236) 5.32 - 5.42 (0.209 - 0.213)
Intake 0.24 - 0.64 (0.0094 - 0.0252)
Height (h2) 0.34 - 0.64 (0.0134 - 0.0252)
Exhaust 0.43 - 0.73 (0.0169 - 0.0287)
Unit: mm (in)
WBIA0177E
Standard Limit
Distortion — 0.1 (0.004)
Grade 1 89.000 - 89.010 (3.5039 - 3.5043)
Inner diameter Grade 2 89.010 - 89.020 (3.5043 - 3.5047) 0.2 (0.008)*
Cylinder bore Grade 3 89.020 - 89.030 (3.5047 - 3.5051)
Out-of-round (X − Y) Less than 0.015 (0.0006) —
Taper (A − B) Less than 0.010 (0.0004) —
Difference in inner diameter between cylinders Less than 0.03 (0.0012) 0.2 (0.008)
Piston-to-cylinder bore clearance 0.020 - 0.040 (0.0008 - 0.0016) —
Cylinder block height (From crankshaft center) 246.95 - 247.05 (9.7224 - 9.7264) 0.2 (0.008)**
* Wear limit
** Total amount of cylinder head resurfacing and cylinder block resurfacing
A
Unit: mm (in)
EM
EM120
E
H
WBIA0176E
Standard Limit
Intake 41.755 - 41.945 (1.644 - 1.651) — I
Cam height (A)
Exhaust 41.815 - 42.005 (1.646 - 1.654) —
Wear limit of cam height — 0.2 (0.008)
J
Camshaft journal to bearing clearance 0.045 - 0.090 (0.0018 - 0.0035) 0.12 (0.0047)
#1 to #5
Inner diameter of camshaft bearing 28.000 - 28.025 (1.1024 - 1.1033) —
journals
K
Outer diameter of camshaft journal #1 to #5
27.935 - 27.955 (1.0998 - 1.1006) —
(D) journals
Camshaft runout* Less than 0.02 (0.0008) 0.04 (0.0016) L
Camshaft end play 0.070 - 0.148 (0.0028 - 0.0058) 0.2 (0.008)
a 224 —
b 224 — M
c −1 —
Valve timing (Degree on crankshaft)
d 45 —
N
e 7 —
f 37 —
* Total indicator reading O
P
PISTON
SEM804E
Grade* Dimension
Grade No. 1 88.970 - 88.980 (3.5027 - 3.5031)
Piston skirt diameter "A" Standard Grade No. 2 88.980 - 88.990 (3.5031 - 3.5035)
Grade No. 3 88.990 - 89.000 (3.5035 - 3.5039)
Height "a" Approximately 48 (1.89)
Piston pin hole diameter "d" 20.993 - 21.005 (0.8265 - 0.8270)
Piston-to-cylinder bore clearance 0.020 - 0.040 (0.0008 - 0.0016)
*: Always check with the Parts Department for the latest parts information
PISTON PIN
Unit: mm (in)
Standard Limit
Piston pin outer diameter 20.989 - 21.001 (0.8263 - 0.8268) —
Interference fit of piston pin to piston pin hole −0.002 to 0.006 (−0.0001 to 0.0002) —
Connecting rod bushing clearance 0.005 - 0.017 (0.0002 - 0.0007) 0.023 (0.0009)
PISTON RING
Unit: mm (in)
Standard Limit
Top 0.040 - 0.080 (0.0016 - 0.0031) 0.1 (0.004)
Side clearance
2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.1 (0.004)
Oil 0.065 - 0.135 (0.0026 - 0.0053) —
Top 0.28 - 0.52 (0.0110 - 0.0205) 1.0 (0.039)
Ring gap 2nd 0.45 - 0.69 (0.0177 - 0.0272) 1.0 (0.039)
Oil (rail ring) 0.20 - 0.69 (0.0079 - 0.0272) 1.0 (0.039)
Unit: mm (in)
WBIA0178E
Standard Limit
Crankshaft INFOID:0000000005472944 D
Unit: mm (in)
SEM394 EM715
H
Grade1 Dimension
Grade No. 0 59.967 - 59.975 (2.3609 - 2.3612) I
Main journal diameter (Dm) Grade No. 1 59.959 - 59.967 (2.3606 - 2.3609)
Grade No. 2 59.951 - 59.959 (2.3603 - 2.3606)
Grade No. 0 49.968 - 49.974 (1.9672 - 1.9675) J
Pin journal diameter (Dp) Grade No. 1 49.962 - 49.968 (1.9670 - 1.9672)
Grade No. 2 49.956 - 49.962 (1.9668 - 1.9670)
K
Center distance (r) 47.95 - 48.05 (1.8878 - 1.8917)
Standard Limit
Journal — 0.01 (0.0004) L
Taper of journal and pin [A - B]
Pin — 0.005 (0.0002)
Journal — 0.01 (0.0004)
Out-of-round of journal and pin [X - Y] M
Pin — 0.005 (0.0002)
Standard Limit
Main bearing clearance 0.020 - 0.047 (0.0008 - 0.0019) 0.1 (0.004)
Connecting rod bearing clearance 0.010 - 0.035 (0.0004 - 0.0014) 0.09 (0.0035)
STANDARD
Unit: mm (in)
UNDERSIZE (SERVICE)
Unit: mm (in)
STANDARD
Unit: mm (in)
UNDERSIZE (SERVICE)
Unit: mm (in)
Unit: mm (in)
SERVICE INFORMATION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT EM
PRE-TENSIONER" INFOID:0000000005779650
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING: D
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer. E
• Improper maintenance, including incorrect removal and installation of the SRS can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SRS section.
F
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
G
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni- H
tion ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a
hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the I
battery, and wait at least 3 minutes before performing any service.
Precaution for Draining Engine Coolant INFOID:0000000005472950
J
Drain engine coolant when engine is cooled.
Precaution for Disconnecting Fuel Piping INFOID:0000000005472951
K
• Before starting work, make sure no fire or spark producing items are in the work area.
• After disconnecting pipes, plug openings to stop fuel leakage.
L
Precaution for Removal and Disassembly INFOID:0000000005472952
• When instructed to use SST, use the specified tools. Always be careful to work safely, avoid forceful or unin-
structed operations. M
• Exercise maximum care to avoid damage to mating or sliding surfaces.
• Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly. N
• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precaution for Inspection, Repair and Replacement INFOID:0000000005472953 O
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
P
Precaution for Assembly and Installation INFOID:0000000005472954
• Use an angle wrench for the final tightening of the following engine parts:
- Cylinder head bolts
- Main bearing cap bolts
- Connecting rod cap nuts
- Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle
tightening)
• Do not use a torque value for final tightening.
• The torque value for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid Gasket INFOID:0000000005472956
PBIC0003E
2. Thoroughly clean the gasket application surface and the mating surface and remove adhering moisture,
grease and foreign materials.
EM
EMA0622D
D
4. Apply the sealant without breaks to the specified location with
the specified dimensions.
• If there is a groove for the sealant application, apply the seal-
E
ant to the groove.
• As for the bolt holes, normally apply the sealant inside the
holes. If specified, it should be applied outside the holes. Make
sure to read the text of this manual. F
• Within five minutes of the sealant application install the mating
component.
• If the sealant protrudes, wipe it off immediately.
G
• Do not retighten after the installation.
SEM159F
• After 30 minutes or more have passed from the installation, fill
the engine with the specified oil and coolant. Refer to LU-19, "Changing Engine Oil" and CO-33,
"Changing Engine Coolant". H
Tool number
Description
Tool name
KV10115600 Installing valve oil seal
Valve oil seal drift Use side A.
Side A
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia.
e: 10.7 (0.421)
NT603
f: 5 (0.20)
Unit: mm (in)
KV10107902 Removing valve oil seal
Valve oil seal puller
1. KV10116100
Valve oil seal puller adapter
S-NT605
NT676
ZZA1188D
NT041
NT045
F
KV10111100 Removing oil pan upper, oil pan lower and rear
Seal cutter chain case, etc.
H
NT046
NT052
NT014 M
EM03470000 Installing piston assembly into cylinder bore
Piston ring compressor
N
O
NT044
NT801
NT803
NT804
NT805
SBIA0224E
SBIA0225E
EM
C
NT048
NT030
Valve guide reamer Reaming valve guide with (1) or hole for over- F
size valve guide with (2)
Intake and Exhaust:
d1 = 6.0 mm (0.236 in) dia.
d2 = 10.2 mm (0.402 in) dia. G
NT016
H
Valve guide drift Removing and installing valve guide
Intake and Exhaust:
a = 9.5 mm (0.374 in) dia.
b = 5.5 mm (0.217 in) dia. I
J
NT015
NT807
PBIC1113E
O
NT807
EM
AWBIA0628ZZ
Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000005472960
INSPECTION
AWBIA0629ZZ
1. Generator pulley 2. Water pump pulley 3. Generator and water pump belt
4. Crankshaft pulley 5. Idler pulley 6. Power steering pump pulley
7. Power steering pump belt 8. A/C compressor belt 9. Idler pulley
10. A/C compressor pulley 11. Idler pulley
• Before inspecting engine, make sure engine has cooled down; wait approximately 30 minutes after engine
has been stopped.
• Visually inspect all belts for wear, damage or cracks on contacting surfaces and edge areas.
• Measure deflection at the marked point ( ).
CAUTION:
• When checking belt deflection immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid variation
in deflection between pulleys.
• Tighten idler pulley lock nut by hand and measure deflection without looseness.
Belt Deflection:
ADJUSTMENT
CAUTION:
• When a new belt is installed as a replacement, adjust it to the value specified under "New" accom-
modations because of insufficient adaptability with pulley grooves.
• If the belt deflection of the current belt is out of the "Limit for re-tightening", adjust to the "Adjusted"
value.
• When checking belt deflection immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust it to the specified value to avoid variation
in deflection between pulleys.
• Make sure the belts are fully positioned into the pulley grooves during installation.
AWBIA0630ZZ
H
Removal and Installation INFOID:0000000005472962
REMOVAL I
1. Remove engine undercover if removing A/C compressor belt.
2. Loosen each belt adjustment. Refer to EM-88, "Checking Drive Belts".
3. Remove power steering oil pump belt. Refer to EM-88, "Checking Drive Belts". J
4. Remove A/C compressor, generator and water pump belt. Refer to EM-88, "Checking Drive Belts".
INSTALLATION K
1. Install each belt on pulley in the reverse order of removal.
2. Adjust belt deflection. Refer to EM-88, "Checking Drive Belts".
3. Tighten nuts provided for adjustment to the specified torque. Refer to EM-88, "Checking Drive Belts". L
4. Make sure again that each belt deflection is as specified. Refer to EM-88, "Checking Drive Belts".
ALBIA0589GB
1. Air duct 2. Mass air flow sensor 3. Air cleaner case cover
4. Air cleaner filter 5. Clip 6. Air cleaner case
7. Air cleaner assembly bracket 8. Clamp Front
A. To turbocharger
REMOVAL
1. Disconnect harness connector from mass air flow sensor.
2. Loosen clamps and remove air duct.
• Add marks as necessary for easier installation.
3. Remove air cleaner assembly bolts and remove air cleaner assembly.
4. Remove mass air flow sensor from air cleaner case cover, if necessary.
CAUTION:
• Do not shock it.
• Do not disassemble it.
• Do not touch its sensor.
5. Remove air cleaner assembly bracket bolts and air cleaner assembly bracket, if necessary.
INSTALLATION
Installation is in the reverse order of removal.
• Align marks. Attach each joint. Tighten clamps firmly.
CHANGING AIR CLEANER FILTER
Removal
1. Disconnect harness connector from mass air flow sensor.
AWBIA0631GB
1. Charge air cooler cover 2. Charge air cooler 3. Air inlet hose
4. Intake manifold 5. Bracket 6. Air inlet pipe
7. Bracket Front
REMOVAL
CAUTION:
When removing charge air cooler, cover opening on turbocharger and on intake manifold with shop
cloth or other suitable material.
1. Remove charge air cooler cover.
2. Remove air inlet hoses.
• Add marks as necessary for easier installation.
3. Remove charge air cooler.
4. Remove air inlet pipe, if necessary.
INSPECTION AFTER REMOVAL
Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler if necessary.
• Be careful not to deform core fins.
• For cleaning procedure of charge air cooler core, refer to CO-32, "System Inspection".
INSTALLATION
Installation is in the reverse order of removal.
• Pay attention to identification mark color and direction when installing air inlet hoses.
• Align marks. Attach each joint. Screw clamps firmly.
AWBIA0633GB
AWBIA0634GB
EM
L
JPBIA2187GB
REMOVAL
WARNING:
ALBIA0602ZZ
12. Remove EGR volume control valve and throttle chamber from intake manifold, if equipped.
INSPECTION AFTER REMOVAL
Surface Distortion
• Check distortion on the mounting surface with a straightedge and
feeler gauge.
PBIC3411E
INSTALLATION
Installation is in the reverse order of removal.
• Install intake manifold.
ALBIA0602ZZ
D
• Install EGR cooler and EGR volume control valve, if equipped.
• Install water hoses and heater feed hose.
- Install water hose by referring to paint marks and avoid twisting. E
- When an insert stopper is provided on the pipe side, insert the hose until it reaches the stopper.
• Before starting engine, bleed air from fuel piping. Refer to EC-481, "Fuel Filter" or EC-726, "Fuel Filter".
INSPECTION AFTER INSTALLATION F
Start engine and increase engine speed to check for fuel leak.
CAUTION:
Do not touch the engine immediately after stopped as engine becomes extremely hot.
NOTE: G
Use mirrors for checking at points out of clear sight.
AWBIA0632GB
EM
I
JPBIA2188GB
REMOVAL
L
1. Remove catalyst covers.
2. Remove exhaust front tube. Refer to EX-6, "Removal and Installation".
3. Remove exhaust manifold cover. Refer to EM-105, "Component". M
4. Remove catalyst and exhaust outlet.
5. Remove catalyst from exhaust outlet, if necessary.
INSTALLATION N
Note the following, and install in the reverse order of removal.
• If stud bolts of turbocharger were removed, tighten them to specification.
O
: 25.5 N·m (2.6 kg-m, 19 ft-lb)
• Pushing bracket against the cylinder block and the catalyst, temporarily tighten the bolt. And then tighten it to
specification.
JPBIA2189GB
EM
REMOVAL
CAUTION:
• There are two kinds of turbochargers, one with an identification mark (blue mark), and the other C
without an identification mark.
- When replacing a turbocharger without an identification mark, never install a turbocharger with an
identification mark.
• Be careful not to deform water tube, oil feed tube and oil return tube. D
• Never disassemble or adjust the turbocharger.
• Be careful not to bring turbocharger into contact with the vehicle.
• Never hold turbocharger boost control actuator and actuator rod. E
• After applying penetrative lubricant to the nuts, check for the penetration of the lubricant, and then loosen
the nuts to remove.
1. Drain engine coolant. Refer to CO-33, "Changing Engine Coolant".
F
2. Remove air cleaner and air duct. Refer to EM-90, "Component".
3. Remove air inlet hose and air inlet pipe. Refer to EM-92, "Component".
4. Remove exhaust manifold cover. Refer to EM-105, "Component". G
5. Remove exhaust outlet and catalyst. Refer to EM-98, "Component".
6. Remove eye bolts and hose from water tube, oil feed pipe and oil return tube.
7. Remove turbocharger with water tube, oil feed pipe and oil return tube. H
8. Remove water tube, oil feed pipe and oil return tube from turbocharger.
9. Remove turbocharger.
I
Oil Tube and Water Tube
• Clean inside of oil feed pipe, oil return tube and water tube, and check tubes for clogging.
• Replace oil feed pipe, oil return tube and/or water tube if clogging still exists after cleaning.
J
INSPECTION AFTER REMOVAL
AWBIA0635GB
P
1. Compressor housing 2. Actuator assembly 3. Turbine wheel
4. Turbine housing and turbine wheel 5. Compressor wheel A. Check for leaks
CAUTION:
When the compressor wheel turbine, wheel or rotor shaft is damaged, remove all the fragments and
foreign matter left in the following passages in order to prevent a secondary malfunction:
AWBIA0636ZZ
AWBIA0637ZZ
Turbine Wheel
• Make sure that there is no engine oil adhesion.
• Make sure that there is no carbon accumulation.
• Make sure that blades of turbine wheel (1) are not bent or broken.
• Make sure that turbine wheel (1) does not interfere with turbine
housing (2).
AWBIA0638ZZ
Compressor Wheel
• Make sure that there is no engine oil adhesion inside the air inlet.
• Make sure that compressor wheel (1) does not interfere with com-
pressor housing (2).
• Make sure that compressor wheel (1) is not bent or broken.
AWBIA0639ZZ
AWBIA0640ZZ
INSTALLATION
• When a stud bolt is pulled out, replace it with a new one and tighten it to the following torque.
EM
JPBIA2189GB
N
1. Exhaust manifold cover 2. Gasket 3. Exhaust manifold
4. Eye-bolt 5. Copper washer 6. Water feed pipe
7. Gasket 8. Ventilation hose connector 9. Air inlet tube O
10. Insulator 11. Gasket 12. Connector
13. Clamp 14. Oil return hose 15. Oil return tube
16. Gasket 17. Clamp 18. Water hose P
19. Water return tube 20. Water hose 21. Air inlet tube
22. Gasket 23. Turbocharger 24. Gasket
25. Eye-bolt 26. Copper washer 27. Oil feed pipe
28. Copper washer 29. Eye-bolt A. No. 1
B. No. 2 C. No. 3 D. No. 4
REMOVAL
1. Drain engine coolant. Refer to CO-33, "Changing Engine Coolant".
2. Remove air cleaner and air duct. Refer to EM-90, "Component".
3. Remove turbocharger. Refer to EM-100, "Component".
4. Remove EGR tube, if equipped. Refer to EM-93, "Component".
5. Loosen exhaust manifold nuts in the reverse order as shown.
: Vehicle front
PBIC3423E
PBIC2210E
INSTALLATION
Installation is in the reverse order of removal.
• If stud bolts were removed, replace them with new ones, and tighten them to specification.
: Vehicle front
PBIC3423E
EM
2WD Models
JPBIA2185GB
EM
I
JPBIA2186GB
REMOVAL L
WARNING:
To avoid the danger of being scalded, do not drain engine oil when engine is hot.
1. Remove engine undercover. M
2. Drain engine oil. Refer to LU-19, "Changing Engine Oil".
3. Remove oil pan (lower) bolts. Loosen bolts in the reverse order
of that shown. N
A : 2WD models
: Front O
AWBIA0644ZZ
A : 4WD models
: Front
AWBIA0645ZZ
SEM365EA
A : 2WD models
: Vehicle front
AWBIA0646ZZ
A : 4WD models A
: Vehicle front
EM
AWBIA0647ZZ
D
17. Remove oil pan (upper).
• Insert the seal cutter between oil pan (upper) and cylinder
block. Slide the seal cutter by tapping on the side of the seal
cutter with a hammer. Remove oil pan (upper). E
• Be careful not to damage aluminum mating surface.
• Do not insert screwdriver, or oil pan flange will be
deformed. F
SEM365EA
H
INSPECTION AFTER REMOVAL
Clean oil strainer if any object attached.
INSTALLATION I
Installation is in the reverse order of removal.
• Install oil pan (upper) with the following procedure.
- Use the scraper (A) to remove old liquid gasket from mating sur-
J
face of oil pan (upper).
• Also remove old liquid gasket from mating surface of cylinder
block and rear chain case.
• Remove old liquid gasket from the bolt hole and thread. K
AWBIA0648ZZ
M
AWBIA0649ZZ
CAUTION:
AWBIA0650ZZ
A : 2WD models
: Front
A :4WD models
: Front
• The shank length under the bolt neck above is the length of the threaded part (pilot portion not included).
AWBIA0653ZZ
A : Bolt hole
B : Groove EM
:Inner side
AWBIA0649ZZ
D
• Use Tool (B) to apply liquid gasket 3.5 to 4.5 mm (0.138 to
0.177 in) (A) wide.
E
Tool number : WS39930000
• Installation should be done within 5 minutes after coating.
NOTE: F
2WD oil pan (lower) shown, 4WD similar.
G
AWBIA0654ZZ
H
- Install oil pan (lower).
• Tighten bolts in numerical order as shown to specification.
I
A : 2WD models
: Front
AWBIA0644ZZ
L
A : 4WD models
: Front
M
NOTE:
Wait at least 30 minutes before refilling engine oil.
N
O
AWBIA0645ZZ
PBIC2436E
REMOVAL
CAUTION:
Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken.
1. Disconnect glow harness from glow plate.
2. Remove glow nut to remove glow plate.
3. Remove glow plug.
CAUTION:
• When removing or installing, do not use such tools as an air impact wrench.
• Handle it carefully without giving any impact, even after removal. [As a guide, if it drops from
height of 10 cm (3.94 in) or higher, always replace it.]
INSTALLATION
Installation is in the reverse order of removal.
• Remove adhered carbon from glow plug installation hole with a reamer.
EM
I
AWBIA0658GB
Standard: N
–94.0 to – 96.1 kPa (– 940 to – 961 mbar, – 705 to – 721 mmHg, – 27.76 to – 28.38 inHg)
• If out of standard, check for air suction in vacuum route, and measure again.
• If still outside of standard, replace vacuum pump. O
REMOVAL
1. Drain engine oil. Refer to LU-19, "Changing Engine Oil".
P
2. Remove primary timing chain. Refer to EM-153, "Removal and Installation".
3. Disconnect vacuum hose from vacuum pump side.
4. Remove oil feed tube and oil return hose.
5. Remove bracket.
6. Remove vacuum pump and O-ring.
INSTALLATION
EM
J
JPBIA2295GB
O
REMOVAL
1. Remove charge air cooler. Refer to EM-92, "Removal and Installation".
P
2. Remove intake manifold. Refer to EM-95, "Removal and Installation".
3. Disconnect harness connector from fuel injectors.
4. Remove spill hose.
CAUTION:
• Do not spill fuel in engine room.
• Do not spill fuel on engine mounting insulator.
5. Following steps below, remove injection tubes.
SBIA0203E
PBIC0944E
PBIC2038E
D
INSTALLATION
1. Record INJECTOR ADJUSTMENT VALUE on the top surface when replacing fuel injector.
• Refer to EC-482, "Injector Adjustment Value Registration" (TYPE 1) or EC-727, "Injector Adjustment
E
Value Registration" (TYPE 2) for use of INJECTOR ADJUSTMENT VALUE.
MBIB1251E
H
Example: Injector Adjustment value = D021ABCD1A061234000000000000E6
2. Following steps below, install fuel injector.
a. Install O-ring and nozzle gasket to fuel injector, and insert them into cylinder head. I
b. Tighten injection tubes temporarily in the order of 3-4-1-2.
c. Be sure to fit nozzle support and pin securely.
J
d. Tighten nozzle support bolts.
e. Loosen injection tubes in the order of 2-1-4-3.
3. Connect spill tube. K
• Tighten spill tube bolts and nut in numerical order as shown.
CAUTION:
When tightening nut, secure spill tube retaining bolt with
suitable tool. L
NOTE:
Connection of spill tube copper washer may be broken, even if
it is tighten to the specified torque. It does not affect perfor- M
mance.
PBIC2038E
Standard:
– 53.3 to – 66.7 kPa (– 533 to – 667 mbar, – 400 to
– 500 mmHg, – 15.75 to – 19.69 inHg)
• If outside of standard, reinstall spill tube. (Replace copper
washer in this case.)
5. Install rocker cover. Refer to EM-129, "Removal and Installa- JEF250Z
tion".
6. Install nozzle oil seal.
• Insert it straight until its flange fully contacts rocker cover.
CAUTION:
• Check gutter spring in nozzle oil seal on fuel injector.
7. Connect injection tubes individually to each cylinder in order of
3-4-1-2.
SBIA0203E
PBIC3437E
NOTE:
Intake manifold and other related parts are omitted for explanation. EM
9. Installation of remaining parts is in the reverse order of removal.
MBIB1251E
PBIC3438E
CAUTION:
• Before removing and installing fuel pump, be sure to remove sprocket. Do not loosen or remove
installation nut in the center of fuel pump. If loosened or removed, replace fuel pump.
• After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike
piston heads.
• When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
surfaces with new engine oil.
• When fuel pump is replaced with new one or another one, perform fuel pump learning value clearing
before starting engine. Refer to EC-483, "Fuel Pump Learning Value Clearing".
REMOVAL
1. Remove heater feed pipe. Refer to CO-42, "Component".
2. Remove fuel hose and spill hose from fuel pump. Refer to EM-117, "Component".
CAUTION:
Do not spill fuel in the engine component.
3. Disconnect harness connectors from fuel pump.
E
MBIA0049E
• Insert the positioning stopper pin until its flange contacts the fuel
pump sprocket. F
PBIC2535E
I
7. Using the hexagon wrench remove tightening bolts of fuel pump
sprocket.
J
PBIC2404E
P
MBIA0074E
SBIA0217E
MBIA0075E
9. Using the extension bar and the TORX socket (size: E10),
remove the bolts.
CAUTION:
Do not disassemble or adjust fuel pump.
PBIC2405E
EM
MBIA0013E
D
14. Remove coupling with a suitable puller.
G
MBIA0014E
SEM984C
INSTALLATION M
1. Install new oil seal to spacer.
P
MBIA0045E
MBIA0013E
MBIA0077E
PBIC3439E
Part No. of adjusting shim* Grade number Measuring dimension L mm (in) Type
16614 8H800 0.5 t 39.23 - 39.77 (1.5445 - 1.5657) A
16614 8H810 1.0 t 38.76 - 39.23 (1.5260 - 1.5445) B
16614 8H860 1.2 t 38.57 - 38.76 (1.5185 - 1.5260) C
16614 8H820 1.6 t 38.18 - 38.57 (1.5031 - 1.5185) D
16614 8H800 + 16614 8H860 0.5 t + 1.2 t 38.09 - 38.18 (1.4996 - 1.5031) A+C
16614 8H810 + 16614 8H810 1.0 t + 1.0 t 37.80 - 38.09 (1.4882 - 1.4996) B+B
16614 8H860 + 16614 8H810 1.2 t + 1.0 t 37.60 - 37.80 (1.4803 - 1.4882) C+B
16614 8H820 + 16614 8H810 1.6 t + 1.0 t 37.21 - 37.60 (1.4650 - 1.4803) D+B
*: Always check with the Parts Department for the latest parts information
EM
MBIA0016E
D
6. Insert fuel pump to the mounting position from the rear side of
the engine, and install the bolts with seal washer.
CAUTION:
E
Be careful not to drop the seal washer into engine.
G
PBIC2438E
7. Using the extension bar and the TORX socket (size: E10),
H
tighten the tightening bolts of fuel pump.
8. Remove the sprocket holder.
I
PBIC2405E
K
9. Using the TORX wrench, turn the pump shaft gradually to adjust
the position of fuel pump sprocket. Then, insert the positioning
stopper pin to the 6 mm (0.24 in) dia. hole of the fuel pump L
sprocket through the pump body.
10. Remove the TORX wrench.
M
N
MBIA0049E
11. Using the hexagon wrench, tighten the sprocket tightening bolt. O
• When the washer of the fuel pump sprocket is removed, install
it with the marking “F” (front) facing the front of the engine.
12. Pull out the positioning stopper pin. P
PBIC2404E
EM
I
PBIC4854E
REMOVAL L
1. Remove charge air cooler. Refer to EM-92, "Removal and Installation".
2. Remove vacuum gallery and ventilation hose. Refer to EM-93, "Component" and EM-90, "Component".
3. Disconnect harness connector from fuel injector. Refer to EM-117, "Component". M
4. Following steps below, remove injection tube. Refer to EM-117, "Component".
a. Put a paint mark or tag on injection tubes to identify each cylinder.
• Use a fuel-resistant method. N
b. Remove injection tubes in order of 2-1-4-3 individually.
CAUTION:
• Do not allow leaked fuel to contaminate engine room. O
• Do not spill fuel on engine mounting insulator.
5. Remove injection nozzle oil seal.
P
PBIC0944E
: Front
PBIC3441E
1 : Cylinder head
2 : Cylinder head rear cover
A : Liquid gasket application area
: Front PBIC3442E
: Front
PBIC3441E
EM
PBIC3443E
CAUTION:
• This engine will have a different valve arrangement from nor-
mal DOHC 4-valve type engines. As both camshafts on this
engine have intake and exhaust camshafts, in this chapter
they are named as follows:
REMOVAL
1. Drain engine coolant. Refer to CO-33, "Changing Engine Coolant".
2. Remove rocker cover. Refer to EM-129, "Component".
3. Remove cylinder head rear cover, camshaft position sensor and rubber washer.
EM
PBIC3445E
D
4. Remove fuel injector. Refer to EM-117, "Component".
5. Remove secondary timing chain. Refer to EM-146, "Component".
E
6. Remove camshaft sprockets and signal plate.
• Loosen the camshaft sprocket bolts and signal plate bolt by
holding the hexagonal portion of camshaft with a suitable tool.
F
H
JEM159G
7. Remove camshaft. I
• Place distinguishing marks on the right and left sides with paint.
• Loosen and remove the camshaft sprocket bolts in the reverse
order as shown. J
JEM160G
M
8. Remove adjusting shim and valve lifter.
• Remove by taking notice of the installation position, and place outside engine in order to install them in
the original position.
N
INSPECTION AFTER REMOVAL
Visual Check of Camshaft
• Check the camshaft for one sided wear or scratches. O
• Replace the camshaft if there are abnormalities.
Camshaft Runout
P
JEM161G
Standard:
Intake : 39.505 - 39.695 mm (1.5553 - 1.5628 in)
Exhaust : 39.905 - 40.095 mm (1.5711 - 1.5785 in)
• If out of the standard, replace camshaft.
SEM549A
Standard:
No. 1 : 30.435 - 30.455 mm
(1.1982 - 1.1990 in)
No. 2, 3, 4, 5 : 23.935 - 23.955 mm
(0.9423 - 0.9431 in)
SEM012A
Standard:
No. 1 : 30.500 - 30.521 mm
(1.2008 - 1.2016 in)
No. 2, 3, 4, 5 : 24.000 - 24.021 mm
(0.9449 - 0.9457 in)
JEM162G
PBIC0366E E
PBIC2320E
JEM164G
M
Visual Inspection of Valve Lifter and Adjusting Shim
Check if surface of valve lifter and adjusting shim has any wear or
cracks. N
• If anything above is found, replace valve lifter or adjusting shim.
SEM160D
SEM961E
PBIC0367E
: Front
PBIC2026E
JEM175G
E
4. Tighten bolts in the order as shown according to the following
procedure:
a. Tighten all bolts.
F
Bolt : 2 N·m (0.2 kg-m, 17 in-lb)
• Make sure camshaft thrusting parts (on rear side) securely fit
G
in their mating parts on the cylinder head.
b. Tighten all bolts.
H
Bolt : 6 N·m (0.6 kg-m, 52 in-lb) JEM160G
PBIC3446E
O
8. Install cylinder head rear cover and tighten bolts in numerical
order as shown.
P
M6 × 50 mm : Bolt No.1, 2
M6 × 20 mm : Bolt No.3, 4
M8 × 20 mm : Bolt No.5, 6
PBIC3445E
The following are procedures checking for fluid leaks, lubrication leaks and exhaust gas leaks.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to LU-18, "Inspection" and CO-32, "System Inspection".
• Use procedure below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids includ-
ing engine oil and engine coolant.
• Bleed air from lines and hoses of applicable components, such as cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level (*2)
Other oils and fluid (*1) Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
*1: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
*2: Check engine oil level 10 minutes after engine stopped.
INSPECTION
• When the camshaft or parts in connection with valves are removed or replaced, and a malfunction has
occurred (poor starting, idling, or other malfunction) due to the misadjustment of the valve clearance, inspect
as follows.
• Inspect and adjust when the engine is cool (at normal temperature).
• Be careful of the intake and exhaust valve arrangement. The valve
arrangement is different from that in a normal engine.
NOTE:
The camshafts have, alternately, either intake valve or exhaust
valve as shown.
SBIA0178E
EM
PBIC2533E
D
4. Remove engine undercover, put an alignment mark with paint,
etc. on crankshaft pulley and on oil pump housing as an angle
indicator.
E
1 : Crankshaft pulley
A : Alignment mark
F
: Vehicle front
G
PBIC3447E
SBIA0181E
Valve clearance: O
Unit: mm (in)
6. Set the No. 4 cylinder at TDC by rotating the crankshaft clockwise once. (360 degrees)
ADJUSTMENTS
• Remove adjusting shim for parts which are outside the specified valve clearance.
1. Remove engine oil on the upper side of the cylinder head (for the air blowing in step 6).
2. Rotate crankshaft to face the camshaft for adjusting shims that
are to be removed upward.
SBIA0183E
PBIC2321E
PBIC2322E
PBIC2324E G
FEM032
K
9. Select the new adjusting shim from the following methods.
JEM184G
PBIC2325E
11. Compress valve spring using the camshaft pliers and remove the lifter stopper.
12. Rotate crankshaft 2 to 3 turns by hand.
13. Confirm that the valve clearance is within the specification.
14. Installation of the remaining parts is in the reverse order of removal.
15. Warm up engine, and check for unusual noise and vibration.
REMOVAL EM
1. Remove camshafts. Refer to EM-132, "Component".
2. Remove adjusting shims and valve lifters. Refer to EM-132, "Component".
• Check the installation positions, and return them to the original position. C
3. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve
from dropping into cylinder.
4. Remove valve collet. D
• Compress the valve spring with Tool. Remove valve collet with
a magnet hand.
CAUTION: E
When working, be careful not to damage valve lifter holes.
G
PBIC2388E
K
JEM153G
INSTALLATION
L
1. Apply new engine oil to valve oil seal joint surface and seal lip.
2. Using the Tool to install valve oil seals to the dimension shown.
M
JEM165G
P
3. Installation of the remaining parts is in the reverse order of removal.
Removal and Installation of Front Oil Seal INFOID:0000000005472991
REMOVAL
1. Remove the engine undercover.
2. Remove the drive belts. Refer to EM-88, "Checking Drive Belts".
PBIC4050E
INSTALLATION
Installation is in the reverse order of removal.
• Apply new engine oil to new front oil seal joint surface and seal lip.
• Install front oil seal so that each seal lip is oriented as shown.
SEM715A
• Using the suitable drift [60 mm (2.36 in) dia.] (A), press fit the oil
seal (2) so that the dimension is as shown.
1 : Oil pump
CAUTION:
Do not touch lips of oil seal. Make sure seal surfaces are free
of foreign materials.
PBIC4051E
REMOVAL
1. Remove transmission and transfer assembly, if equipped. Refer to MT-52, "Removal and Installation".
SEM715A F
• Press in rear oil seal (2) to rear oil seal retainer (1) as shown.
• Using the drift [100 mm (3.94 in) dia.] (A), press fit so that the G
dimension is as shown.
• Avoid inclined fitting. Force fit perpendicularly.
H
M
PBIC4052E
JPBIA1324GB
CAUTION:
• After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike
piston heads.
• When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
surfaces with new engine oil.
REMOVAL
• For preparative work for removing/installing secondary timing chain to remove/install fuel pump, refer to EM-
122, "Component".
• To prepare for removing/installing secondary timing chain to remove/install camshaft, refer to EM-132,
"Removal and Installation".
1. Remove radiator shroud (upper and lower). Refer to CO-35, "Component".
2. Remove cooling fan (crankshaft driven type). Refer to CO-38, "Removal and Installation".
3. Remove EGR cooler and related water hoses or EGR tube, if equipped. Refer to EM-93, "Component".
CAUTION:
• Perform this step when engine is cold.
• Do not spill engine coolant on drive belts.
JEM121G D
SBIA0189E
H
5. Set the No. 1 piston to TDC on its compression stroke.
• Turn crankshaft pulley clockwise so that the alignment mark
(punched mark) on each camshaft sprocket is positioned as
I
shown.
• No position indicator is provided on crankshaft pulley.
• When installing, color coded links on secondary timing
chain can be used as alignment marks. Marking may not J
be necessary for removal; however, make alignment
marks as required because the alignment mark on fuel
pump sprocket may not be easy to see. K
SEM515G
L
6. Remove chain tensioner.
a. Push the plunger of chain tensioner and keep it pressed with a
push pin.
M
JEM124G
SBIA0227E
SBIA0228E
JEM127G
SEM984C
INSTALLATION
1. Install secondary timing chain.
G
PBIC4048E
3. Use the Tool to install slack guide bolts and slack guide.
H
SBIA0228E
K
4. Install chain tensioner.
a. Push the plunger of chain tensioner. While holding it with a push
pin, install chain tensioner. L
b. Use the Tool to tighten bolts.
c. Pull out the push pin, etc. holding the plunger.
• Make sure again that the alignment marks on the sprock- M
ets and the colored alignment marks on the timing chain
are aligned.
N
SBIA0227E
SBIA0189E
JEF370Y
JEM121G
The following procedures are checking for fluid leaks, lubrication leaks and exhaust gas leaks.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to LU-18, "Inspection", and CO-32, "System Inspection".
• Use procedure below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids includ-
ing engine oil and engine coolant.
• Bleed air from lines and hoses of applicable components, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
AWBIA0659GB
CAUTION:
• After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike
F
piston heads.
• When installing camshafts, chain tensioners, oil seals or other sliding parts, lubricate contacting
surfaces with new engine oil.
G
REMOVAL
1. Remove power steering oil pump and power steering oil pump bracket. Refer to PS-13, "Description".
2. Remove idler pulleys. Refer to EM-88, "Checking Drive Belts". H
3. Remove rocker cover. Refer to EM-129, "Component".
4. Remove oil pan (upper and lower). Refer to EM-108, "Component".
5. Remove fuel injector. Refer to EM-117, "Component". I
6. Remove secondary timing chain and associated parts. Refer to EM-146, "Component".
7. When removing rear chain case, remove camshaft sprockets. Refer to EM-132, "Component".
J
8. Remove crankshaft pulley.
a. Hold crankshaft pulley with a suitable tool.
b. Loosen crankshaft pulley bolt and pull out the bolt approximately K
10 mm (0.39 in).
PBIC3469E
JEM132G
PBIC3470E
JEM134G
MBIA0049E
• Insert the Tool until its flange contacts fuel pump sprocket.
PBIC2535E
EM
PBIC2404E
D
16. Remove primary timing chain with fuel pump sprocket and
crankshaft sprocket.
E
G
MBIA0079E
K
JEM885G
SBIA0211E
SEM984C
INSTALLATION
NOTE:
The illustration shows the relationship between the mating mark on each timing chain and that on the corre-
sponding sprocket, with the components installed.
EM
PBIC3473E F
CAUTION: I
Before starting work, make sure that No. 1 piston is on its compression stroke.
1. Install rear chain case.
a. Apply a continuous bead of liquid gasket with the Tool on loca- J
tions shown.
Use Genuine Liquid Gasket or equivalent. Refer to GI-43,
"Recommended Chemical Product and Sealant". K
A: Apply bead so that it does not protrude into the oil passage.
B, C: Minimize overlapping area of bead, by starting and ending
at areas of bead as shown. Apply so that the portion marked *
comes at an external location but cannot be viewed externally L
after engine assembly.
D: Leave the start and end areas of the bead slightly protruding
from the case surface. M
PBIC1255E
JEM141G
16 mm (0.63 in) : Bolt No. 1, 2, 16, 17, 18, 19, 20, 21, 22
20 mm (0.79 in) : Bolt No. 3, 4, 6, 9, 10, 11, 13, 14
25 mm (0.98 in) : Bolt No. 12, 15
35 mm (1.38 in) : Bolt No. 5, 7, 8
• The shank length under the bolt neck above is the length of
threaded part (pilot portion not included).
e. After tightening all the bolts, re-tighten in the same order.
SBIA0211E
JEM885G
MBIA0079E
D
8. Use the Tool to hold the fuel pump sprocket and install the bolt.
• Use the Tool to turn the fuel pump shaft little by little to adjust
the position of the fuel pump sprocket. Insert Tool into the hole
E
6 mm (0.24 in) in diameter on fuel pump sprocket so that the
stopper pin goes through the fuel pump body. While the stop-
per pin is in place, install the bolt.
F
G
MBIA0049E
PBIC2404E
K
9. Install timing chain slack guide.
10. Install chain tensioner. L
• Push the plunger of the chain tensioner. While keeping
plunger pressed down with a push pin, etc., install chain ten-
sioner.
• After installation, pull out the push pin holding the plunger. M
CAUTION:
Make sure again that the alignment marks on sprockets and
the colored alignment marks on timing chain are aligned. N
JEM134G
11. Install front oil seal (1) to oil pump housing (2). O
• Using the suitable drift (A) [62 mm (2.44 in) dia.], force fit the
seal until it hits the bottom.
CAUTION: P
Do not touch lips of oil seal. Make sure seal surfaces are
free of foreign materials.
PBIC3448E
JEM143G
JEM145G
JEM144G
PBIC3470E
D
16. Install crankshaft pulley.
CAUTION:
Be careful not to damage front oil seal.
E
a. Install crankshaft pulley to crankshaft.
b. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
c. Hold crankshaft pulley with a suitable tool. F
d. Tighten crankshaft pulley bolt to specification.
PBIC3469E I
e. Put an alignment mark on crankshaft pulley that aligns with one
of the punched marks on the bolt as shown.
f. Tighten bolt another 60 - 66 degrees (angle tightening) [target: J
60 degrees (turn by 1 notch)].
JEM147G
17. Install secondary timing chain and the associated parts. Refer to EM-146, "Removal and Installation". M
18. Installation of the remaining parts is in the reverse order of removal.
INSPECTION AFTER INSTALLATION N
Inspection for Leaks
The following procedures are for checking fluid leaks, lubrication leaks and exhaust gas leaks.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required O
quantity, fill to the specified level. Refer to LU-18, "Inspection" and CO-32, "System Inspection".
• Use procedure below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak- P
age at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids includ-
ing engine oil and engine coolant.
• Bleed air from lines and hoses of applicable components, such as in cooling system.
A : Injector
B : Connector F
PBIC4771E
H
6. Wind the insulating tape around the electrode of the discon-
nected connectors. Tie them together and secure them on the
harness side. I
A :Connector
J
K
PBIC4772E
7. Remove glow plugs from all the cylinders. Refer to EM-114, "Component". L
CAUTION:
• Before removal, clean the surrounding area to prevent entry of any foreign materials into engine.
• Carefully remove glow plugs to prevent any damage or breakage. M
• Handle with care to avoid applying any shock to glow plugs.
• When engine rpm is out of the specified range, check the specific gravity of battery liquid. Measure
again under corrected conditions.
• If engine rpm exceeds the limit, check valve clearance and combustion chamber components (valves,
valve seats, cylinder head gaskets, piston rings, pistons, cylinder bores, cylinder block upper and lower
surfaces) and measure again.
• If compression pressure is low in some cylinders, apply engine oil from glow plug installation hole. Then
check pressure again.
- If compression pressure becomes normal after applying engine oil, piston ring may be worn or dam-
aged. Check piston ring for malfunction. If any, replace piston ring.
- If compression pressure is still low after applying engine oil, valve may be malfunctioning. Check valve
for malfunction. If contact malfunction is found, replace valve or valve seat.
• If compression pressure in adjacent two cylinders is low after applying engine oil, pressure may be leak-
ing from gasket. In this case, replace cylinder head gasket.
11. Complete this operation as follows:
a. Turn the ignition switch to “OFF”.
b. Disconnect the battery cable from the negative terminal. Refer to SC-6, "Removal and Installation".
c. Install glow plug and install all the parts removed in step 4.
d. Connect all the connectors of the fuel injector.
e. Connect the battery cable to the negative terminal. Refer to SC-6, "Removal and Installation".
f. Check DTC. If DTC is displayed, erase it. Refer to EC-484, "Diagnostic Trouble Code (DTC)"
Component INFOID:0000000005472998
PBIC3477E
A
REMOVAL
1. Drain engine coolant. Refer to CO-33, "Changing Engine Coolant".
EM
2. Remove the following:
• Rocker cover (Refer to EM-129, "Component".)
• Spill tube and fuel injector (Refer to EM-117, "Component".)
• Intake manifold (Refer to EM-93, "Component".) C
• Turbocharger (Refer to EM-100, "Component".)
• Exhaust manifold (Refer to EM-105, "Component".)
• Secondary timing chain (Refer to EM-146, "Component".) D
• Camshaft (Refer to EM-132, "Component".)
3. Remove cylinder head assembly.
• Remove bolts between rear chain case and cylinder head. Refer to EM-152, "Component".
E
• Remove cylinder head bolts in the reverse order as shown
with the suitable tool.
• Lift up cylinder head assembly to avoid interference with dowel
pins located between the cylinder block and cylinder head, F
and remove cylinder head assembly.
CAUTION:
Remove glow plug in advance to avoid damage as the tip
G
of the glow plug projects from the bottom of cylinder
head, or, place wood blocks beneath both ends of cylin-
der head to keep the cylinder bottom from any contact.
• For glow plug removal, the following shall be noted. H
JEM149G
CAUTION:
• To avoid breakage, do not remove glow plug unless necessary.
• Perform continuity test with glow plug installed. I
• Keep glow plug from any impact. [Replace if dropped from a height 10 cm (3.94 in) or higher.]
• Do not use air impact wrench.
INSPECTION AFTER REMOVAL J
Cylinder Head Bolt Deformation
• Using micrometer, measure the outer diameters d1 and d2 of bolt
thread as shown. K
• If the necking point can be identified, set it as measuring point d1.
• Calculate the difference between d1 and d2.
L
Limit : 0.15 mm (0.0059 in)
• If it exceeds the limit, replace cylinder head bolt.
M
JEM171G
N
Cylinder Head Distortion
1. Wipe off oil and remove water scale (like deposit), gasket, sealer, carbon, etc. with scraper.
CAUTION:
Use utmost care not to allow gasket debris to enter passages for oil or water. O
SEM496G
INSTALLATION
Before installation, remove old liquid gasket from mating surface of all liquid gasket applied parts.
1. Install cylinder head gasket.
• Cylinder head gasket to be installed is selected by its thickness through the following procedure.
- When replacing gasket alone
• Install a gasket with same thickness as that of the one removed.
• Identify the thickness of gasket by the number of cut-outs on
the rear RH side.
1.025 (0.0404) 6 5
1
: Measured with head bolts tightened
2: Always check with the Parts Department for the latest parts information
PBIC3478E
SEM507G
Identification
Piston protrusion mm (in) Gasket thickness* mm (in) E
Number of cut-outs
0.230 - 0.255 (0.0091 - 0.0100) 0.900 (0.0354) 0
0.255 - 0.280 (0.0100 - 0.0110) 0.925 (0.0364) 1 F
0.280 - 0.305 (0.0110 - 0.0120) 0.950 (0.0374) 2
0.305 - 0.330 (0.0120 - 0.0130) 0.975 (0.0384) 3
0.330 - 0.355 (0.0130 - 0.0140) 1.000 (0.0394) 4 G
0.355 - 0.400 (0.0140 - 0.0157) 1.025 (0.0404) 5
*: Measured with head bolts tightened H
e. If out of above protrusion, check replaced parts.
2. Apply a continuous bead of liquid gasket with the Tool as shown.
Use Genuine Liquid Gasket or equivalent. Refer to GI-43, I
"Recommended Chemical Product and Sealant".
A: Apply bead so that it does not protrude into oil passage.
B: Minimize the overlapping area of the bead, with start and end
areas of bead as shown. J
Apply so that the portion marked * comes at an external loca-
tion but cannot be viewed externally after engine is assembled.
K
Tool number : WS39930000
PBIC1256E
L
3. Install cylinder head assembly.
• Tighten bolts in numerical order as shown according to the fol-
lowing procedure:
a. Apply engine oil to bolt threads and seat surfaces. M
b. Tighten all bolts.
N
: 39.2 N·m (4.0 kg-m, 29 ft-lb)
O
JEM149G
JEM172G
The following procedures are for checking fluid leaks, lubrication leaks and exhaust gas leaks.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to LU-18, "Inspection" and CO-32, "System Inspection".
• Use procedure below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids includ-
ing engine oil and engine coolant.
• Bleed air from lines and hoses of applicable components, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level (*2)
Other oils and fluid (*1) Level Leakage Level
J
PBIC2328E
M
DISASSEMBLY
1. Remove adjusting shims and valve lifters.
• Record the installation positions for assembly to original locations. N
2. Remove valve collet.
• Use the Tool to compress valve spring. Use a magnet hand to
remove valve collets.
O
PBIC2388E
SBIA0196E
JEM153G
ASSEMBLY
1. Install valve guides.
2. Install valve seats.
3. Use Tool to install valve oil seals following the dimension shown.
4. Install valve spring seats.
JEM165G
5. Install valves.
• Install the valves with bigger outer diameter to intake valve
side.
• Note that valve layout here is different from that of conven-
tional engine.
SBIA0196E
PBIC2388E
D
9. Install valve lifters and adjusting shims to the original positions.
INSPECTION AFTER DISASSEMBLY
E
Valve Dimension
• Check dimensions of each valve. For dimensions, refer to EM-202,
"Standard and Limit".
• If dimensions are out of the standard, replace valve. F
SEM188A
SEM938C
M
Valve Guide Inner Diameter
• Measure inner diameter of valve guide with inside micrometer.
N
Standard
Intake and Exhaust : 6.000 - 6.018 mm (0.2362 - 0.2369 in)
O
Valve Guide Clearance
• (Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter).
SEM008A
2. Using the valve guide drift, tap valve guides out from the com-
bustion chamber side.
WARNING:
Cylinder head contains heat, when working, wear protective
equipment to avoid getting burned.
SEM931C
3. Ream cylinder head valve guide hole with the valve guide
reamer.
SEM932C
SEM008A
PBIC2497E
D
6. Using the valve guide reamer, perform reaming to the press-fit-
ted valve guides.
E
Reaming specifications:
Intake and Exhaust
6.000 - 6.018 mm (0.2362 - 0.2369 in) F
G
SEM932C
SBIA0322E
K
SEM795A
P
SEM008A
SEM934C
PBIC0080E
AWBIA0663GB
WARNING:
• Situate vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels.
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS
CATALOG.
• Always be careful to work safely, avoid forceful or uninstructed operations.
• Do not start working until exhaust system and engine coolant are cool enough.
CAUTION:
• If items or work required are not covered by the engine main body section, follow the applicable pro-
cedures.
• Always use the support point specified for lifting.
• Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid-
able reasons, support at the rear axle jacking point with transmission jack or similar tool before
starting work, in preparation for the backward shift of center of gravity.
• For supporting points for lifting and jacking point at rear axle, refer to GI-38, "Lifting Points".
REMOVAL
Description of work
N
Engine slinger bolts:
: 28.0 N·m (2.9 kg-m, 21 ft-lb)
PBIC3480E O
SEM896G
INSTALLATION
Installation is in the reverse order of removal.
• Do not allow engine oil to get on mounting insulator. Be careful not to damage mounting insulator.
• When installation directions are specified, install parts according to the direction marks on them referring to
figure of components. Refer to EM-176, "Component".
• Make sure that each mounting insulator is seated properly, and tighten bolts and nuts.
• Insert vacuum hose to vacuum gallery until vacuum hose comes in contact with the stopper when a stopper
is provided at vacuum gallery.
• Insert vacuum hose up to 15 mm (0. 59 in) when a stopper is not provided at vacuum gallery.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following procedures are for checking fluid leaks, lubrication leaks and exhaust gas leaks.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to LU-18, "Inspection" and CO-32, "System Inspection".
• Use procedure below to check for fuel leakage.
- Before starting engine, check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids includ-
ing engine oil and engine coolant.
• Bleed air from lines and hoses of applicable components, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level (*2)
Other oils and fluid (*1) Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
*1: Transmission/transaxle/AT fluid, power steering fluid, brake fluid, etc.
*2: Check engine oil level 10 minutes after engine stopped.
EM
AWBIA0660GB
DISASSEMBLY
1. Remove engine from the vehicle. Refer to EM-176, "Component".
2. Remove clutch cover and disc. Refer to CL-16, "Removal and
Installation".
3. Remove pilot bushing, if necessary.
• Use the Tool to remove the pilot bushing from rear end of
crankshaft.
SEM500G
1 : Flywheel
A : KV10105630
B : TORX bit (size: T55)
CAUTION:
• Do not disassemble flywheel.
• Do not place flywheel with signal plate facing down.
• When handling signal plate, take care not to damage or PBIC3482E
scratch it.
• Handle signal plate in a manner that prevents it from becoming magnetized.
PBIC0085E
1 : Cylinder block
2 : Drain plug EM
PBIC3483E
D
7. Remove the following parts and related parts. (Only major parts are listed.)
• Intake manifold (Refer to EM-93, "Component".)
• Turbocharger (Refer to EM-100, "Component".) E
• Exhaust manifold (Refer to EM-105, "Component".)
• Rocker cover (Refer to EM-129, "Component".)
• Fuel injector (Refer to EM-117, "Component".)
• Oil pan and oil strainer (Refer to EM-108, "Component".) F
• Water pump (Refer to CO-40, "Component".)
• Thermostat and water piping (Refer to CO-42, "Component".)
• Secondary timing chain (Refer to EM-146, "Component".) G
• Primary timing chain (Refer to EM-152, "Component".)
• Fuel pump (Refer to EM-122, "Component".)
• Vacuum pump (Refer to EM-115, "Component".)
• Camshaft (Refer to EM-132, "Component".) H
• Cylinder head (Refer to EM-164, "Component".)
• Oil cooler (Refer to LU-23, "Component".)
• Accessory, accessory bracket and mount brackets I
8. Remove fuel pump bracket.
9. Remove rear oil seal retainer.
• Insert a suitable tool between main bearing cap and rear oil seal retainer to remove retainer. J
10. Remove rear oil seal from rear oil seal retainer. Refer to EM-144, "Removal and Installation of Rear Oil
Seal".
• Punch out with a suitable tool. K
CAUTION:
Be careful not to damage rear oil seal retainer.
11. Remove piston and connecting rod assembly. L
• Before removing piston and connecting rod assembly, check
connecting rod side clearance. Refer to EM-192, "Inspection
After Disassembly".
a. Move crankshaft pin to be removed to approximately BDC. M
b. Remove connecting rod caps.
c. Using the grip of a hammer, press the piston and connecting rod
assembly out to cylinder head side. N
CAUTION:
• Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod JEM195G
O
big end.
FEM086
13. Remove piston rings from pistons using a suitable piston ring
expander.
CAUTION:
• When removing, prevent pistons from being damaged.
• Do not expand piston rings excessively. This may damage
piston rings.
JEM196G
JEM197G
PBIC0089E
EMM0072D
JEM200G
D
16. Remove main bearing caps.
• Using main bearing cap bolts, remove by rocking bearing cap
back and forth. E
17. Remove crankshaft.
18. Remove main bearings and thrust bearings from cylinder block
and main bearing caps. F
CAUTION:
Check the correct installation locations of removed parts.
Store them so they do not get mixed up.
G
19. Remove oil jet.
JEM201G
20. Remove oil jet relief valve.
ASSEMBLY H
1. Blow air sufficiently to inside engine coolant passage, engine oil passage, crankcase and cylinder bore to
remove foreign matter.
CAUTION: I
Use goggles to protect your eyes.
2. Install drain plug (2) to cylinder block (1).
• Apply liquid gasket to drain plug. J
Use Genuine Liquid Gasket or equivalent. Refer to GI-43,
"Recommended Chemical Product and Sealant".
K
PBIC3483E
M
3. Install oil jet relief valve.
4. Install oil jet.
• Align knock pin on back of oil jet with hole on cylinder block N
when installing oil jet.
PBIC0389E
JEM224G
JEM225G
9. With the TORX socket (size: E14), tighten the main bearing cap
bolts according to the following procedure:
a. Apply engine oil to the threaded part and seat surface of each
bolt.
b. Tighten all bolts in numerical order shown.
PBIC0089E
E
• Assemble piston and connecting rod with front mark of piston
head and cylinder No. stamped on connecting rod being posi-
tioned as shown. F
c. Install snap ring to front side of piston.
• Fit snap ring correctly into grooves.
• After installation, check connecting rods for smooth move-
G
ment.
H
MBIA0024E
Punched mark:
Top ring : RTOP K
Second ring : R2ND
• Install rings so that the closed gap positions are 120 degrees L
apart from one another.
• Closed gaps do not need to face in a specific directions, as
long as each are positioned 120 degrees apart. JEM228G
M
13. Install connecting rod bearing to connecting rod and cap.
• While installing connecting rod bearing, apply engine oil to
bearing surfaces (inside). Do not apply engine oil to rear sur- N
faces, but clean them completely.
• Align protrusions on connecting rod bearings with connecting
rod cut-outs to install connecting rod bearings.
O
P
JEM229G
MBIA0024E
c. Loosen completely.
JEM231G
JEM232G
D
18. Install rear oil seal retainer to cylinder block.
• Apply new engine oil to the oil and dust seal lips.
• Apply liquid gasket to rear oil seal retainer using Tool as E
shown.
JEM234G
K
PBIC2329E
O
21. Assembly is in the reverse order of disassembly.
22. Remove engine from engine stand.
23. Install flywheel. P
PBIC2538E
PBIC1112E
• Hold ring gear with Tool to tighten flywheel bolts with TORX
socket (size: T55).
• Tighten bolts uniformly in a crisscross manner.
PBIC2406E
- If these are not aligned correctly, engine runs roughly and “MI” turns on.
24. Installation is in the reverse order of removal.
How to Select Piston and Bearing INFOID:0000000005473006
DESCRIPTION
F
JEM208G
G
When Re-using an Old Cylinder Block
MBIA0025E J
1. Measure cylinder bore inner diameter. Refer to EM-192, "Inspection After Disassembly".
2. Follow the “Cylinder bore inner diameter” in “Piston Selection Table” determine the bore grade.
3. Select piston of the same grade. K
Piston Selection Table
Unit: mm (in)
L
Grade (punched) 1 2 3
Cylinder bore in-
89.000 - 89.010 (3.5039 - 3.5043) 89.010 - 89.020 (3.5043 - 3.5047) 89.020 - 89.030 (3.5047 - 3.5051)
ner diameter
M
Piston outer di-
88.928 - 88.942 (3.5011 - 3.5016) 88.938 - 88.952 (3.5015 - 3.5020) 88.948 - 88.962 (3.5019 - 3.5024)
ameter
NOTE: N
Piston is available together with piston pin as an assembly.
HOW TO SELECT CONNECTING ROD BEARING
O
When Using New Crankshaft and Connecting Rod
JEM215G
Connecting rod big end inner diameter 55.000 - 55.013 (2.1654 - 2.1659)
Unit: mm (in)
Crankshaft pin outer diameter Grade (Mark) Dimension (Bearing thickness range) Bearing grade No. Color
51.968 - 51.974 (2.0460 - 2.0462) 0 1.492 - 1.496 (0.0587 - 0.0589) STD 0 Black
51.961 - 51.968 (2.0457 - 2.0460) 1 1.496 - 1.500 (0.0589 - 0.0591) STD 1 Brown
51.954 - 51.961 (2.0454 - 2.0457) 2 1.500 - 1.504 (0.0591 - 0.0592) STD 2 Green
Size Thickness
US 0.08 (0.0031) 1.536 - 1.540 (0.0605 - 0.0606)
US 0.12 (0.0047) 1.556 - 1.560 (0.0613 - 0.0614)
US 0.25 (0.0098) 1.621 - 1.625 (0.0638 - 0.0640)
CAUTION:
When grinding the crankshaft pin to use an undersize bearing,
avoid damaging the fillet R.
JEM216G
JEM208G
E
2. Identify the journal grade (No. 0, 1, or 2) on the front surface of
crankshaft, and locate the applicable grade under the “Grade”
column in the “Main Bearing Grade Table”.
F
H
JEM215G
3. The main bearing to be used (STD 0 to STD 4) can be located in the cell where the row and column cross.
I
When Re-using Removed Cylinder Block and Crankshaft
1. Measure the inner diameter of cylinder block main bearing housing. Refer to EM-192, "Inspection After
Disassembly".
J
2. Locate the applicable cell where the measurement falls, on “Inner diameter of Cylinder block main bearing
housing” row in the “Main Bearing Grade Table”.
3. Measure the outer diameter of crankshaft journal. Refer to EM-192, "Inspection After Disassembly".
K
4. Locate the applicable cell where the measurement falls, under “Crankshaft journal outer diameter” column
in the “Main Bearing Grade Table”.
5. The main bearing to be used (STD 0 to STD 4) can be located in the cell where the row and column cross. L
Main Bearing Grade Table
Unit: mm (in)
Size Thickness
US 0.25(0.0098) 1.949 - 1.953 (0.0767 - 0.0769)
CAUTION:
When grinding crank journals to use undersize bearings, keep
corners radius of fillet R. (All journals)
JEM216G
JEM203G
D
PISTON TO PISTON PIN CLEARANCE
Piston Pin Bore Diameter
Using inside micrometer, measure piston pin bore diameter. E
PBIC0116E H
Piston Pin Outer Diameter
Using micrometer, measure piston pin outer diameter.
I
Standard : 27.995 - 28.000 mm (1.1022 - 1.1024 in)
PBIC0117E
L
Calculation of Piston to Piston Pin Clearance
(Piston pin clearance) = (Piston pin bore diameter) − (Piston pin outer diameter)
M
Standard : 0.003 - 0.014 mm (0.0001 - 0.0006 in)
• If out of the standard, replace piston/piston pin assembly.
NOTE:
N
Piston is available together with piston pin as assembly.
PISTON RING SIDE CLEARANCE
• Using feeler gauge, measure the side clearance between piston O
ring and piston ring groove.
Unit: mm (in)
SEM024AA
FEM100
PBIC2077E
PBIC1641E
D
CONNECTING ROD BUSHING OIL CLEARANCE
Connecting Rod Bushing Inner Diameter
Use inside micrometer to measure bushing inner diameter. E
PBIC0120E H
Piston Pin Outer Diameter
Use micrometer to measure piston pin outer diameter.
I
Standard : 27.995 - 28.000 mm (1.1022 - 1.1024 in)
PBIC0117E
FEM110
PBIC0125E
FEM114 M
CRANKSHAFT PIN JOURNAL DIAMETER
• Use micrometer to measure crankshaft pin journal diameter.
N
Standard : 51.954 - 51.974 mm (2.0454 - 2.0462 in)
• If out of the standard, measure the connecting rod bearing oil
O
clearance. then use the undersize bearing.
PBIC0127E
SEM502G M
CRUSH HEIGHT OF CONNECTING ROD BEARING
• When connecting rod bearing cap is removed after being tightened
to specification with connecting rod bearings installed, the tip end N
of bearing must protrude. Refer to EM-180, "Disassembly and
Assembly".
O
Standard : There must be crush height.
• If out of the standard, replace connecting rod bearings.
P
PBIC1646E
JEM219G
OIL JET
• Check nozzle for deformation and damage.
• Blow compressed air from nozzle, and check for clogs.
JEM221G
Standard:
Valve moves smoothly with proper reaction force.
• If out of the standard, replace oil jet relief valve.
JEM222G
FLYWHEEL DEFLECTION
PBIC2646E
D
MOVEMENT AMOUNT OF FLYWHEEL
CAUTION:
Do not disassemble double mass flywheel.
E
Movement Amount of Thrust (Fore-and-Aft) Direction
• 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.
F
Standard : 1.3 mm (0.051 in) or less
• If measured value is out of the standard, replace flywheel.
G
Movement Amount in Radial (Rotation) Direction
Check the movement amount of radial (rotation) direction with the following procedure:
1. Install a bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel H
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 I
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, J
and mark the movement amount on the mass on the transmis-
sion side.
4. Measure the dimensions of movement amounts “A” and “B” on
circumference of the flywheel on the transmission side. K
GENERAL SPECIFICATIONS
Valve timing
EM120
Unit: degree
a b c d e f
224 212 2 30 -2 46
Item Limit
Intake manifold 0.1 (0.004)
Surface distortion
Exhaust manifold 0.3 (0.012)
DRIVE BELTS
Belt Deflection:
E
JEM204G
VALVE F
Valve Dimensions
Unit: mm (in)
G
J
SEM188
Available Shims
SEM512G
*: Always check with the Parts Department for the latest parts information
Valve Spring
Valve Lifter C
Unit: mm (in)
Item Standard
Valve lifter outer diameter 29.960 - 29.975 (1.1795 - 1.1801) D
Valve lifter bore diameter 30.000 - 30.021 (1.1811 - 1.1819)
Valve lifter clearance 0.025 - 0.061 (0.0010 - 0.0024)
E
Valve Guide
Unit: mm (in)
F
I
JEM156G
PBIC4054E
JEM253G
Cylinder head seat (1) recess diame- Intake 30.000 - 30.016 (1.1811 - 1.1817) 30.500 - 30.516 (1.2008 - 1.2014)
ter “D” Exhaust 29.000 - 29.016 (1.1417 - 1.1424) 29.500 - 29.516 (1.1614 - 1.1620)
Intake (A) 30.080 - 30.100 (1.1842 - 1.1850) 30.580 - 30.600 (1.2039 - 1.2047)
Valve seat outer diameter “d”
Exhaust (B) 29.080 - 29.096 (1.1449 - 1.1455) 29.580 - 29.596 (1.1646 - 1.1652)
Intake (A) 0.064 - 0.100 (0.0025 - 0.0039)
Valve seat interference fit
Exhaust (B) 0.064 - 0.096 (0.0025 - 0.0038)
Intake (A) 27.15 - 27.65 (1.0689 - 1.0886) 26.05 - 26.55 (1.0256 - 1.0453)
Diameter “d1”
Exhaust (B) 24.95 - 25.45 (0.982 - 1.0020) 24.15 - 24.65 (0.9508 - 0.9705)
Intake (A) 26.00 - 26.50 (1.0236 - 1.0433) —
Diameter “d2”
Exhaust (B) —
Intake (A) 25.3 - 25.7(0.996 - 1.012)
Diameter “d3”
Exhaust (B) 23.3 - 23.7 (0.917 - 0.933)
SEM671
L
Intake 39.505 - 39.695 (1.5553 - 1.5628)
Cam height “A”
Exhaust 39.905 - 40.095 (1.5711 - 1.5785)
*: Total indicator reading M
CYLINDER BLOCK
Unit: mm (in)
N
SEM899G
MBIA0026E
Grade* Dimension
Grade No. 1 88.928 - 88.942 (3.5011 - 3.5016)
Piston outer diameter “A” Standard Grade No. 2 88.938 - 88.952 (3.5015 - 3.5020)
Grade No. 3 88.948 - 88.962 (3.5019 - 3.5024)
“a” dimension 11.0 (0.43)
Piston pin bore diameter 28.003 - 28.009 (1.1025 - 1.1027)
Piston to cylinder bore clearance 0.058 - 0.082 (0.0023 - 0.0032)
*: Always check with the Parts Department for the latest parts information
Piston Ring
Unit: mm (in)
Piston Pin
Unit: mm (in)
CONNECTING ROD
Unit: mm (in) EM
Center distance 154.5 (6.083)
Bend [per 100 (3.94)] Limit 0.12 (0.0047)
C
Torsion [per 100 (3.94)] Limit 0.12 (0.0047)
Connecting rod bushing inner diameter* 28.026 - 28.038 (1.1034 - 1.1039)
Connecting rod big end inner diameter* 55.000 - 55.013 (2.1654 - 2.1659) D
Standard 0.20 - 0.35 (0.0079 - 0.0138)
Side clearance
Limit 0.40 (0.0157)
*: After installing in connecting rod
E
CRANKSHAFT
Unit: mm (in) F
Main journal dia. “Dm” 62.951 - 62.975 (2.4784 - 2.4793)
Pin journal dia. “Dp” 51.954 - 51.974 (2.0454 - 2.0462)
Center distance “r” 49.97 - 50.03 (1.9673 - 1.9697)
G
SEM645 SBIA0535E
N
*: Total indicator reading
SEM255G
Undersize
Unit: mm (in)
Undersize
Unit: mm (in)
MISCELLANEOUS COMPONENTS
Flywheel
Unit: mm (in)
Flywheel deflection [TIR]* [At 210 (8.27) dia.] Standard 0.45 (0.0177) or less
Radial movement amount Standard 1.3 (0.051) or less
Thrust movement amount Standard 32.0 (1.620) or less
*: Total indicator reading
Bearing Clearance