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ENGINE MECHANICAL

SECTION

EM

GI MA EM

CONTENTS
PRECAUTIONS .......................................................... 2 Parts Requiring Angular Tightening ........................ 2 Liquid Gasket Application Procedure...................... 2 PREPARATION........................................................... 3 Special Service Tools.............................................. 3 Commercial Service Tools ...................................... 6 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ................................................ 8 NVH Troubleshooting Chart -- Engine Noise ........ 9 OUTER COMPONENT PARTS ................................ 10 COMPRESSION PRESSURE................................... 13 Measurement of Compression Pressure .............. 13 OIL PAN .................................................................... 15 Removal ................................................................ 15 Installation ............................................................. 17 TIMING CHAIN ......................................................... 19 Removal ................................................................ 21 Upper Timing Chain.......................................... 21 Idler Sprocket ................................................... 22 Lower Timing Chain.......................................... 22 Inspection.............................................................. 23 Installation ............................................................. 24 Lower Timing Chain.......................................... 24 Upper Timing Chain.......................................... 24 OIL SEAL REPLACEMENT ..................................... 26 Valve Oil Seal ....................................................... 26 Front Oil Seal........................................................ 26 Rear Oil Seal ........................................................ 27 ACCEL-DRUM UNIT................................................. 28 Adjustment ............................................................ 28 CYLINDER HEAD..................................................... 30 Removal ................................................................ 31 Installation ............................................................. 31 Disassembly.......................................................... 32 Inspection.............................................................. 32 Cylinder Head Distortion .................................. 32 Camshaft Visual Check .................................... 33 Camshaft Runout.............................................. 33 Camshaft Cam Height ...................................... 33 Camshaft Journal Clearance ............................ 33 Camshaft End Play........................................... 34 Camshaft Sprocket Runout .............................. 34 Valve Guide Clearance..................................... 34 Valve Guide Replacement ................................ 35 Valve Seats....................................................... 36 Replacing Valve Seat For Service Parts .......... 36 Valve Dimensions ............................................. 36 Valve Spring...................................................... 37 Valve Lifter And Valve Shim ............................. 37 Assembly............................................................... 38 Valve Clearance.................................................... 38 ENGINE REMOVAL.................................................. 41 Removal ................................................................ 42 Installation ............................................................. 43 CYLINDER BLOCK .................................................. 44 Disassembly.......................................................... 45 Piston And Crankshaft...................................... 45 Inspection.............................................................. 46 Piston And Piston Pin Clearance ..................... 46 Piston Ring Side Clearance ............................. 46 Piston Ring End Gap........................................ 46 Connecting Rod Bend And Torsion .................. 47 Cylinder Block Distortion .................................. 47 Piston-To-Bore Clearance ................................ 47 Crankshaft ........................................................ 48 Bearing Clearance............................................ 49 Connecting Rod Bushing Clearance (Small end)................................................................... 51 Replacement of Connecting Rod Bushing (Small end) ....................................................... 51 Flywheel/Drive Plate Runout ............................ 52 Assembly............................................................... 52 Piston................................................................ 52 Crankshaft ........................................................ 53 Replacing Pilot Bushing ................................... 54 SERVICE DATA AND SPECIFICATIONS (SDS) ..... 55 General Specifications .......................................... 55 Inspection and Adjustment.................................... 55

LC EC FE CL MT AT FA RA BR ST RS BT HA EL IDX

PRECAUTIONS Parts Requiring Angular Tightening
q

q q q

Use an angle wrench for the final tightening of the following engine parts: (1) Cylinder head bolts (2) Main bearing cap bolts (3) Connecting rod cap nuts Do not use a torque value for final tightening. The torque value for these parts is for a preliminary step. Ensure thread and seat surfaces are clean and coated with engine oil.

Liquid Gasket Application Procedure
a. Use a scraper to remove all traces of old liquid gasket from mating surfaces and grooves. Also, completely clean any oil from these areas. b. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine RTV silicone sealant Part No. 999MP-A7007 or equivalent.) q For oil pan, be sure liquid gasket diameter is 3.5 to 4.5 mm (0.138 to 0.177 in). q For areas except oil pan, be sure liquid gasket diameter is 2.0 to 3.0 mm (0.079 to 0.118 in). c. Apply liquid gasket around the inner side of bolt holes (unless otherwise specified). d. Assembly should be done within 5 minutes after coating. e. Wait at least 30 minutes before refilling engine oil and engine coolant.

SEM164F

AEM080

EM-2

PREPARATION Special Service Tools
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number (Kent-Moore No.) Tool name ST0501S000 ( -- ) Engine stand assembly 1 ST05011000 ( -- ) Engine stand 2 ST05012000 ( -- ) Base KV10114300 ( -- ) Engine sub-attachment

GI
Description

MA
Disassembling and assembling

EM LC EC
NT042

FE CL
NT239

MT AT

KV10106500 ( -- ) Engine stand shaft

NT028

FA
Disassembling and assembling valve components

KV10109250 (J-26336-B) Valve spring compressor 1 KV10109210 ( -- ) Compressor 2 KV10109220 ( -- ) Adapter or (J-39773) Valve spring compressor kit KV10116300 (J-38955) Valve oil seal drift

RA BR ST RS

NT021

BT
Installing valve oil seal
a: 25 (0.98) dia. b: 14.4 (0.567) dia. c: 11.8 (0.465) dia. d: 10 (0.39) dia. e: 11 (0.43) f: 9 (0.35)

HA EL IDX

NT602

Unit: mm (in)

EM-3

PREPARATION Special Service Tools (Cont'd)
Tool number (Kent-Moore No.) Tool name KV10110300 ( -- ) Description

Disassembling and assembling piston with connecting rod

Piston pin press stand assembly
1 KV10110310

2

3

4

5

6

( -- ) Cap KV10110330 ( -- ) Spacer ST13030020 ( -- ) Press stand ST13030030 ( -- ) Spring KV10110340 ( -- ) Drift KV10110320 ( -- ) Center shaft
NT036

EM03470000 (J8037) Piston ring compressor

Installing piston assembly into cylinder bore

NT044

(J36467) Valve oil seal remover

Displacement valve oil seal

NT034

KV10111100 (J37228) Seal cutter

Removing oil pan

NT046

WS39930000 ( -- ) Tube presser

Pressing the tube of liquid gasket

NT052

ST16610001 (J23907) Pilot bushing puller

Removing crankshaft pilot bushing

NT045

EM-4

PREPARATION Special Service Tools (Cont'd)
Tool number (Kent-Moore No.) Tool name ST10120000 (J-24239-01) Cylinder head bolt wrench Description

GI
Loosening and tightening cylinder head bolt

MA
a: 13 (0.51) dia. b. 12 (0.47) c: 10 (0.39)
NT583

EM LC EC FE

Unit: mm (in) Changing shims

KV10115150 (J-38972) Lifter stopper set 1 KV10115110 (J-38972-1) Camshaft pliers 2 KV10115120 (J-38972-2) Lifter stopper KV10112100 (BT8653-A) Angle wrench

NT041

CL
Tightening bolts for bearing cap, cylinder head, etc.

MT AT

NT014

FA
Loosening or tightening front heated oxygen sensor [22 mm (0.87 in) type]

KV10117100 (J36471-A) Front heated oxygen sensor wrench
NT630

RA BR ST RS BT HA EL IDX

EM-5

PREPARATION Commercial Service Tools
Tool name Spark plug wrench Description Removing and installing spark plug

NT047

Pulley holder

Holding camshaft pulley while tightening or loosening camshaft bolt

NT035

Valve seat cutter set

Finishing valve seat dimensions

NT048

Piston ring expander

Removing and installing piston ring

NT030

Valve guide drift

Removing and installing valve guide
Intake & Exhaust: a: 10.5 mm (0.413 in) dia. b: 6.6 mm (0.260 in) dia.

NT015

Valve guide reamer

Reaming valve guide 1 or hole for oversize valve guide 2
Intake & Exhaust: d1: 7.0 mm (0.28 in) dia. d2: 11.175 mm (0.4400 in) dia.

NT016

Oxygen Sensor thread cleaner (J-43897-18) (J-43897-12)

Reconditioning the exhaust system threads before installing a new oxygen sensor. Use with anti-seize lubricant shown below.

AEM488

a: J-43897-18 18 mm diameter, for Zirconia oxygen sensor. b: J-43897-12 12 mm diameter, for Titania oxygen sensor.

EM-6

PREPARATION Commercial Service Tools (Cont'd)
Anti-seize lubricant (PermatexTM 133 AR or equivalent meeting MIL specification MIL-A-907) Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads.

GI MA EM LC EC FE CL MT AT FA RA BR ST RS BT HA EL IDX

AEM489

EM-7

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

WEM003

EM-8

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart -- Engine Noise
Use the chart below to help you find the cause of the symptom. GI 1. Locate the area where noise occurs. 2. Confirm the type of noise. MA 3. Specify the operating condition of engine. 4. Check specified noise source. If necessary, repair or replace these parts.
Operating Condition of Engine. Location of Noise Type of Noise Ticking or click Rattle Slap or knock Crankshaft Pulley Cylinder block (Side of Engine) Oil pan Knock Front of Engine Timing Chain Cover Tapping or ticking Squeak or fizzing Creaking Front of Engine Squall or creak Water pump noise LC-12 Section ("Water Pump Inspection", "Engine Cooling System") A B -- A B C Slap or rap Before After warm-up warm-up C C -- A A A When starting -- -- -- When idling A A B When revving B B B While driving -- C -- Source of Noise Check Item Reference page

EM LC

Top of Engine Rocket Cover Cylinder Head

Tappet noise Camshaft bearing noise Piston pin noise

Valve clearance Camshaft journal clearance Camshaft runout Pistion and piston pin clearance Connecting rod bushing clearance Piston-to-bore clearance Piston ring side clearance Piston ring end gap Connecting rod bend and torsion

EM-38 EM-33 EM-46, 51

EC FE

A

--

--

B

B

A

Piston slap noise Connecting rodbearing noise Main bearing noise Timing chain and chain tensioner noise Other drive belts (sticking or slipping) Other drive belts (slipping)

EM-46, 47

CL
EM-48, 49

Knock

A

B

C

B

B

B

Connecting rod bearing clearance (Big end) EM-50, 51 Connecting rod bushing clearance (Small end) Main bearing oil clearance Crankshaft runout Timing chain cracks and wear Timing chain tensioner operation

MT AT

A

A

--

B

B

B

EM-23 MA-10 Section ("Checking Drive Belts", "Engine Maintenance")

A

B

--

B

--

C

Drive belts deflection

FA RA BR ST RS BT HA EL IDX

A

B

A

B

A

B

Idler pulley bearing operation

A

B

--

B

A

B

Water pump operation

A: Closely related

B: Related

C: Sometimes related

--: Not related

EM-9

OUTER COMPONENT PARTS

WEM011

EM-10

OUTER COMPONENT PARTS

GI MA EM LC EC FE CL MT AT FA RA BR ST RS BT HA
WEM004

EL IDX

EM-11

OUTER COMPONENT PARTS
Tightening procedure

WEM005

EM-12

COMPRESSION PRESSURE Measurement of Compression Pressure
1. Warm up engine. 2. Turn ignition switch OFF. GI 3. Release fuel pressure. Refer to EC-34, ``Fuel Pressure Release''. 4. Remove all spark plugs. MA q Clean area around plug with compressed air before removing the spark plug. 5. Disconnect camshaft position sensor harness connector at EM the distributor. 6. Disconnect all fuel injector harness connectors.

LC

EC FE CL MT AT FA RA BR ST RS BT HA EL IDX

AEM052

7. Attach a compression tester to No. 1 cylinder. 8. Depress accelerator pedal fully to keep throttle valve wide open. 9. Crank engine and record highest gauge indication. 10. Repeat the measurement on each cylinder. q Always use a fully-charged battery to obtain specified engine speed. Compression pressure: kPa (kg/cm2, psi)/300 rpm Standard 1,226 (12.5, 178)/300 Minimum 1,030 (10.5, 149)/300 Difference limit between cylinders 98 (1.0, 14)/300 11. If compression in one or more cylinders is low: a. Pour a small amount of engine oil into cylinders through spark plug holes. b. Retest compression. q If adding oil helps compression, piston rings may be worn or damaged. If so, replace piston rings after checking piston. q If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. (Refer to SDS.) If valve or valve seat is damaged excessively, replace. q If compression stays low in two cylinders that are next to each other: a. The cylinder head gasket may be leaking, or b. Both cylinders may have valve component damage. Inspect and repair as necessary. 12. Reconnect fuel pump fuse, all fuel injector harness connectors, and camshaft position sensor harness connector at the distributor and reinstall spark plugs. 13. Erase the DTC stored in the ECM.

EM-13

COMPRESSION PRESSURE Measurement of Compression Pressure (Cont'd)
CAUTION: q Always erase the DTC after checking compression. Refer to EC-44, ``Emission-related Diagnostic Information''.

EM-14

OIL PAN

GI MA EM LC EC FE CL MT AT
AEM317

Removal
1. Remove engine undercover. 2. Drain engine oil.

FA RA BR ST RS BT

3. Remove steel oil pan bolts. q Remove in reverse order as shown.

SEM118E

HA
4. Remove steel oil pan. a. Insert Tool between aluminum oil pan and steel oil pan. EL q Be careful not to damage aluminum mating surface. q Do not insert screwdriver or oil pan flange will be damaged. IDX b. Slide Tool by tapping on the side of Tool with hammer.

SEM365E

EM-15

OIL PAN Removal (Cont'd)
5. Remove baffle plate. 6. Remove oil strainer.

AEM318

7. Remove exhaust front tube. 8. Set a suitable transmission jack under transaxle and lift engine with engine slinger. 9. Remove center member.

SEM120E

10. Remove compressor gusset.

SEM121E

11. Remove rear cover plate.

SEM122E

12. Remove aluminum oil pan nuts and bolts. q Remove in reverse order as shown.

SEM123E

EM-16

OIL PAN Removal (Cont'd)
13. Remove aluminum oil pan. a. Insert Tool between cylinder block and aluminum oil pan. q Be careful not to damage aluminum mating surface. GI q Do not insert screwdriver or oil pan flange will be damaged. MA b. Slide Tool by tapping on the side of Tool with a hammer.

EM
SEM365E

Installation

LC

1. Use a scraper to remove old liquid gasket from mating surEC face of aluminum oil pan. q Also remove old liquid gasket from mating surface of cylinder block.

FE

CL
SEM050D

2. Apply a continuous bead of liquid gasket to mating surface of aluminum oil pan. q Use Genuine RTV silicone sealant Part No. 999MP- AT A7007 or equivalent. q Apply to groove on mating surface. q Allow 7 mm (0.28 in) clearance around bolt holes. FA

MT

RA
SEM015E q

q q

For areas marked with `` '', apply liquid gasket around the outer side of the bolt hole. Be sure liquid gasket diameter is 3.5 to 4.5 mm (0.138 ST to 0.177 in). Attaching should be done within 5 minutes after coating. RS

BR

BT
SEM127E

HA
3. Install aluminum oil pan. q Tighten nuts and bolts in numerical order shown. 4. Install rear cover plate.

EL IDX

SEM123E

EM-17

OIL PAN Installation (Cont'd)
5. 6. 7. 8. 9. Install Install Install Install Install compressor gusset. center member. front tube. oil strainer. baffle plate.

SEM121E

10. Use a scraper to remove old liquid gasket from mating surface of steel oil pan. q Also remove old liquid gasket from mating surface of aluminum oil pan.

SEM128E

11. Apply a continuous bead of liquid gasket to mating surface of steel oil pan. q Use Genuine RTV silicone sealant Part No. 999-A7007 or equivalent. q Apply to groove on mating surface. q Allow 7 mm (0.28 in) clearance around bolt holes.

SEM015E q q

Be sure liquid gasket diameter is 3.5 to 4.5 mm (0.138 to 0.177 in). Attaching should be done within 5 minutes after coating.

SEM129E

12. Install steel oil pan. q Tighten bolts in numerical order shown. q Wait at least 30 minutes before refilling engine oil.

SEM118E

EM-18

TIMING CHAIN

GI MA EM LC EC FE CL MT AT FA RA BR ST RS BT HA EL IDX

WEM006

EM-19

TIMING CHAIN
Liquid gasket application places

SEM135E

BEM002

SEM137E

EM-20

TIMING CHAIN Removal
CAUTION: q After removing timing chain, do not turn crankshaft and GI camshaft separately, or valves will strike piston heads. q When installing chain tensioners or other sliding parts, MA lubricate contacting surfaces with new engine oil. q Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprockets and crankshaft pulEM ley. q Do not spill engine coolant on drive belts.

UPPER TIMING CHAIN
1. Remove the spark plug wires.

LC EC FE CL MT

2. Set No.1 piston at TDC on its compression stroke. 3. Remove vacuum hoses, electrical harness connectors, and harness clamps. AT 4. Remove the power steering belt, A/C compressor belt and generator belt. 5. Remove the generator support bracket and generator, posi- FA tion aside. 6. Remove the power steering reservoir tank and reposition it for clearance. RA
SEM140E

7. Install the engine support eye bracket at the right rear of the cylinder head and support engine. 8. Remove the upper right engine mount and bracket. ST 9. Remove the rocker cover. q Remove in numerical order as shown.

BR

RS BT
SEM142E

10. Remove the camshaft sprocket cover. q The stoppers on camshaft sprocket cover prevent upper timing chain from disengaging idler sprocket. EL

HA

IDX

SEM143E

EM-21

TIMING CHAIN Removal (Cont'd)
11. Wipe off the links of 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. 12. Remove cam sprocket bolts, cam sprockets, upper timing chain tensioner, and upper timing chain.

WEM010

IDLER SPROCKET
1. Remove upper timing chain. Refer to ``UPPER TIMING CHAIN'', ``Removal'', EM-21. 2. Support lower timing chain by using a suitable tool to avoid chain tensioner spring from coming out. NOTE: This step is only to be applied when the lower cover is not being removed.
LEL009

3. Remove the idler sprocket bolt. 4. Remove the idler sprocket.

AEM321

LOWER TIMING CHAIN
1. Drain coolant by removing the cylinder block drain plug and opening the radiator drain cock. Refer to MA-11, ``Changing Engine Coolant''. 2. Remove oil pan. Refer to ``Removal'', ``OIL PAN'', EM-15. 3. Remove the power steering pump and position it to the side. Remove the idler pulley and bracket. 4. Set No. 1 piston at TDC on its compression stroke.
AMA098

5. Remove the crankshaft pulley. 6. Remove the oil separator. 7. Remove the front cover. CAUTION: Be careful not to tear or damage the cylinder head gasket. NOTE: Engine may need to be lowered to provide clearance for the timing cover to clear the frame. Engine height may need to be adjusted when removing the cover.
SEM146E

EM-22

TIMING CHAIN Removal (Cont'd)
8. Remove the following parts: q Lower timing chain tensioner (Push piston and insert a suitable pin into pin hole.) GI q Chain tension arm q Lower timing chain guide q Oil pump drive spacer MA 9. Remove the idler sprocket. Refer to ``IDLER SPROCKET'', ``Removal'', EM-22.

EM
AEM087

10. Wipe off the links of the timing chain next to the timing LC marks on the sprockets. Put paint marks on the timing chain, matching them with the timing marks on the crankEC shaft sprocket and idler sprocket. 11. Remove the lower timing chain and sprocket.

FE CL MT AT FA RA
AEM482

Inspection

BR

Check for cracks and excessive wear at roller links. ST Replace chain if necessary.

RS BT
AEM403

HA EL IDX

AEM088

EM-23

TIMING CHAIN Installation
LOWER TIMING CHAIN
1. Install crankshaft sprocket and oil pump drive spacer. q Make sure that mating marks of crankshaft sprocket face front of engine. 2. Position crankshaft so that No. 1 piston is set at TDC on compression stroke. 3. 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. 4. Install chain guide and chain tension arm. 5. Install lower chain tensioner and remove the pin securing the piston into the tensioner body. 6. Install oil pump drive spacer.

AEM325

7. Front cover installation: q Using a scraper or other suitable tool remove all traces of liquid gasket from the cylinder block and front cover mating surfaces. q Install a new crankshaft seal in front of cover. q Apply a continuous bead of liquid gasket to front cover. Refer to EM-20. NOTE: USE Genuine Nissan RTV Silicone Sealant P/N 999MP-A7007 or equivalent.
SEM715A

Be sure to install new front oil seal. Refer to EM-26. Also place RTV sealant on the head gasket surface. q Install front cover to the engine. CAUTION: Be careful not to tear or damage the cylinder head gasket. 8. Install oil pan. Refer to ``Installation'', ``OIL PAN'', EM-17. 9. Install the following parts: q Crankshaft pulley. q A/C compressor and idler pulley bracket. q Power steering pump.
q q SEM292D

UPPER TIMING CHAIN
1. Install lower timing chain (if removed). Refer to ``LOWER TIMING CHAIN'', ``Installation'', EM-24.

SEM748D

EM-24

TIMING CHAIN Installation (Cont'd)
2. Install upper timing chain and sprockets, to the painted reference marks made during removal. 3. Install chain tensioner. Remove the pin holding the tensioner piston in the bore of the tensioner. 4. Install camshaft sprocket cover. q Use a scraper to remove all traces of liquid gasket from mating surfaces of the engine block and camshaft sprocket cover. q Apply a continuous bead of RTV sealant to the cover. Refer to EM-20. q Also place RTV sealant on the head gasket surface. NOTE: Use Nissan Genuine RTV Silicone Sealant, Part No. 999 MPA7007 or equivalent. CAUTION: Be careful not to tear or damage the cylinder head gasket. CAUTION: Be careful upper timing chain does not slip or jump when installing camshaft sprocket cover.

GI MA EM LC EC FE CL MT AT FA RA BR ST RS BT HA EL IDX

AEM326

AEM089

5. Install rocker cover using the following procedure: a. Tighten nuts and bolts 1 - 5 - 6 - 4 in that order to 4 Nm (0.4 kg-m, 35 in-lb). b. Tighten nuts and bolts to 1 to 11 in numerical order to 8 to 11 Nm (0.8 to 1.1 kg-m, 69 to 95 in-lb). Install all spark plugs with high-tension cords. 6. Install upper right engine mount and bracket. 7. Install power steering fluid reservoir tank. 8. Install generator support bracket and generator. 9. Install power steering, generator and A/C compressor drive belts. 10. Install vacuum hoses, electrical harnesses and connectors. 11. Install the spark plug wires.

EM-25

OIL SEAL REPLACEMENT Valve Oil Seal
1. Remove rocker cover. 2. Remove camshaft. Refer to EM-21. 3. Remove valve spring and valve oil seal with Tool or suitable tool. q Piston must be set at TDC to prevent valve from falling. 4. Apply engine oil to new valve oil seal and install it with Tool.

SEM289D

SEM290D

Front Oil Seal
1. Remove radiator shroud and crankshaft pulley. 2. Remove front oil seal. q Be careful not to scratch front cover.

SEM150E

3. Apply engine oil to new oil seal and install it using a suitable tool. q Install new oil seal in the direction shown.

SEM715A

SEM151E

EM-26

OIL SEAL REPLACEMENT Rear Oil Seal
1. Remove drive plate or flywheel. 2. Remove rear oil seal retainer. 3. Remove traces of liquid gasket using scraper.

GI MA EM

SEM896A

4. Remove rear oil seal from rear oil seal retainer. q Be careful not to scratch rear oil seal retainer.

LC EC FE CL

SEM895A

5. Apply engine oil to new oil seal and install it using a suitable tool. q Install new oil seal in the direction shown. AT

MT

FA RA
SEM715A

BR ST RS BT
SEM897A

HA
6. Apply a continuous bead of liquid gasket to mating surface of rear oil seal retainer. q Use Genuine RTV silicone sealant Part No. 999MP- EL A7007 or equilavant. q Apply around inner side of bolt holes.

IDX

SEM144B

EM-27

ACCEL-DRUM UNIT Adjustment
Adjust accel-drum unit after any of the following parts are installed: q Accel-drum unit q Throttle body q Rod (Always replace with a new one after removal.) 1. Install accel-drum unit and throttle body. 2. Apply grease all over the inside of the rod couplings. Use genuine Nissan grease or equivalent. 3. Attach each coupling to ball links on throttle body and acceldrum unit.

AEM191

4. Loosen lock nut. 5. Loosen adjusting screw.

SEM148E

6. Manually turn accel-drum until throttle valve is fully open. q Check that stopper lever is not touching adjusting screw. If it is, loosen adjusting screw to maintain clearance between the two.

AEM192

EM-28

ACCEL-DRUM UNIT Adjustment (Cont'd)
7. Turn adjusting screw until it touches stopper lever. 8. Release accel-drum.

GI MA EM
SEM208D

9. Turn adjusting screw 3 rotations clockwise. 10. Tighten lock nut to specification.

LC EC FE CL

SEM209DA

MT AT FA RA BR ST RS BT HA EL IDX

EM-29

CYLINDER HEAD

WEM007

EM-30

CYLINDER HEAD
CAUTION: q When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting surfaces GI with new engine oil. q Apply new engine oil to threads and seat surfaces when installing cylinder head, camshaft sprocket, crankshaft MA pulley, and camshaft bracket. q Attach tags to valve lifters so as not to mix them up. q Before removing camshaft and idler sprockets, apply EM paint marks to them for retiming.

Removal

LC

1. Remove upper timing chain and idler sprocket. Refer to ``TIMING CHAIN'', ``Removal'', ``UPPER TIMING EC CHAIN'' (EM-21). q For retiming during cylinder head removal/installation, apply paint marks to camshaft sprockets, upper timing FE chain, lower timing chain and idler sprocket.

CL MT

2. Remove camshaft brackets and camshafts. q Mark these parts original positions for reassembly. 3. Remove cylinder head bolts in numerical order. AT q Removing bolts in incorrect order could result in a warped or cracked cylinder head.

FA RA
AEM322

Loosen cylinder head bolts in two or three steps. 4. Remove cylinder head and cylinder head gasket.
q

BR ST RS BT

SEM274D

Installation

HA

1. Tighten cylinder head bolts in numerical order using the folEL lowing procedure: a. Tighten all bolts to 29 N m (3.0 kg-m, 22 ft-lb). b. Tighten all bolts to 79 N m (8.1 kg-m, 59 ft-lb).

IDX

SEM275D

EM-31

CYLINDER HEAD Installation (Cont'd)
c. Loosen all bolts completely. d. Tighten all bolts to 25 to 34 N m (2.5 to 3.5 kg-m, 18 to 25 ft-lb). e. Turn all bolts 86 to 91 degrees clockwise. If angle wrench is not available, mark all cylinder head bolts on the side facing engine front. Then, turn each cylinder head bolt 86 to 91 degrees clockwise.

SEM276D

2. Install camshafts and camshaft brackets in the order shown using the following procedure. a. Set camshafts and camshaft brackets. b. Tighten all bolts to 2 N m (0.2 kg-m, 17 in-lb). c. Tighten all bolts to 9.0 to 11.8 N m (0.92 to 1.2 kg-m, 79.9 to 104.2 in-lb). q Apply new engine oil to bolt threads and seat surfaces. 3. Install upper timing chain and idler sprocket. Refer to ``TIMING CHAIN'', ``Installation'', ``UPPER TIMING CHAIN'' (EM-24).
AEM322

Disassembly
1. Remove intake manifold and exhaust manifold. Refer to "Outer Components Parts" (EM-10). 2. Remove valve components with Tool. 3. Remove valve oil seal with a suitable tool. (Refer to OIL SEAL REPLACEMENT, EM-26.) CAUTION: Keep parts in order so that they can be installed in their original positions during assembly.
SEM692D

Inspection
CYLINDER HEAD DISTORTION
Clean surface of cylinder head. Use a reliable straightedge and feeler gauge to check the flatness of cylinder head surface. q Check along six positions shown in figure. Head surface flatness: Standard: Less than 0.03 mm (0.0012 in) Limit: 0.1 mm (0.004 in) If beyond the specified limit, replace or resurface. Resurfacing limit: The limit for cylinder head resurfacing is determined by the cylinder block resurfacing. Amount of cylinder head resurfacing is ``A''. Amount of cylinder block resurfacing is ``B''. The maximum limit is as follows: A + B = 0.2 mm (0.008 in) After resurfacing cylinder head, check that camshaft rotates freely by hand. If resistance is felt, cylinder head must be replaced. Nominal cylinder head height: 126.3 - 126.5 mm (4.972 - 4.980 in)
q q

SEM294D

EM-32

CYLINDER HEAD Inspection (Cont'd)
CAMSHAFT VISUAL CHECK
Check camshaft for scratches, seizure and wear.

GI MA EM LC EC FE CL
SEM926C

CAMSHAFT RUNOUT
1. Measure camshaft runout at the center journal. Runout (Total indicator reading): Standard Less than 0.02 mm (0.0008 in) Limit 0.04 mm (0.0016 in) 2. If it exceeds the limit, replace camshaft.

CAMSHAFT CAM HEIGHT
1. Measure camshaft cam height. Standard cam height: Intake 42.040 - 42.230 mm (1.6551 - 1.6626 in) Exhaust 42.040 - 42.230 mm (1.6551 - 1.6626 in) Cam wear limit: Intake & Exhaust 0.2 mm (0.008 in) 2. If wear is beyond the limit, replace camshaft.

MT AT FA RA BR

SEM549A

CAMSHAFT JOURNAL CLEARANCE

1. Install camshaft brackets and tighten bolts to the specified ST torque. Refer to EM-30. 2. Measure inner diameter of camshaft bearing. Standard inner diameter: RS #1 to #5 journals 28.000 - 28.025 mm (1.1024 - 1.1033 in)

BT
SEM295D

3. Measure outer diameter of camshaft journal. Standard outer diameter: #1 to #5 journals EL 27.935 - 27.955 mm (1.0998 - 1.1006 in) 4. If clearance exceeds the limit, replace camshaft and/or cylinder head. IDX Camshaft journal clearance: Standard 0.045 - 0.090 mm (0.0018 - 0.0035 in) Limit 0.12 mm (0.0047 in)
SEM012A

HA

EM-33

CYLINDER HEAD Inspection (Cont'd)
CAMSHAFT END PLAY
1. Install camshaft in cylinder head. Refer to EM-30. 2. Measure camshaft end play. Camshaft end play: Standard 0.070 - 0.148 mm (0.0028 - 0.0058 in) Limit 0.20 mm (0.0079 in) 3. If end play exceeds the limit, replace camshaft and remeasure camshaft end play. 4. If end play still exceeds the limit after replacing camshaft, replace cylinder head.

SEM296D

CAMSHAFT SPROCKET RUNOUT
1. Install sprocket on camshaft. 2. Measure camshaft sprocket runout. Runout (Total indicator reading): Limit 0.12 mm (0.0047 in) 3. If it exceeds the limit, replace camshaft sprocket.

AEM328

VALVE GUIDE CLEARANCE
1. Measure valve deflection as shown in figure. (Valve and valve guide mostly wear in this direction.) Valve intake and exhaust deflection limit (Dial gauge reading): 0.2 mm (0.008 in)

SEM297D

2. If it exceeds the limit, check 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)
Standard Intake Exhaust 0.020 - 0.053 (0.0008 - 0.0021) 0.040 - 0.073 (0.0016 - 0.0029) Limit 0.08 (0.0031) 0.1 (0.004)

c.
q

If it exceeds the limit, replace valve and remeasure clearance. If clearance still exceeds the limit after replacing valve, replace the valve guide.

SEM298D

EM-34

CYLINDER HEAD Inspection (Cont'd)
VALVE GUIDE REPLACEMENT
1. To remove valve guide, heat cylinder head to 120 to 140C (248 to 284F). GI

MA EM
SEM008A

2. Drive out valve guide using a hammer and suitable tool or LC a press [under a 20 kN (2 ton, 2.2 US ton, 2.0 Imp ton) pressure].

EC FE CL

SEM299D

3. Ream cylinder head valve guide hole. Valve guide hole diameter (for service parts): Intake & Exhaust 11.175 - 11.196 mm (0.4400 - 0.4408 in)

MT AT FA RA

SEM177E

4. Heat cylinder head to 120 to 140C (248 to 284F) and press service valve guide onto cylinder head. Projection ``L'': ST 13.3 - 13.9 mm (0.524 - 0.547 in)

BR

RS BT
SEM301D

5. Ream valve guide. Finished size: Intake & Exhaust 7.000 - 7.018 mm (0.2756 - 0.2763 in)

HA EL IDX

SEM177E

EM-35

CYLINDER HEAD Inspection (Cont'd)
VALVE SEATS
Check valve seats for pitting at contact surface. Resurface or replace if excessively worn. q Before repairing valve seats, check valve and valve guide for wear. If they are worn, replace them. Then correct valve seat. q Use both hands to cut uniformly.

SEM302D

REPLACING VALVE SEAT FOR SERVICE PARTS
1. Bore out old seat until it collapses. Set machine depth stop so that boring cannot contact bottom face of seat recess in cylinder head. 2. Ream cylinder head recess. Reaming bore for service valve seat Oversize [0.5 mm (0.020 in)]: Intake 38.000 - 38.016 mm (1.4961 - 1.4967 in) Exhaust 32.700 - 32.716 mm (1.2874 - 1.2880 in) Use the valve guide center for reaming to ensure valve seat will have the correct fit. 3. Heat cylinder head to 120 to 140C (248 to 284F). 4. Press fit valve seat until it seats on the bottom.

SEM795A

SEM008A

SEM892B

5. Cut or grind valve seat using suitable tool to the specified dimensions. Refer to SDS, EM-58. 6. After cutting, lap valve seat with abrasive compound. 7. Check valve seating condition. Seat face angle `` '': 4453 - 4507 Contacting width ``W'': Intake 1.48 - 1.63 mm (0.0583 - 0.0642 in) Exhaust 1.8 - 2.0 mm (0.071 - 0.079 in)

VALVE DIMENSIONS
Check dimensions of each valve. Refer to SDS, EM-55. When valve head has been worn down to 0.5 mm (0.020 in) in margin thickness, replace valve. Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or less.

SEM188A

EM-36

CYLINDER HEAD Inspection (Cont'd)
VALVE SPRING Squareness
1. Measure dimension ``S''. Out-of-square ``S'': Less than 2.3 mm (0.091 in) 2. If it exceeds the limit, replace spring.

GI MA EM

SEM288A

Pressure
Check valve spring pressure at specified spring height. Pressure: Standard 369.0 N (37.64 kg, 82.95 lb) at 27.25 mm (1.0728 in) Limit More than 347.0 N (35.38 kg, 78.01 lb) at 27.25 mm (1.0728 in) If it exceeds the limit, replace spring.
EM113

LC EC FE CL MT AT FA RA

VALVE LIFTER AND VALVE SHIM
1. Check contact and sliding surfaces for wear or scratches.

AEM410

2. Check diameter of valve lifter and valve lifter guide bore. Valve lifter diameter: 33.965 - 33.975 mm (1.3372 - 1.3376 in)

BR ST RS BT

AEM411

Lifter guide bore diameter: 34.000 - 34.021 mm (1.3386 - 1.3394 in) Valve lifter to valve lifter guide clearance: EL 0.025 - 0.056 mm (0.0010 - 0.0022 in) If it exceeds the standard diameter or clearance, replace valve lifter or cylinder head. IDX

HA

SEM303D

EM-37

CYLINDER HEAD Assembly
Install valve component parts. q Always use new valve oil seal. Refer to EM-26. q Before installing valve oil seal, install valve spring seat. q Install outer valve spring (uneven pitch type) with its narrow pitch side toward cylinder head side. q After installing valve components, use plastic hammer to lightly tap valve stem tip to assure a proper fit.
SEM638B

Valve Clearance
CHECKING
Check valve clearance while engine is warm but not running. 1. Remove rocker cover and all spark plugs. 2. Set No. 1 cylinder at TDC on its compression stroke. q Align pointer with TDC mark on crankshaft pulley. q 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. 3. Check only those valves shown in the figure.

SEM140E

AEM329 q q

Using a feeler gauge, measure clearance between valve lifter and camshaft. Record any valve clearance measurements which are out of specification. They will be used later to determine the required replacement adjusting shim. Valve clearance (Hot): Intake 0.31 - 0.39 mm (0.012 - 0.015 in) Exhaust 0.39 - 0.47 mm (0.015 - 0.018 in)

SEM304D

4. Turn crankshaft one revolution (360) and align mark on crankshaft pulley with pointer. 5. Check valves shown in the figure. q Use the same procedure mentioned in step 4. 6. If all valve clearances are within specification, install the following parts: q Rocker cover q All spark plugs

AEM330

EM-38

CYLINDER HEAD Valve Clearance (Cont'd)
ADJUSTING
Adjust valve clearance while engine is cold. 1. Turn crankshaft to position cam lobe upward on camshaft of GI valve being adjusted. 2. Place Tool (A) around camshaft as shown in figure. MA 3. Rotate Tool (A) so that lifter is pushed down. Before placing Tool (A), rotate notch toward center of cylinder head (see figure). This will simplify shim removal later. EM CAUTION: Be careful not to damage cam surface with Tool (A). 4. Place Tool (B) between camshaft and valve lifter to retain valve lifter. CAUTION: EC q Place Tool (B) as close to camshaft bracket as possible. q Be careful not to damage cam surface with Tool (B). FE 5. Remove Tool (A).

SEM515EA

LC

CL
SEM516EA

6. Rotate adjusting shim until hole is visible. Blow air into the hole to separate adjusting shim from valve lifter.

MT AT FA RA

AEM447

7. Remove adjusting shim using a small screwdriver and a magnetic finger.

BR ST RS BT

SEM517EA

8. Determine replacement adjusting shim size as follows: a. Using a micrometer, determine thickness of removed shim. b. Calculate thickness of new adjusting shim so valve clear- EL ance comes within specified values. R = Thickness of removed shim N = Thickness of new shim IDX M = Measured valve clearance Intake: N = R + [M - 0.35 mm (0.0138 in)] Exhaust: N = R + [M - 0.37 mm (0.0146 in)]
SEM145D

HA

EM-39

CYLINDER HEAD Valve Clearance (Cont'd)
Shims are available in thicknesses from 1.96 mm (0.0772 in) to 2.68 mm (0.1055 in), in steps of 0.02 mm (0.0008 in). c. Select new shim with thickness as close as possible to calculated value. Refer to SDS, EM-57.

AEM236

9. Install new shim using a suitable tool. Install with the surface on which the thickness is stamped facing down. 10. Place Tool (A) as mentioned in steps 2 and 3. 11. Remove Tool (B). 12. Remove Tool (A). 13. Recheck valve clearance. Refer to EM-38.
SEM518EA

EM-40

ENGINE REMOVAL

GI MA EM LC EC FE CL MT AT FA RA BR ST RS BT HA EL IDX

AEM331

EM-41

ENGINE REMOVAL
WARNING: q Position vehicle on a flat and solid surface. q Do not remove engine until exhaust system has completely cooled; otherwise, you may burn yourself and/or fire may break out in fuel line. q Before disconnecting fuel hose, release fuel pressure. Refer to EC-34 section (``Fuel Pressure Release'', ``BASIC SERVICE PROCEDURE''). q Before removing front axle from transaxle, place safety stands under designated front supporting points. Refer to GI section for lifting points and towing. q Be sure to hoist engine and transaxle in a safe manner. q For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS CATALOG. CAUTION: q When lifting engine, be sure to clear surrounding parts. Use special care near accelerator wire casing, brake lines and brake master cylinder. q In hoisting the engine, always use engine slingers in a safe manner. q When removing drive shaft, be careful not to damage grease seal of transaxle. q Before separating engine and transaxle, remove crankshaft position sensor (OBD) from the assembly. q Always be extra careful not to damage edge of crankshaft position sensor (OBD), or ring gear teeth.

AAT894

Removal
1. Remove engine undercover and hood. 2. Drain coolant from drain plug on water pipe, and radiator. Refer to MA-11 section (``Changing Engine Coolant'', ``ENGINE MAINTENANCE''). 3. Release fuel pressure. Refer to EC-34 section (``Fuel Pressure Release'', ``BASIC SERVICE PROCEDURE'').

4. Remove battery and its bracket, air cleaner and air duct. 5. Remove vacuum hoses, fuel hoses, wires, harnesses and connectors and so on. 6. Remove front exhaust tube and drive shafts. 7. Remove radiator and fans. Refer to LC-14 section (``Radiator'', ``ENGINE COOLING SYSTEM''). 8. Remove drive belts. 9. Remove generator and A/C compressor from engine. 10. Set a suitable transmission jack under transaxle. Hoist engine with engine slinger.
AMT068

EM-42

ENGINE REMOVAL Removal (Cont'd)
11. Remove RH and LH engine mountings and center member. q Make sure engine is hoisted level to allow easy removal of mounting thru bolts. GI 12. Remove front and rear engine mountings.

MA EM
SEM120E

13. Remove engine with transaxle as shown.

LC EC FE CL MT AT FA RA BR ST RS BT HA EL IDX

SEM153E

Installation
Installation is in the reverse order of removal.

EM-43

CYLINDER BLOCK

WEM008

1 2 3 4 5 6 7

Piston rings Piston Piston pin Snap ring Connecting rod Connecting rod bearing Main bearing cap

8 9
10 11 12 13 14

Crankshaft Main bearing Oil jet Cylinder block Rear oil seal retainer Rear oil seal Rear plate

15 16 17 18 19 20

Pilot converter (A/T) Drive plate (A/T) Drive plate reinforcement Pilot bushing (M/T) Flywheel (M/T) Cylinder block heater

EM-44

CYLINDER BLOCK
CAUTION: q When installing sliding parts such as bearings and pistons, apply new engine oil on the sliding surfaces. q Place removed parts such as bearings and bearing GI caps in their proper order and direction. q When installing connecting rod nuts and main bearing cap bolts, apply new engine oil to threads and seating MA surfaces. q Do not allow any magnetic materials to contact the ring EM gear teeth of flywheel or drive plate.

Disassembly
PISTON AND CRANKSHAFT
1. Place engine on a work stand. 2. Remove timing chains. Refer to EM-21.

LC EC FE CL

SEM574C

3. Remove pistons with connecting rods. q To disassemble piston and connecting rod, first remove snap rings. Heat piston to 60 to 70C (140 to 158F) then AT use piston pin press to remove pin. CAUTION: q When piston rings are not replaced, make sure that FA piston rings are mounted in their original positions. q When piston rings are being replaced and no punchmark is present, piston rings can be mounted with RA either side up.
SEM877B

MT

BR ST RS BT
EM156-A

HA
4. Remove main bearing cap and crankshaft. q Before removing main bearing cap, measure crankshaft EL end play. Refer to EM-53. q Bolts should be loosened in two or three steps in numerical order as shown.

IDX

SEM248C

EM-45

CYLINDER BLOCK Inspection
PISTON AND PISTON PIN CLEARANCE
1. Measure inner diameter of piston pin hole ``dp''. Standard diameter ``dp'': 20.993 - 20.999 mm (0.8265 - 0.8267 in)

AEM023

2. Measure outer diameter of piston pin ``Dp''. Standard diameter ``Dp'': 20.989 - 21.001 mm (0.8263 - 0.8268 in) 3. Calculate interference fit of piston pin to piston. Dp - dp: -0.002 to 0.01 mm (-0.0001 to 0 in) If it exceeds the above value, replace piston assembly with pin.

AEM024

PISTON RING SIDE CLEARANCE
Side clearance: Top ring 0.040 - 0.080 mm (0.0016 - 0.0031 in) 2nd ring 0.030 - 0.070 mm (0.0012 - 0.0028 in) Max. limit of side clearance: 0.1 mm (0.004 in) If out of specification, replace piston ring. If clearance exceeds maximum limit with new ring, replace piston.
SEM249CA

PISTON RING END GAP
End gap: Top ring 0.28 - 0.52 mm (0.0110 - 0.0205 in) 2nd ring 0.45 - 0.69 mm (0.0177 - 0.0272 in) Oil ring 0.20 - 0.69 mm (0.0079 - 0.0272 in) Max. limit of end gap: 1.0 mm (0.039 in) If out of specification, replace piston ring. If gap exceeds maximum limit with new ring, rebore cylinder and use oversized piston and piston rings. Refer to SDS, EM-61. When replacing the piston, check the cylinder block surface for scratches or seizure. If scratches or seizure are found, hone or replace the cylinder block.

AEM096

EM-46

CYLINDER BLOCK Inspection (Cont'd)
CONNECTING ROD BEND AND TORSION
Bend: Limit 0.15 mm (0.0059 in) per 100 mm (3.94 in) length Torsion: Limit 0.30 mm (0.0118 in) per 100 mm (3.94 in) length If it exceeds the limit, replace connecting rod assembly.

GI MA EM

SEM150B

CYLINDER BLOCK DISTORTION
1. Clean upper surface of cylinder block. Use a reliable straightedge and feeler gauge to check the flatness of cylinder block surface. Check along six positions shown in figure. Block surface flatness: Standard: Less than 0.03 mm (0.0012 in) Limit: 0.10 mm (0.0039 in) 2. If out of specification, resurface it. Resurfacing limit: The limit for cylinder block resurfacing is determined by the cylinder head resurfacing. Amount of cylinder head resurfacing is ``A''. Amount of cylinder block resurfacing is ``B''. The maximum limit is as follows: A + B = 0.2 mm (0.008 in) Nominal cylinder block height from crankshaft center: 246.95 - 247.05 mm (9.7224 - 9.7264 in) 3. If necessary, replace cylinder block.
SEM255C

LC EC FE CL MT AT FA RA BR ST RS BT HA EL IDX

PISTON-TO-BORE CLEARANCE
1. Using a bore gauge, measure cylinder bore for wear, outof-round and taper. Standard inner diameter: 89.000 - 89.030 mm (3.5039 - 3.5051 in) Wear limit: 0.2 mm (0.008 in) If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary. Out-of-round (X - Y) standard: Less than 0.015 mm (0.0006 in) Taper (A - B) standard: Less than 0.01 mm (0.0004 in) 2. Check for scratches and seizure. If seizure is found, hone it. q If cylinder block and piston are replaced, match piston grade with grade number on cylinder block surface.

SEM040

SEM257C

EM-47

CYLINDER BLOCK Inspection (Cont'd)
3. Measure piston skirt diameter. Piston diameter ``A'': Refer to SDS, EM-61. Measuring point ``a'' (Distance from the top): Approximately 48 mm (1.89 in) 4. Check that piston-to-bore clearance is within specification. Piston-to-bore clearance ``B'': 0.020 - 0.040 mm (0.0008 - 0.0016 in)

SEM258C

5. Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. Refer to SDS, EM-61. 6. Cylinder bore size is determined by adding piston-to-bore clearance ``B'' to piston diameter ``A''. Rebored size calculation: D = A + B - C where, D: Bored diameter A: Piston diameter as measured B: Piston-to-bore clearance C: Honing allowance 0.02 mm (0.0008 in) 7. Install main bearing caps and tighten to the specified torque. This will prevent distortion of cylinder bores. 8. Cut cylinder bores. q When any cylinder needs boring, all other cylinders must also be bored. q Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so at a time. 9. Hone cylinders to obtain specified piston-to-bore clearance. 10. Measure finished cylinder bore for out-of-round and taper. q Measurement should be done after cylinder bore cools down.

CRANKSHAFT
q q

SEM316A

Check crankshaft main and pin journals for score, wear or cracks. With a micrometer, measure journals for taper and out-ofround. Out-of-round (X - Y): Main 0.01 mm (0.0004 in) Pin 0.005mm (0.0002 in) Taper (A - B): Main 0.01 mm (0.0004 in) Pin 0.005 mm (0.0002 in)

EM-48

CYLINDER BLOCK Inspection (Cont'd)
q

Measure crankshaft runout. Runout (Total indicator reading): 0.10 mm (0.0039 in)

GI MA EM

SEM254C

BEARING CLEARANCE
q

LC

Use Method A or Method B. Method A is preferred because it is more accurate. EC

Method A (Using bore gauge & micrometer) Main bearing
1. Set main bearings in their proper positions on cylinder block and main bearing cap.

FE CL

SEM448C

2. Install main bearing cap to cylinder block. q Tighten all bolts in correct order in two or three stages. Refer to EM-53. AT 3. Measure inner diameter ``A'' of each main bearing.

MT

FA RA
AEM025

AEM026

4. Measure outer diameter ``Dm'' of each crankshaft main journal. 5. Calculate main bearing clearance. ST Main bearing clearance = A - Dm Standard: 0.020 - 0.047 mm (0.0008 - 0.0019 in) RS Limit: 0.1 mm (0.004 in) If it exceeds the limit, replace bearing. If clearance cannot be adjusted using any standard bearing BT grade, grind crankshaft main journal and use undersized bearing. When grinding crankshaft journal, confirm that ``L'' dimension in fillet roll is more than the specified limit. ``L'': 0.1 mm (0.004 in) EL Refer to EM-62 for grinding crankshaft and available service parts.

BR

HA

IDX

SEM964

EM-49

CYLINDER BLOCK Inspection (Cont'd)
If crankshaft is replaced, select thickness of main bearings as follows: a. Grade number of each cylinder block main journal is punched on the respective cylinder block. These numbers are punched in either Arabic or Roman numerals.
q

AEM097

b. Grade number of each crankshaft main journal is punched on crankshaft. These numbers are punched in either Arabic or Roman numerals. c. Select main bearing with suitable thickness according to the following table. Main bearing grade number:
Crankshaft main journal grade number
AEM098

Cylinder block main journal grade number 0 0 (Black) 1 (Brown) 2 (Green) 1 or I 1 (Brown) 2 (Green) 3 (Yellow) 2 or II 2 (Green) 3 (Yellow) 4 (Blue)

0 1 or I 2 or II

For example: Cylinder block main journal grade number: 1 Crankshaft main journal grade number: 2 Main bearing grade number = 1 + 2 = 3 (Yellow)

Connecting rod bearing (Big end)
1. Install connecting rod bearing to connecting rod and connecting rod cap. 2. Install connecting rod cap to connecting rod. q Tighten bolts to the specified torque. Refer to EM-53. 3. Measure inner diameter ``C'' of each bearing.

AEM027

4. Measure outer diameter ``Dp'' of each crankshaft pin journal. 5. Calculate connecting rod bearing clearance. Connecting rod bearing clearance = C - Dp Standard: 0.010 - 0.035 mm (0.0004 - 0.0014 in) Limit: 0.09 mm (0.0035 in) If it exceeds the limit, replace bearing. If clearance cannot be adjusted using any standard bearing grade, grind crankshaft pin journal and use undersized bearing. Refer to step 5 on EM-49 for fillet roll remarks and EM-62 for grinding crankshaft and available service parts.
AEM028

EM-50

CYLINDER BLOCK Inspection (Cont'd)
If crankshaft is replaced with a new one, select connecting rod bearings according to the following table. Connecting rod bearing grade number: GI These numbers are punched in either Arabic or Roman numerals.
q

Crankshaft pin journal grade number 0 1 or I
AEM099

Connecting rod bearing grade number 0 (Black) 1 (Brown) 2 (Green)

MA EM LC

2 or II

Method B (Using plastigage)

CAUTION: q Do not turn crankshaft or connecting rod while plasti- EC gage is being inserted. q When bearing clearance exceeds the specified limit, ensure that the proper bearing has been installed. Then FE if excessive bearing clearance exists, use a thicker main bearing or undersized bearing so that the speciCL fied bearing clearance is obtained.
EM142

CONNECTING ROD BUSHING CLEARANCE (Small end)

MT

AT 1. Measure inner diameter ``C'' of bushing. 2. Measure outer diameter ``Dp'' of piston pin. 3. Calculate connecting rod bushing clearance. FA C - Dp = 0.005 - 0.017 mm (0.0002 - 0.0007 in) (Standard) 0.023 mm (0.0009 in) (Limit) If it exceeds the limit, replace connecting rod assembly RA and/or piston set with pin.
AEM332

REPLACEMENT OF CONNECTING ROD BUSHING (Small end)

BR

SEM062A

1. Drive in small end bushing until it is flush with end surface ST of rod. Be sure to align the oil holes. RS 2. Ream the bushing so that clearance with piston pin is within specification. Clearance between small end bushing and piston BT pin: 0.005 - 0.017 mm (0.0002 - 0.0007 in)

HA EL IDX

EM-51

CYLINDER BLOCK Inspection (Cont'd)
FLYWHEEL/DRIVE PLATE RUNOUT
Runout (Total indicator reading): Flywheel (M/T model) Less than 0.15 mm (0.0059 in) Drive plate (A/T model) Less than 0.15 mm (0.0059 in) CAUTION: q Be careful not to damage the ring gear teeth. q Check drive plate for deformation and cracks. q Do not allow any magnetic materials to contact the ring gear teeth. q Do not resurface the flywheel. Replace as necessary.

AEM100

Assembly
PISTON
1. Install new snap ring on one side of piston pin hole.

SEM166B

2. Heat piston to 60 to 70C (140 to 158F) and assemble piston, piston pin, connecting rod and new snap ring. q Align the direction of piston and connecting rod. q Numbers stamped on connecting rod and cap correspond to each cylinder. q After assembly, make sure connecting rod swings smoothly.

SEM311D

3. Set piston rings as shown. CAUTION: q When piston rings are not being replaced, make sure that piston rings are mounted in their original positions. q When piston rings are being replaced and no punchmark is present, piston rings can be mounted with either side up.

SEM264C

EM-52

CYLINDER BLOCK Assembly (Cont'd)
q

Align piston rings so that end gaps are positioned as shown.

GI MA EM
SEM160B

CRANKSHAFT

LC

1. Set main bearings in their proper positions on cylinder block and main bearing cap. EC q Confirm that correct main bearings are used. Refer to EM-49. FE q Apply new engine oil to bearing surfaces.

CL
SEM448C

2. Install crankshaft and main bearing cap and tighten bolts to the specified torque. q Apply new engine oil to bolt threads and seat surfaces. AT q Prior to tightening bearing cap bolts, shift crankshaft back and forth to properly seat the bearing cap. q Tighten bearing cap bolts gradually in two or three FA stages. Start with center bearing and move outward as shown in figure. q After securing bearing cap bolts, make sure crankshaft RA turns smoothly by hand.
AEM101

MT

3. Measure crankshaft end play. Crankshaft end play: Standard 0.05 - 0.18 mm (0.0020 - 0.0071 in) Limit 0.3 mm (0.012 in) If beyond the limit, replace bearing with a new one.

BR ST RS BT

SEM158B

HA
4. Install connecting rod bearings in connecting rods and connecting rod caps. q Confirm that correct bearings are used. Refer to EM-50. EL q Install bearings so that oil hole in connecting rod aligns with oil hole of bearing. q Apply new engine oil to bearing surfaces, bolt threads IDX and seating surfaces.

SEM159B

EM-53

CYLINDER BLOCK Assembly (Cont'd)
5. Install pistons with connecting rods. a. Install them into corresponding cylinders with Tool. q Be careful not to scratch cylinder wall with connecting rod. q Arrange so that front mark on piston head faces toward engine front. q Be careful not to scratch crankshaft journals with connecting rod bolts. q Apply new engine oil to piston rings and sliding surface of piston.
SEM269C

b. Install connecting rod bearing caps. Apply new engine oil to threads and seat surfaces. Tighten connecting rod bearing cap nuts in the following procedure: (1) Tighten to 14 to 16 N m (1.4 to 1.6 kg-m, 10 to 12 ft-lb). (2) Turn all nuts 60 to 65 degrees clockwise. If an angle wrench is not available, mark all connecting rod bearing cap nuts on the side facing engine front. Then, turn each nut 60 to 65 degrees clockwise.
SEM270C

6. Measure connecting rod side clearance. Connecting rod side clearance: Standard 0.2 - 0.4 mm (0.008 - 0.016 in) Limit 0.6 mm (0.024 in) If beyond the limit, replace connecting rod and/or crankshaft.

EEM124

REPLACING PILOT BUSHING
1. Remove pilot bushing (M/T) or pilot converter (A/T).

AEM102

2. Install pilot bushing (M/T) or pilot converter (A/T).

AEM103

EM-54

SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications
Unit: kPa (kg/cm2, psi)/300 rpm
Cylinder arrangement Displacement Bore and stroke Valve arrangement Firing order Number of piston rings Compression Oil Number of main bearings Compression ratio 2 1 5 9.2 cm3 (cu in) mm (in) In-line 4 2,389 (145.78) 89 x 96 (3.50 x 3.78) DOHC 1-3-4-2 Compression pressure Standard Minimum Difference limit between cylinders 1,226 (12.5, 178) 1,030 (10.5, 149) 98 (1.0, 14)

GI MA EM LC EC FE

Inspection and Adjustment
CYLINDER HEAD
Standard Head surface distortion Less than 0.03 (0.0012)

Unit: mm (in)
Limit 0.1 (0.004)

VALVE

Unit: mm (in)

CL MT AT FA RA

SEM188

Valve head diameter ``D'' Intake Nominal cylinder head height: H = 126.3 - 126.5 (4.972 - 4.980) Limit: 0.2 (0.008)* Exhaust
SEM956C

BR
36.5 - 36.8 (1.437 - 1.449) 31.2 - 31.5 (1.228 - 1.240)

Valve length ``L'' Intake Exhaust Valve stem diameter ``d'' Intake Exhaust Valve face angle `` '' Intake 4525' - 4575' Exhaust Valve margin ``T'' Intake Exhaust Valve margin ``T'' limit Valve stem end surface grinding limit 0.95 - 1.25 (0.0374 - 0.0492) 1.15 - 1.45 (0.0453 - 0.0571) More than 0.5 (0.020) Less than 0.2 (0.008) 6.965 - 6.980 (0.2742 - 0.2748) 6.945 - 6.960 (0.2734 - 0.2740) 99.17 - 99.47 (3.9043 - 3.9161) 96.67 - 96.97 (3.8059 - 3.8177)

ST RS BT HA EL IDX

* Total amount of cylinder head resurfacing plus cylinder block resurfacing

EM-55

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont'd)
VALVE SPRING
Free height Pressure N (kg, lb) at height mm (in) Standard Limit Out-of-square mm (in) 369.0 (37.63, 82.97) at 27.25 (1.0728) 347.0 (35.38, 78.02) at 27.25 (1.0728) Less than 2.3 (0.091) mm (in) 50.15 (1.9744)

VALVE GUIDE

Unit: mm (in)

VALVE LIFTER
Valve lifter diameter Lifter guide bore diameter Clearance between lifter and lifter guide

Unit: mm (in)
33.965 - 33.975 (1.3372 - 1.3376) 34.000 - 34.021 (1.3386 - 1.3394) 0.025 - 0.056 (0.0010 - 0.0022) Standard Valve guide Outer diameter Valve guide Inner diameter (Finished size) Cylinder head valve guide hole diameter Intake Exhaust Intake & Exhaust Intake & Exhaust 11.023 - 11.034 (0.4340 - 0.4344)

SEM301D

Service

11.223 - 11.234 (0.4418 - 0.4423)

7.000 - 7.018 (0.2756 - 0.2763) 7.000 - 7.018 (0.2756 - 0.2763) 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 0.08 (0.0031) 0.1 (0.004)

Intake Stem to guide clearance Exhaust Valve deflection limit Projection length ``L''

0.020 - 0.053 (0.0008 - 0.0021) 0.040 - 0.073 (0.0016 - 0.0029)

0.2 (0.008) 13.3 - 13.9 (0.524 - 0.547)

EM-56

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont'd)
VALVE CLEARANCE ADJUSTMENT
Unit: mm (in)
Valve clearance (Hot) Intake Exhaust 0.31 - 0.39 (0.012 - 0.015) 0.39 - 0.47 (0.015 - 0.019)

GI MA EM
AEM236

Available shims
Thickness mm (in) 2.40 (0.0945) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0976) 2.50 (0.0984) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 2.58 (0.1016) 2.60 (0.1024) 2.62 (0.1031) 2.64 (0.1039) 2.66 (0.1047) 2.68 (0.1055) 2.70 (0.1063) 2.72 (0.1071) 2.74 (0.1079) 2.76 (0.1087) 2.78 (0.1094) 2.80 (0.1102) 2.82 (0.1110) 2.84 (0.1118) 2.86 (0.1126) 2.88 (0.1134) 2.90 (0.1142) 2.92 (0.1150) 2.94 (0.1157) 2.96 (0.1165) 2.98 (0.1173) 3.00 (0.1181) 3.02 (0.1189) 3.04 (0.1197) 3.06 (0.1205) 3.08 (0.1213) 3.10 (0.1220) Identification mark 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 292 294 296 298 300 302 304 306 308 310

LC EC FE CL MT AT FA RA BR ST RS BT HA EL IDX

EM-57

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont'd)
VALVE SEAT
Unit: mm (in)

WEM012

Standard In. Cylinder head seat recess diameter (D) Ex. In. Valve seat interference fit Ex. In. Valve seat outer diameter (d) Ex. In. Depth (H) Ex. In. Height (h1) Ex. In. Height (h2) Ex. 6.1 - 6.3 (0.240 - 0.248) 5.8 - 6.0 (0.228 - 0.236) 5.9 - 6.0 (0.232 - 0.236) 32.280 - 32.296 (1.2709 - 1.2715) 0.064 - 0.096 (0.0025 - 0.0038) 37.580 - 37.596 (1.4795 - 1.4802) 32.200 - 32.216 (1.2677 - 1.2683) 37.500 - 37.516 (1.4764 - 1.4770)

Service 38.000 - 38.016 (1.4961 - 1.4967) 32.700 - 32.716 (1.2874 - 1.2880)

0.064 - 0.096 (0.0025 - 0.0038)

38.080 - 38.096 (1.4992 - 1.4998) 32.780 - 32.796 (1.2905 - 1.2912)

6.1 - 6.3 (0.240 - 0.248)

5.3 - 5.5 (0.209 - 0.217) 5.32 - 5.42 (0.2094 - 0.2134)

0.24 - 0.64 (0.0094 - 0.0252) 0.43 - 0.73 (0.0169 - 0.0287)

EM-58

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont'd)
CYLINDER BLOCK
Unit: mm (in)

GI MA EM LC EC FE CL MT
SEM447C

Standard Distortion Grade 1 Inner diameter Cylinder bore Out-of-round (X -Y) Taper (A -B) Difference in inner diameter between cylinders Nominal cylinder block height : H (From crankshaft center) Grade 2 Grade 3 Less than 0.03 (0.0012) 89.000 - 89.010 (3.5039 - 3.5043) 89.010 - 89.020 (3.5043 - 3.5047) 89.020 - 89.030 (3.5047 - 3.5051) Less than 0.015 (0.0006) Less than 0.010 (0.0004) Less than 0.03 (0.0012) 246.95 - 247.05 (9.7224 - 9.7264)

Limit 0.10 (0.0039)

AT FA

0.2 (0.008)

RA
-- -- 0.2 (0.008) 0.2 (0.008)*

BR ST RS BT HA EL IDX

* Total amount of cylinder head resurfacing plus cylinder block resurfacing

EM-59

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont'd)
CAMSHAFT AND CAMSHAFT BEARING
Unit: mm (in)

SEM568A

EM120

Standard Intake Cam height (A) Exhaust Wear limit of cam height Camshaft journal to bearing clearance Inner diameter of camshaft bearing Outer diameter of camshaft journal (D) Camshaft runout* Camshaft end play a b c Valve timing (Degree on crankshaft) d e f 45 7 53 #1 to #5 journals #1 to #5 journals 42.040 - 42.230 (1.6551 - 1.6626) -- 0.045 - 0.090 (0.0018 - 0.0035) 28.000 - 28.025 (1.1024 - 1.1033) 27.935 - 27.955 (1.0998 - 1.1006) Less than 0.02 (0.0008) 0.070 - 0.148 (0.0028 - 0.0058) 240 224 -1 42.040 - 42.230 (1.6551 - 1.6626)

Limit -- -- 0.2 (0.008) 0.12 (0.0047) -- -- 0.04 (0.0016) 0.20 (0.0079) -- -- -- -- -- --

*: Total indicator reading

EM-60

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont'd)
PISTON, PISTON RING AND PISTON PIN Piston
Unit: mm (in)

CONNECTING ROD

Unit: mm (in)

GI MA EM LC

BEM003

EC
SEM180E

Grade No. 1 Standard Piston skirt diameter (A) Grade No. 2 Grade No. 3 0.5 (0.020) 1.0 (0.039)

88.970 - 88.980 (3.5027 - 3.5031) 88.980 - 88.990 (3.5031 - 3.5035) 88.990 - 89.000 (3.5035 - 3.5039) 89.470 - 89.500 (3.5224 - 3.5236) 89.970 - 90.000 (3.5421 - 3.5433) Center distance (S) Bend [per 100 mm (3.94 in)] Torsion [per 100 mm (3.94 in)] Piston pin bushing inner diameter (d) Connecting rod big end inner diameter (D)* Side clearance Standard 164.95 - 165.05 (6.4941 - 6.4980) -- -- 23.987 - 24.000 (0.9444 - 0.9449) 53.000 - 53.013 (2.0866 - 2.0871) 0.2 - 0.4 (0.008 - 0.016)

Limit -- 0.15 (0.0059) 0.30 (0.0118) --

FE CL MT AT

Service (Oversize)

Measuring point - Distance from top (a) Piston pin hole diameter (dp) Piston-to-bore clearance

Approximately 48 (1.89) 20.993 - 20.999 (0.8265 - 0.8267) 0.020 - 0.040 (0.0008 - 0.0016)

-- 0.6 (0.024)

FA RA

* Without bearing

Piston pin
Standard Piston pin outer diameter Interference fit of piston pin to piston pin hole Piston pin to connecting rod bushing clearance 20.989 - 21.001 (0.8263 - 0.8268) -0.002 to 0.01 (-0.0001 to 0) 0.005 - 0.017 (0.0002 - 0.0007)

Unit: mm (in)
Limit --

BR ST

-- 0.023 (0.0009)

RS BT

Piston ring
Standard Top Side clearance 2nd Top End gap 2nd Oil (rail ring) 0.040 - 0.080 (0.0016 - 0.0031) 0.030 - 0.070 (0.0012 - 0.0028) 0.28 - 0.52 (0.0110 - 0.0205) 0.45 - 0.69 (0.0177 - 0.0272) 0.20 - 0.69 (0.0079 - 0.0272)

Unit: mm (in)
Limit 0.1 (0.004) 0.1 (0.004) 1.0 (0.039) 1.0 (0.039) 1.0 (0.039)

HA EL IDX

EM-61

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont'd)
CRANKSHAFT
Unit: mm (in)

SEM394

EM715

No. 0 Main journal diameter (Dm) Grade No. 1 No. 2 No. 0 Pin journal diameter (Dp) Grade No. 1 No. 2 Center distance (r)

59.967 - 59.975 (2.3609 - 2.3612) 59.959 - 59.967 (2.3606 - 2.3609) 59.951 - 59.959 (2.3603 - 2.3606) 49.968 - 49.974 (1.9672 - 1.9675) 49.962 - 49.968 (1.9670 - 1.9672) 49.956 - 49.962 (1.9668 - 1.9670) 47.95 - 48.05 (1.8878 - 1.8917) Standard Limit -- -- -- -- -- 0.3 (0.012)

Taper of main or pin journal ( A - B )

Main Pin

0.01 (0.0004) 0.005 (0.0002) 0.01 (0.0004) 0.005 (0.0002) 0.10 (0.0039) 0.05 - 0.18 (0.0020 - 0.0071) More than 0.1 (0.004)

Out-of-round of main or pin journal ( X - Y ) Runout [TIR]* Free end play Fillet roll

Main Pin

* Total indicator reading

EM-62

SERVICE DATA AND SPECIFICATIONS (SDS) Inspection and Adjustment (Cont'd)
BEARING CLEARANCE
Standard Main bearing clearance Connecting rod bearing clearance 0.020 - 0.047 (0.0008 - 0.0019) 0.010 - 0.035 (0.0004 - 0.0014)

Unit: mm (in)
Limit 0.1 (0.004) 0.09 (0.0035)

AVAILABLE CONNECTING ROD BEARING Standard
Grade number 0 Thickness 1.505 - 1.508 (0.0593 - 0.0594) 1.508 - 1.511 (0.0594 - 0.0595) 1.511 - 1.514 (0.0595 - 0.0596)

GI
Unit: mm (in)

Identification color Black

MA EM

AVAILABLE MAIN BEARING Standard
Grade number 0 1 2 3 4 Thickness 1.821 - 1.825 (0.0717 - 0.0719) 1.825 - 1.829 (0.0719 - 0.0720) 1.829 - 1.833 (0.0720 - 0.0722) 1.833 - 1.837 (0.0722 - 0.0723) 1.837 - 1.841 (0.0723 - 0.0725)

1

Brown Green

Unit: mm (in)
Identification color Black Brown Green Yellow Blue

2

LC EC FE CL MT

Undersize (service)
Thickness 0.08 (0.0031) 0.12 (0.0047) 0.25 (0.0098) 1.540 - 1.548 (0.0606 - 0.0609) 1.560 - 1.568 (0.0614 - 0.0617) 1.625 - 1.633 (0.0640 - 0.0643)

Unit: mm (in)
Crank pin journal diameter ``Dp''

Grind so that bearing clearance is the specified value.

Undersize (service)
Thickness 0.25 (0.0098) 1.952 - 1.960 (0.0769 - 0.0772)

Unit: mm (in)
Main journal diameter ``Dm'' Grind so tha