Infiniti G20 P11 (2000) Service Manual – ENGINE MECHANICAL

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EXIT

PRECAUTIONS ...............................................................3

Parts Requiring Angular Tightening.............................3

Liquid Gasket Application Procedure ..........................3

PREPARATION ...............................................................4

Special Service Tools ..................................................4

Commercial Service Tools...........................................6

NOISE, VIBRATION AND HARSHNESS (NVH)

TROUBLESHOOTING.....................................................8

NVH Troubleshooting - Engine Noise .........................9

OUTER COMPONENT PARTS.....................................10

Removal and Installation...........................................10

MEASUREMENT OF COMPRESSION PRESSURE....13

OIL PAN.........................................................................14

Components...............................................................14

Removal.....................................................................14

Installation..................................................................16

TIMING CHAIN ..............................................................19

Components...............................................................19

Removal.....................................................................20

Inspection...................................................................23

Installation..................................................................23

OIL SEAL.......................................................................28

Replacement..............................................................28

VALVE OIL SEAL FRONT OIL SEAL REAR OIL SEAL

CYLINDER HEAD..........................................................30

Components...............................................................30

Removal.....................................................................31

Disassembly...............................................................34

Inspection...................................................................36

CYLINDER HEAD DISTORTION CAMSHAFT VISUAL CHECK CAMSHAFT RUNOUT CAMSHAFT CAM HEIGHT CAMSHAFT JOURNAL CLEARANCE CAMSHAFT END PLAY CAMSHAFT SPROCKET RUNOUT VALVE GUIDE CLEARANCE VALVE GUIDE REPLACEMENT

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ENGINE MECHANICAL

SECTION

CONTENTS

VALVE SEATS REPLACING VALVE SEAT FOR SERVICE PARTS VALVE DIMENSIONS VALVE SPRING HYDRAULIC LASH ADJUSTER ROCKER ARM, SHIM AND ROCKER ARM GUIDE

Assembly ...................................................................42

Installation..................................................................46

ENGINE ASSEMBLY.....................................................55

Removal and Installation...........................................55

REMOVAL INSTALLATION

CYLINDER BLOCK.......................................................58

Components...............................................................58

Removal and Installation...........................................59

Disassembly...............................................................59

PISTON AND CRANKSHAFT

Inspection...................................................................59

PISTON AND PISTON PIN CLEARANCE PISTON RING SIDE CLEARANCE PISTON RING END GAP CONNECTING ROD BEND AND TORSION CYLINDER BLOCK DISTORTION AND WEAR PISTON-TO-BORE CLEARANCE CRANKSHAFT BEARING CLEARANCE CONNECTING ROD BUSHING CLEARANCE (SMALL END) REPLACEMENT OF CONNECTING ROD BUSHING (SMALL END) REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T) FLYWHEEL/DRIVE PLATE RUNOUT

Assembly ...................................................................67

PISTON CRANKSHAFT

SERVICE DATA AND SPECIFICATIONS (SDS).........71

General Specifications...............................................71

Compression Pressure..............................................71

Cylinder Head............................................................71

Valve ..........................................................................72

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....40

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.....42

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.........................................................68

IDX

CONTENTS (Cont’d)

EXIT

....................................................................72

VALVE VALVE SPRING HYDRAULIC LASH ADJUSTER (HLA) VALVE GUIDE VALVE SHIM CLEARANCE ADJUSTMENT AVAILABLE SHIM VALVE SEAT VALVE SEAT RESURFACE LIMIT

Camshaft and Camshaft Bearing..............................76

Cylinder Block............................................................77

Piston, Piston Ring and Piston pin............................78

PISTON PISTON RING

.......................................................72

.......................72

.........................................................73

................73

....................................................74

...........................................................75

.............................76

..................................................................78

.........................................................78

PISTON PIN

Connecting Rod.........................................................79

Crankshaft..................................................................80

Main Bearing..............................................................81

STANDARD UNDERSIZE

Connecting Rod Bearing ...........................................81

STANDARD SIZE UNDERSIZE

Bearing Clearance.....................................................82

Miscellaneous Components.......................................82

............................................................78

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EM-2

PRECAUTIONS

Parts Requiring Angular Tightening

EXIT

SEM164F

Parts Requiring Angular Tightening

I Use an angle wrench for the final tightening of the following

engine parts: a) Cylinder head bolts b) Main bearing cap bolts c) Connecting rod cap nuts

I Do not use a torque value for final tightening. I The torque value for these parts are for a preliminary step. I Ensure thread and seat surfaces are clean and coated with

engine oil.

Liquid Gasket Application Procedure

1. Use a scraper to remove old liquid gasket from mating

surfaces and grooves. Also, completely clean any oil from

these areas.

2. Apply a continuous bead of liquid gasket to mating sur-

faces. (Use Genuine RTV silicone sealant part No. 999MP-

A7007 or equivalent.) I For oil pan, be sure liquid gasket diameter is 4.0 to 5.0 mm

(0.157 to 0.197 in). I For areas except oil pan, be sure liquid gasket diameter is

2.0 to 3.0 mm (0.079 to 0.118 in).

3. Apply liquid gasket around the inner side of bolt holes

(unless otherwise specified).

4. Assembly should be done within 5 minutes after coating.

5. Wait at least 30 minutes before refilling engine oil and

engine coolant.

NCEM0001

NCEM0002

AEM080

IDX

EM-3

Special Service Tools

PREPARATION

EXIT

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

KV10106500 (—) Engine stand shaft

KV10115300 (—) Engine sub-attachment

Description

Disassembling and assembling

NT042

NT028

NCEM0003

ST10120000 (J24239-01) Cylinder head bolt wrench

KV10116200 (J26336-B) Valve spring compressor 1 KV10115900 (J26336-20) Attachment

KV10115600 (J38958) Valve oil seal drift

KV10107902 (J38959) Valve oil seal puller

NT008

Loosening and tightening cylinder head bolt

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

Unit: mm (in)

NT583

Disassembling valve mechanism

NT022

Installing valve oil seal

NT024

Displacement valve lip seal

NT011

EM-4

Tool number (Kent-Moore No.) Tool name

Description

PREPARATION

Special Service Tools (Cont’d)

EXIT

KV10115700 (J38957) Dial gauge stand

(J38957-N) Valve shim gauge plate kit 1— (J35772) Plastic case 2— (J38957-8) Dial indicator 3— (J38957-2) Collar 4— (J38957-1) Plate 5— (—) Hex bolts

EM03470000 (J8037) Piston ring compressor

NT012

AEM274

Adjusting shims

Measuring valve shims

Installing piston assembly into cylinder bore

KV10107400 (J26365-12, J26365)

Piston pin press stand 1 KV10107310 (—) Center shaft 2 ST13040020 (—) Stand 3 ST13040030 (—) Spring 4 KV10107320 (—) Cap 5 ST13040050 (—) Drift

KV10111100 (J37228) Seal cutter

NT044

NT013

NT046

Disassembling and assembling piston pin

Removing oil pan

IDX

EM-5

Special Service Tools (Cont’d)

Tool number (Kent-Moore No.) Tool name

Description

PREPARATION

EXIT

WS39930000 (—) Tube presser

KV10112100 (BT-8653-A) Angle wrench

ST16610001 (J23907) Pilot bushing puller

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

Pressing the tube of liquid gasket

NT052

Tightening bolts for bearing cap, cylinder head, etc.

NT014

Removing pilot bushing

NT045

Loosening or tightening front (heated) oxygen sensor

Tool number (Kent-Moore No.) Tool name

(J-43897–18) (J-43897–12) Oxygen sensor thread cleaner

Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907)

NT379

Description

AEM488

Commercial Service Tools

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

a: J-43897-18 [18 mm (0.71 in) dia.] for zirconia oxygen sensor b: J-43897-12 [12 mm (0.47 in) dia.] for titania oxygen sensor

Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads

NCEM0004

AEM489

EM-6

Tool number (Kent-Moore No.) Tool name

Description

PREPARATION

Commercial Service Tools (Cont’d)

EXIT

Spark plug wrench

Valve seat cutter set

Piston ring expander

Valve guide drift

Valve guide reamer

Front oil seal drift

NT047

NT048

NT030

NT015

NT016

Removing and installing spark plug

Finishing valve seat dimensions

Removing and installing piston ring

Removing and installing valve guide

Intake & Exhaust: a: 9.5 mm (0.374 in) dia. b: 5.0 mm (0.197 in) dia.

Reaming valve guide 1 or hole for oversize valve guide 2

Intake & Exhaust: d

: 6.0 mm (0.236 in) dia.

: 10.175 mm (0.4006 in) dia.

Installing front oil seal

a: 75 mm (2.95 in) dia. b: 45 mm (1.77 in) dia.

Rear oil seal drift

NT049

EM-7

Installing rear oil seal

a: 110 mm (4.33 in) dia. b: 80 mm (3.15 in) dia.

IDX

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NCEM0005

EXIT

AEM400

EM-8

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

Use the table below to help you find the cause of the symptom.

1. Locate the area where noise occurs.

2. Confirm the type of noise.

3. Specify the operating condition of the engine.

4. Check the specified noise source. If necessary, repair or replace these parts.

EXIT

Location of

noise

Top of engine Rocker cover Cylinder head

Crankshaft pulley Cylinder block (Side of engine) Oil pan

Type of

noise

Ticking or clicking

Rattle C A — A B C

Slap or knock

Slap or rap A — — B B A

Knock A B C B B B

Knock A B — A B C

Front of engine Timing chain cover

Front of engine

Tapping or ticking

Squeaking or fizzing

Creaking A B A B A B

NVH Troubleshooting — Engine Noise

Operating condition of engine

Before

warm-

CA—AB—

—A—BB—

A A — BBB

AB—B—C

After

warm-

When

starting

When

idling

When racing

While

driv-

ing

Source of

noise

Tappet noise

Camshaft bearing noise

Piston pin noise

Piston slap noise

Connecting rod bearing noise

Main bearing noise

Timing chain and chain tensioner noise

Other drive belts (Sticking or slipping)

Other drive belts (Slipping)

NCEM0005S01

Check item

Hydraulic lash adjuster EM-41

Camshaft journal clearance Camshaft runout

Piston 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

Connecting rod bushing clearance (Small end) Connecting rod bearing clearance (Big end)

Main bearing oil clearance Crankshaft runout

Timing chain cracks and wear

Drive belt deflection

Idler pulley bearing operation

Reference

page

EM-36, 37

EM-59, 66

EM-62, 60

EM-65, 66

EM-63, 63

EM-23

MA-13, “Checking Drive Belts”

Squall Creak

A: Closely related B: Related C: Sometimes related —: Not related

A B — BAB

EM-9

Water pump noise

Water pump operation

LC-11, “Water Pump Inspection”

IDX

Removal and Installation

OUTER COMPONENT PARTS

EXIT

Removal and Installation

NCEM0006

1. Oil filler cap

2. Rocker cover

3. PCV valve

4. Distributor

5. Intake manifold supports

6. Knock sensor

7. Oil filter

8. Oil filter bracket

9. Water inlet

10. Thermostat housing

SEM017GA

11. Water pipe assembly

12. Thermostat

13. Starter motor

14. Power steering oil pump adjusting bar

15. Power steering oil pump bracket

EM-10

OUTER COMPONENT PARTS

Removal and Installation (Cont’d)

EXIT

EM-11

IDX

SEM018G

Removal and Installation (Cont’d)

OUTER COMPONENT PARTS

EXIT

1. Oil level gauge

2. Generator adjusting bar

3. A/C compressor bracket

4. Generator bracket

5. Water outlet

6. Cylinder block drain plug

SEM019GA

7. Exhaust manifold (With three way catalyst)

8. Exhaust manifold cover

9. Heated oxygen sensor

EM-12

MEASUREMENT OF COMPRESSION PRESSURE

SEM973E

SEM387C

NCEM0007

1. Warm up engine.

2. Turn ignition switch OFF.

3. Release fuel pressure. Refer to EC-50, “Fuel Pressure Release”.

4. Remove all spark plugs.

5. Disconnect distributor coil connector.

6. Attach a compression tester to No. 1 cylinder.

7. Depress accelerator pedal fully to keep throttle valve wide open.

8. Crank engine and record highest gauge indication.

9. Repeat the measurement on each cylinder.

I Always use a fully-charged battery to obtain specified

engine speed.

Compression pressure: kPa (kg/cm

Standard

1,275 (13.0, 185)/300

Minimum

1,079 (11.0, 156)/300

Difference limit between cylinders

98 (1.0, 14)/300

10. 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.

I If adding oil helps compression, piston rings may be worn

or damaged. If so, replace piston rings after checking piston.

I If pressure stays low, a valve may be sticking or seating

improperly. Inspect and repair valve and valve seat. Refer to SDS, EM-75. If valve or valve seat is damaged excessively, replace them.

I 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.

, psi)/rpm

EXIT

EM-13

IDX

Components

OIL PAN

EXIT

Components

NCEM0008

Removal

1. Remove engine side cover.

2. Drain engine oil.

3. Remove steel oil pan bolts in numerical order.

SEM020G

NCEM0009

SEM021G

EM-14

OIL PAN

Removal (Cont’d)

4. Remove steel oil pan.

a. Insert Tool between aluminum oil pan and steel oil pan.

I Be careful not to damage aluminum mating surface. I Do not insert screwdriver, or oil pan flange will be dam-

aged.

b. Slide Tool by tapping on the side of the Tool with a hammer. c. Remove steel oil pan.

EXIT

SEM365E

SEM045D

AEM234

5. Remove front exhaust tube. Refer to FE-8, “EXHAUST SYSTEM”.

6. Set a suitable transmission jack under transaxle and lift engine with engine slinger.

7. Remove center member.

8. Remove A/T control cable. (A/T only)

9. Remove A/C compressor gussets.

10. Remove rear cover plate.

SEM043D

SEM022G

11. Remove aluminum oil pan bolts in numerical order.

EM-15

IDX

Removal (Cont’d)

SEM506F

OIL PAN

12. Remove baffle plate.

13. Remove two engine-to-transaxle bolts and install one of them into open bolt hole as shown. Tighten installed bolt to separate aluminum oil pan from cylinder block.

14. Remove aluminum oil pan.

EXIT

SEM023G

SEM024G

SEM050D

15. Remove the engine-to-transaxle bolts previously installed in aluminum oil pan.

Installation

NCEM0010

1. Install aluminum oil pan.

a. Use a scraper to remove old liquid gasket from mating sur-

faces.

I Also remove old liquid gasket from mating surfaces of

cylinder block and front cover.

b. Apply a continuous bead of liquid gasket to mating surface of

aluminum oil pan.

I Use Genuine RTV silicone sealant part No. 999MP-A7007

or equivalent.

I Apply to groove on mating surface. I Allow 7 mm (0.28 in) clearance around bolt holes.

SEM357E

EM-16

OIL PAN

Installation (Cont’d)

I For areas marked with “★”, apply liquid gasket around the

outer side of the bolt hole as shown.

I Be sure liquid gasket diameter is 4.0 to 5.0 mm (0.157 to

0.197 in).

I Attaching should be done within 5 minutes after coating.

EXIT

BEM008

SEM025G

SEM224D

c. Tighten nuts and bolts in numerical order.

Bolts1-16:

: 16 - 19 N·m (1.6 - 1.9 kg-m, 12 - 14 ft-lb)

Bolts 17, 18:

: 6.4 - 7.5 N·m (0.65 - 0.76 kg-m, 56.4 - 66.0 in-lb)

2. Install the two engine-to-transaxle bolts. Fortighteningtorque,refertoMT-12orAT-280,“REMOVALAND INSTALLATION”.

3. Install rear cover plate.

4. Install A/C compressor gussets.

5. Install A/T control cable. (A/T only)

6. Install center member.

7. Install front exhaust tube.

8. Install baffle plate.

AEM235

SEM026G

9. Install steel oil pan.

a. Use a scraper to remove old liquid gasket from mating surface

of steel oil pan.

I Also remove old liquid gasket from mating surface of alu-

minum oil pan.

EM-17

IDX

Installation (Cont’d)

SEM015E

OIL PAN

b. Apply a continuous bead of liquid gasket to mating surface of

steel oil pan.

I Use Genuine RTV silicone sealant part No. 999MP-A7007

or equivalent.

I Apply to groove on mating surface. I Allow 7 mm (0.28 in) clearance around bolt hole.

I Be sure liquid gasket diameter is 4.0 to 5.0 mm (0.157 to

0.197 in).

I Attaching should be done within 5 minutes after coating.

EXIT

SEM027G

c. Tighten bolts in numerical order as shown.

I Wait at least 30 minutes before refilling engine oil.

SEM028G

EM-18

TIMING CHAIN

Components

EXIT

Components

CAUTION:

I After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike

piston heads.

I When installing rocker arms, camshafts, chain tensioner, oil seals, or other sliding parts, lubricate

contacting surfaces with new engine oil.

I Apply new engine oil to bolt threads and seat surfaces when installing, camshaft sprockets,

crankshaft pulley, and camshaft brackets.

NCEM0011

1. Cylinder block

2. RH camshaft sprocket

3. Chain tensioner

4. Chain guide

5. Front cover

6. Crankshaft pulley

7. Oil pump drive spacer

8. Crankshaft sprocket

EM-19

9. Chain guide

10. Timing chain

11. LH camshaft sprocket

SEM081GA

IDX

Removal

TIMING CHAIN

EXIT

SEM029G

Removal

1. Remove engine under cover.

2. Remove front RH wheel and engine side cover.

3. Remove drive belts and water pump pulley.

4. Disconnect the following parts:

I Vacuum hoses I Wires I Harness I Connectors

5. Remove rocker cover bolts in numerical order.

6. Remove rocker cover.

7. Remove cylinder head outside bolts.

NCEM0012

SEM287G

8. Set No. 1 piston at TDC of its compression stroke.

SEM983C

I Rotate crankshaft until mating mark on camshaft sprocket

is set at position indicated in figure.

SEM031G

EM-20

TIMING CHAIN

Removal (Cont’d)

9. Remove oil pans. Refer to EM-14.

10. Remove oil strainer.

11. Temporarily install center member to support engine.

EXIT

SEM038G

SEM980C

SEM039G

12. Remove crankshaft pulley.

13. Remove generator.

14. Remove A/C compressor and position it to the side.

15. Remove A/C bracket.

16. Remove generator bracket.

17. Set a suitable transmission jack under main bearing beam.

18. Remove RH engine mounting.

SEM040G

IDX

EM-21

Removal (Cont’d)

SEM041G

TIMING CHAIN

19. Remove RH engine mounting bracket.

20. Remove oil pump drive spacer.

CAUTION:

Be careful not to damage oil pump drive spacer and front oil seal.

21. Remove front cover.

CAUTION:

I Be careful not to rear or damage the cylinder gasket. I Inspect for oil leakage at front oil seal. Replace seal if oil

leak is present.

EXIT

SEM721E

22. Remove chain tensioner.

SEM032G

23. Remove timing chain guides.

SEM982CA

24. Remove camshaft sprockets.

I For retiming in cylinder head removal, apply paint mark to

timing chain matched with mating marks of camshaft sprockets.

25. Remove timing chain and crankshaft sprocket.

SEM034G

EM-22

TIMING CHAIN

Inspection

EXIT

SEM984C

SEM470E

Inspection

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

Installation

1. Install crankshaft sprocket on crankshaft.

I Make sure that mating marks on crankshaft sprocket face

front of engine.

2. Position crankshaft so that No. 1 piston is set at TDC and key way is at 12 o’clock. Fit timing chain on crankshaft sprocket, aligning the mating marks.

NCEM0013

NCEM0014

SEM985C

SEM500E

I Mating mark color on timing chain.

1: Yellow 2, 3: Blue

3. Install timing chain and timing chain guides.

SEM982CA

IDX

EM-23

Installation (Cont’d)

SEM048G

TIMING CHAIN

4. Install camshaft sprockets and timing chain on them.

Line up mating marks on timing chain with mating marks on camshaft sprockets.

I Lock camshafts as shown in figure and tighten to specified

torque.

: 137 - 157 N·m (14.0 - 16.0 kg-m, 101 - 116 ft-lb)

Apply new engine oil to threads and seating surfaces of camshaft sprocket bolts before installing them.

EXIT

SEM049G

5. Install chain tensioner.

Make sure the camshaft sprockets are tightened completely. Press cam stopper down and “press-in” sleeve until hook can be engaged on pin. When tensioner is bolted in position the hook will release automatically. Make sure arrow “A” points toward engine front.

SEM990C

SEM991C

6. Use a scraper to remove old liquid gasket from mating surface of front cover.

I Also remove old liquid gasket from mating surface of cyl-

inder block.

SLC491A

EM-24

TIMING CHAIN

Installation (Cont’d)

7. Apply a continuous bead of liquid gasket to front cover. Also apply liquid gasket to matching surface to cylinder head gasket.

I Use Genuine RTV silicone sealant part No. 999MP-A7007

or equivalent. Be sure to install new front oil seal in the right direction. Refer to “OIL SEAL”, EM-28.

EXIT

BEM010

SEM721E

SEM042G

8. Install oil pump drive spacer.

9. Install front cover.

I Wipe off excessive liquid gasket.

10. Install cylinder head outside bolts.

SEM287G

SEM040G

11. Install RH engine mounting and bracket.

12. Install generator bracket and generator.

13. Install A/C compressor bracket and compressor.

EM-25

IDX

Installation (Cont’d)

SEM073D

TIMING CHAIN

14. Install crankshaft pulley.

15. Set No. 1 piston at TDC of its compression stroke.

16. Install oil strainer.

17. Install oil pans. Refer to EM-16.

EXIT

SEM038G

18. Remove old liquid gasket from mating surfaces of rocker cover and cylinder head.

19. Apply a continuous bead of liquid gasket to rocker cover gasket and cylinder head as shown in the illustrations.

I Use Genuine RTV silicone sealant Part No. 999MP-A7007

or equivalent.

BEM006

SEM051G

20. Install rocker cover and oil separator.

I Be sure to install washers between bolts and rocker cover. I Tightening procedure

STEP 1: Tighten bolts1-10-11-13-8inthat order. STEP 2: Tighten bolts1-13inthat order.

:8-10N·m(0.8 - 1.0 kg-m, 69 - 87 in-lb)

21. Install the following parts:

I Spark plugs and leads I Water pump pulley and drive belts.

SEM052G

EM-26

TIMING CHAIN

Installation (Cont’d)

For adjusting drive belt deflection, refer to MA-13, “Checking Drive Belts”.

I Front RH wheel I Engine under cover

22. Connect the following:

I Vacuum hoses I Wire harnesses and connectors

EXIT

EM-27

IDX

Replacement

OIL SEAL

EXIT

SEM077D

SEM053G

Replacement

VALVE OIL SEAL

NCEM0015

NCEM0015S01

1. Remove accelerator wire.

2. Remove rocker cover.

3. Remove camshafts and sprockets. Refer to EM-20.

4. Remove spark plugs.

5. Install air hose adapter into spark plug hole and apply air pressure to hold valves in place. Apply a pressure of 490 kPa (5 kg/cm

, 71 psi).

6. Remove rocker arm, rocker arm guide and shim.

7. Remove valve spring with Tool.Temporarily install camshaft as shown.

Piston concerned should be set at TDC to prevent valve from falling.

8. Remove valve oil seal with a suitable tool.

SEM054G

SEM055G

SEM997C

9. Apply new engine oil to new valve oil seal and install it with Tool.

FRONT OIL SEAL

NCEM0015S02

1. Remove the following parts:

I Engine under cover I Front RH wheel and engine side cover I Drive belts I Crankshaft pulley

2. Remove front oil seal.

Be careful not to scratch front cover.

EM-28

OIL SEAL

Replacement (Cont’d)

3. Apply new engine oil to new oil seal and install it using a suitable tool.

I Install new oil seal in the direction shown.

EXIT

SEM715A

SEM998C

SEM999C

REAR OIL SEAL

1. Remove transaxle. (Refer to MT or AT section.)

2. Remove flywheel or drive plate.

3. Remove rear oil seal.

I Be careful not to scratch rear oil seal retainer.

4. Apply new engine oil to new oil seal and install it using a suitable tool.

I Install new oil seal in the direction shown.

NCEM0015S03

SEM715A

SEM001D

IDX

EM-29

Components

CYLINDER HEAD

EXIT

Components

NCEM0016

1. Oil filler cap

2. Rocker cover

3. Rocker arm guide

4. Rocker arm

5. Shim

6. Hydraulic lash adjuster

7. Chain tensioner

8. Camshaft sprocket

9. Camshaft

10. Camshaft bracket

11. Water outlet

12. Cylinder head

13. Valve

SEM056GA

14. Valve spring seat

15. Valve spring

16. Valve spring retainer

17. Valve collet

18. Spark plug

19. Cylinder head bolt

EM-30

CYLINDER HEAD

Removal

EXIT

Removal

1. Release fuel pressure. Refer to “Releasing Fuel Pressure” in EC-50.

2. Remove engine under covers.

3. Remove front RH wheel and engine side cover.

4. Drain coolant by removing cylinder block drain plug and lower radiator hose.

5. Remove radiator.

6. Remove air duct to intake manifold.

7. Remove drive belts and water pump pulley.

8. Remove alternator and power steering oil pump.

9. Remove vacuum hoses, fuel hoses, wires, and harness connectors.

10. Remove all spark plugs.

11. Remove rocker cover, loosen bolts in numerical order.

12. Remove front exhaust tube. Refer to FE-8 (“Exhaust System”).

13. Remove the lower intake manifold supports.

NCEM0017

SEM773E

SEM580D

14. Remove oil filter bracket and power steering oil pump bracket.

15. Set No. 1 piston at TDC on the compression stroke by rotating crankshaft.

SEM983C

IDX

EM-31

Removal (Cont’d)

SEM695DA

CYLINDER HEAD

I Rotate crankshaft until mating mark on camshaft sprocket

is set at position indicated in figure at left.

I Apply paint to timing chain and camshaft sprockets for

alignment during installation.

16. Remove chain tensioner.

EXIT

SEM603D

17. Remove distributor.

Do not turn rotor with distributor removed.

SEM594G

18. Remove timing chain guide.

SEM071D

19. Remove camshaft sprockets.

SEM583D

EM-32

CYLINDER HEAD

20. Remove camshafts and camshaft brackets.

Removal (Cont’d)

EXIT

SEM590G

SEM354D

MEC756B

21. Remove starter motor.

22. Remove the following water hoses:

I Water hose to water pump. I Water hoses for heater.

23. Remove knock sensor harness connector.

24. Remove cylinder head outside bolts.

SEM977C

SEM978C

25. Remove cylinder head bolts.

I Bolts should be loosened in two or three steps.

26. Remove cylinder head completely with intake and exhaust manifolds.

EM-33

IDX

Disassembly

CYLINDER HEAD

EXIT

AEM116

Disassembly

NCEM0018

CAUTION:

I When installing rocker arms, camshaft and oil seal, lubri-

cate contacting surfaces with new engine oil.

I When tightening cylinder head bolts, camshaft sprocket

bolts and camshaft bracket bolts, lubricate bolt threads and seat surfaces with new engine oil.

I If a hydraulic lash adjuster is kept on its side, there is a

risk of air entering it. When hydraulic lash adjusters are removed, stand them straight up or soak them in new engine oil.

I Do not disassemble hydraulic lash adjusters. I Attach tags to lash adjusters so as not to mix them up.

1. Remove rocker arms, shims, rocker arm guides and hydraulic lash adjusters from cylinder head.

CAUTION:

Keep parts in order so they can be installed in their original positions during assembly.

SEM057G

2. Remove exhaust manifold cover.

3. Remove EGR tube.

SEM058G

4. Remove exhaust manifold as shown.

SEM059G

EM-34

CYLINDER HEAD

Disassembly (Cont’d)

5. Remove EGR volume control valve assembly.

EXIT

SEM060G

SEM082D

SEM061G

6. Remove water outlet.

7. Remove intake manifold with intake manifold collector as shown.

8. Remove valve components with Tool. Install camshaft temporarily.

SEM053G

SEM054G

9. Remove valve oil seal with a suitable tool.

EM-35

IDX

Inspection

CYLINDER HEAD

EXIT

SEM925C

Inspection

CYLINDER HEAD DISTORTION

NCEM0019

NCEM0019S01

I Clean mating surface of cylinder head. I Use a reliable straightedge and feeler gauge to check the flat-

ness of cylinder head mating surface.

I 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 it.

Resurfacing limit: The limit for cylinder head resurfacing is determined by the amount of 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:

136.9 - 137.1 mm (5.390 - 5.398 in)

CAMSHAFT VISUAL CHECK

NCEM0019S02

Check camshaft for scratches, seizure and wear.

SEM926C

SEM549A

CAMSHAFT RUNOUT

1. Measure camshaft runout at the center journal.

Runout (Total indicator reading):

Standard

Less than 0.02 mm (0.0008 in)

Limit

0.1 mm (0.004 in)

2. If it exceeds the limit, replace camshaft.

CAMSHAFT CAM HEIGHT

1. Measure camshaft cam height.

Standard cam height:

Intake

37.550 - 37.740 mm (1.4783 - 1.4858 in)

Exhaust

37.920 - 38.110 mm (1.4929 - 1.5004 in)

Cam height wear limit:

Intake & Exhaust

0.2 mm (0.008 in)

2. If wear is beyond the limit, replace camshaft.

NCEM0019S03

NCEM0019S04

EM-36

CYLINDER HEAD

Inspection (Cont’d)

EXIT

SEM927C

SEM012A

CAMSHAFT JOURNAL CLEARANCE

1. Install camshaft bracket and tighten bolts. Refer to EM-23.

2. Measure inner diameter of camshaft bearing.

Standard inner diameter:

28.000 - 28.021 mm (1.1024 - 1.1032 in)

3. Measure outer diameter of camshaft journal.

Standard outer diameter:

27.935 - 27.955 mm (1.0998 - 1.1006 in)

27.950 - 27.970 mm (1.1004 - 1.1012 in) for engine serial number after SR20-266590

4. Calculate camshaft journal clearance.

Camshaft journal clearance = standard inner diameter

− standard outer diameter: Standard

0.045 - 0.090 mm (0.0018 - 0.0035 in)

0.030 - 0.071 mm (0.0012 - 0.0028 in) for engine serial number after SR20-266590

Limit

0.15 mm (0.0059 in)

5. If clearance exceeds the limit, replace camshaft and remeasure camshaft journal clearance.

I If clearance still exceeds the limit after replacing camshaft,

replace cylinder head.

NCEM0019S05

SEM062G

CAMSHAFT END PLAY

1. Install camshaft in cylinder head. Refer to EM-23.

2. Measure camshaft end play.

Camshaft end play:

Standard

0.055 - 0.139 mm (0.0022 - 0.0055 in)

Limit

0.20 mm (0.0079 in)

3. If end play exceeds the limit, replace camshaft and remeasure camshaft end play.

I If end play still exceeds the limit after replacing camshaft,

replace cylinder head.

NCEM0019S06

IDX

EM-37

Inspection (Cont’d)

CYLINDER HEAD

EXIT

SEM929C

SEM003D

SEM938C

CAMSHAFT SPROCKET RUNOUT

NCEM0019S07

1. Install sprocket on camshaft.

2. Measure camshaft sprocket runout.

Runout (Total indicator reading):

Limit 0.25 mm (0.0098 in)

3. If it exceeds the limit, replace camshaft sprocket.

VALVE GUIDE CLEARANCE

NCEM0019S08

1. Measure valve deflection as shown in illustration. (Valve and valve guide mostly wear in this direction.)

Valve deflection limit (Dial gauge reading):

Intake & Exhaust

0.2 mm (0.008 in)

2. If it exceeds the limit, check valve to valve guide clearance.

a. Measure valve stem diameter and valve guide inner diameter. b. Calculate valve to valve guide clearance.

Valve to valve guide clearance = valve guide inner diameter − valve stem diameter:

Standard

Intake 0.020 - 0.053 mm (0.0008 - 0.0021 in) Exhaust 0.040 - 0.073 mm (0.0016 - 0.0029 in)

Limit

Intake 0.08 mm (0.0031 in) Exhaust 0.1 mm (0.004 in)

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

valve guide.

SEM008A

VALVE GUIDE REPLACEMENT

NCEM0019S09

1. To remove valve guide, heat cylinder head to 110 to 130°C (230 to 266°F).

EM-38

CYLINDER HEAD

Inspection (Cont’d)

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

EXIT

SEM931C

SEM932C

SEM083D

3. Ream cylinder head valve guide hole.

Valve guide hole diameter (for service parts):

Intake & Exhaust

10.175 - 10.196 mm (0.4006 - 0.4014 in)

4. Heat cylinder head to 110 to 130°C (230 to 266°F) and press service valve guide into cylinder head.

Projection “L”:

14.0 - 14.2 mm (0.551 - 0.559 in)

5. Ream valve guide.

Finished size:

Intake & Exhaust

6.000 - 6.018 mm (0.2362 - 0.2369 in)

SEM932C

SEM934C

VALVE SEATS

Check valve seats for pitting at contact surface. Resurface or replace if excessively worn.

I Before repairing valve seats, check valve and valve guide

for wear. If they are worn, replace them. Then correct valve seat.

I Use both hands to cut uniformly.

NCEM0019S10

EM-39

IDX

Inspection (Cont’d)

CYLINDER HEAD

EXIT

SEM795A

REPLACING VALVE SEAT FOR SERVICE PARTS

NCEM0019S11

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 35.500 - 35.516 mm (1.3976 - 1.3983 in) Exhaust 31.500 - 31.516 mm (1.2402 - 1.2408 in)

Use the valve guide center for reaming to ensure valve seat will have the correct fit.

3. Heat cylinder head to 110 to 130°C (230 to 266°F).

4. Press fit valve seat until it seats on the bottom.

SEM008A

SEM892B

5. Cut or grind valve seat to the specified dimensions using a suitable tool. Refer to SDS, EM-75.

6. After cutting, lap valve seat with abrasive compound.

7. Check valve seating condition.

Seat face angle “α”:

44°53′ - 45°07′

Contacting width “W”:

Intake

1.05 - 1.35 mm (0.0413 - 0.0531 in)

Exhaust

1.25 - 1.55 mm (0.0492 - 0.0610 in)

EM-40

CYLINDER HEAD

Inspection (Cont’d)

Use a depth gauge to measure the distance between the mounting surface ofthe cylinder headspring seat andthe valve stemend. If the distance is shorter than the specified valve, repeat step 5 above to adjust it. If it is longer, replace the valve seat with a new one.

Valve seat resurface limit:

42.74 - 43.26 mm (1.6827 - 1.7031 in)

EXIT

AEM343

SEM188A

SEM288A

EM113

VALVE DIMENSIONS

Check dimensions of each valve. Refer to SDS, EM-72. 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.

VALVE SPRING Squareness

1. Measure dimension “S”.

Out-of-square “S”:

Less than 2.1 mm (0.083 in)

2. If it exceeds the limit, replace spring.

Pressure

Check valve spring pressure at specified spring height.

Pressure:

Standard

519 - 571 N (52.9 - 58.2 kg, 116.7 - 128.4 lb) at 27.0 mm (1.063 in)

Limit

More than 491.8 N (50.16 kg, 110.56 lb) at 27.0 mm (1.063 in)

If it exceeds the limit, replace spring.

HYDRAULIC LASH ADJUSTER

1. Check contact and sliding surfaces for wear or score.

NCEM0019S12

NCEM0019S13

NCEM0019S1301

NCEM0019S1302

NCEM0019S14

SEM935C

IDX

EM-41

Inspection (Cont’d)

SEM936C

CYLINDER HEAD

2. Check diameter of lash adjuster.

Outer diameter:

16.980 - 16.993 mm (0.6685 - 0.6690 in)

3. Check lash adjuster guide hole diameter.

Inner diameter:

17.000 - 17.020 mm (0.6693 - 0.6701 in)

Standard clearance between lash adjuster and adjuster guide hole:

0.007 - 0.040 mm (0.0003 - 0.0016 in)

EXIT

SEM084D

SEM063G

ROCKER ARM, SHIM AND ROCKER ARM GUIDE

NCEM0019S15

Check contact and sliding surfaces of rocker arms, shims and rocker arm guides for wear or score.

Assembly

NCEM0020

CAUTION:

I When installing rocker arms, camshaft and oil seal, lubri-

cate contacting surfaces with new engine oil.

I When tightening cylinder head bolts, camshaft sprocket

bolts and camshaft bracket bolts, lubricate bolt threads and seat surfaces with new engine oil.

AEM116

I If a hydraulic lash adjuster is kept on its side, there is a

risk of air entering it. When hydraulic lash adjusters are removed, stand them straight up or soak them in new engine oil.

I Do not disassemble hydraulic lash adjusters. I Attach tags to lash adjusters so as not to mix them up.

EM-42

CYLINDER HEAD

Assembly (Cont’d)

1. Install valve component parts.

I Install valves, noting their identification marks as indi-

cated in the table below.

Identification mark Intake valve 2J3 Exhaust valve J21

EXIT

SEM595D

SEM085D

SEM093D

I Always use new valve oil seal.

Refer to EM-28.

I Before installing valve oil seal, install valve spring seat. I Install valve spring (uneven pitch type) with its narrow

pitched side (paint mark) toward cylinder head side.

I After installing valve components, use plastic hammer to

lightly tap valve stem tip to assure a proper fit.

2. Check hydraulic lash adjusters. a. Push on the rocker arm above the hydraulic lash adjuster. If it

moves 1 mm (0.04 in) or more, there is air in the high pressure chamber of hydraulic lash adjuster. Noise will be emitted from hydraulic lash adjuster if engine is started without bleeding air.

b. Remove hydraulic lash adjuster and dip in a container filled

with new engine oil. While pushing plunger as shown in figure, lightly push check ball using a thin rod. Air is completely bled when plunger no longer moves.

Air cannot be bled from this type of lash adjuster by running engine.

AEM117

SEM057G

3. Remove camshafts, rocker arms and shims. For future reference, identify each shim with the cylinder it was removed from. Since the shims are reusable, it may not be necessary to replace all of the existing shims.

EM-43

IDX

Assembly (Cont’d)

SEM364D

CYLINDER HEAD

4. Before attempting any measurement, make sure the valve, valve spring, collet, retainer and rocker arm guide are properly installed in the head.

I Always replace rocker arm guide with a new one.

CAUTION:

Install parts in their original positions.

5. Install the J38957-1 gauge plate into the tapped holes at the cam journals and secure it to the head using two of the hex bolts supplied with the kit. (The two remaining bolts are spares.)

EXIT

AEM201

AEM236

AEM202

6. Place the J38957-2 collar on the J38957-8 dial indicator. Make sure the dished side of the collar is facing “up” (toward the dial indicator). Secure the collar to the dial indicator by tightening the set screw in the collar.

7. Place the indicator and collar over #1 cylinder intake valve shim side. Slide the tip of the dial indicator through the access hole and place it on the end of the valve stem. While resting the dial indicator collar on the gauge plate, “zero” the dial indicator.

8. Move the dial indicator and collar to the adjacent hole in the gauge plate and place the tip of the indicator in the center of the rocker arm guide. Write down the dial indicator reading. This measured distance between the valve stem end and the contact surface of the rocker arm guide is the “T

9. Match the measured “T

” dimension (in inches) to the available

” dimension.

shim chart (in millimeters). Refer to SDS, EM-74. (The “T dimension is equivalent to the thickness and size designation of the valve shim.) Select the closest size shim to the measured “T

” dimension. For example, if the measured “T1”

dimension is 0.1152 in, use a 2.925 mm (0.1152 in) shim. Shims are available in 17 different thicknesses ranging from

2.800 mm (0.1102 in) to 3.200 mm (0.1260 in) and increase in increments of 0.025 mm (0.0010 in).

”

EM-44

CYLINDER HEAD

Assembly (Cont’d)

10. Repeat this procedure on the remaining cylinders.

11. Install intake manifold with intake manifold collector as shown.

EXIT

SEM064G

SEM059GA

SEM060G

12. Install exhaust manifold.

I Tighten exhaust manifold bolts in numerical order.

Exhaust manifold:

: 37.8 - 48.1 N·m (3.8 - 4.9 kg-m, 28 - 35 ft-lb)

13. Install EGR volume control valve assembly.

14. Install EGR tube.

15. Install exhaust manifold cover.

SEM058G

IDX

EM-45

Assembly (Cont’d)

BEM005

CYLINDER HEAD

16. Install water outlet.

a. Remove old liquid gasket from mating surface of water outlet.

I Also remove old liquid gasket from mating surface of cyl-

inder head.

b. Apply a continuous bead of liquid gasket to mating surface of

water outlet.

I Use Genuine RTV silicone sealant part No. 999MP-A7007

or equivalent.

EXIT

SEM470E

SEM985C

Installation

NCEM0041

1. Install crankshaft sprocket on crankshaft.

I Make sure that mating marks on crankshaft sprocket face

front of engine.

2. Position crankshaft so that No. 1 piston is set at TDC and key way is at 12 o’clock. Fit timing chain on crankshaft sprocket, aligning the mating marks.

I Mating mark color on timing chain.

1: Copper 2, 3: Silver

SEM500E

SEM982CA

3. Install timing chain and timing chain guides.

EM-46

CYLINDER HEAD

Installation (Cont’d)

4. Before installing front cover, remove all traces of liquid gasket from mating surface using a scraper.

I Also remove traces of liquid gasket from mating surface of

cylinder block.

EXIT

SLC491A

SLC492A

SEM721E

5. Apply a continuous bead of liquid gasket to mating surface of front cover.

I Use Genuine Liquid Gasket or equivalent. I Be sure to install new front oil seal in the right direction.

Refer to EM-28.

6. Install oil pump drive spacer and front cover.

I Wipe off excessive liquid gasket.

SEM351D

SEM591G

IDX

EM-47

Installation (Cont’d)

SEM597D

CYLINDER HEAD

7. Install front engine mounting.

8. Install crankshaft pulley.

9. Set No. 1 piston at TDC on its compression stroke.

EXIT

SEM073D

10. Install oil strainer.

11. Install oil pan. Refer to “Installation” in “OIL PAN” (EM-16).

SEM592G

12. Before installing cylinder head gasket, apply a continuous bead of liquid gasket to mating surface of cylinder block.

SEM353D

EM-48

SEM020D

CYLINDER HEAD

Installation (Cont’d)

13. Install cylinder head completely with intake and exhaust manifolds.

I Apply engine oil to threads and seating surfaces of cylin-

der head bolts before installing them.

I Be sure to install washers between bolts and cylinder

head.

CAUTION:

The cylinder head bolts can be reused providing dimension “A” is not exceeded.

Dimension “A”:

158.2 mm (6.228 in)

EXIT

SEM877A

SEM986C

SEM575EA

I Tightening procedure:

a) Tighten all bolts to 39.2 N·m (4.0 kg-m, 29 ft-lb). b) Tighten all bolts to 78.5 N·m (8.0 kg-m, 58 ft-lb). c) Loosen all bolts completely. d) Tighten all bolts to 39.2 N·m (4.0 kg-m, 29 ft-lb).

e) Method A:

Turn all bolts 90 to 95 degrees clockwise with Tool or suitable angle wrench. Method B: If angle wrench is not available, do the following. Mark the side of all bolts with paint marks facing the front of the engine. Then turn them 90 to 95 degrees clockwise.

f) Turn all bolts 90 to 95 degrees clockwise. g) Ensure that paint mark on each bolt faces the rear of the

engine. (Method B only) Do not turn any bolt 180 to 190 degrees clockwise all at

once.

SEM576EA

IDX

EM-49

Installation (Cont’d)

SEM074DB

CYLINDER HEAD

Tightening torque N·m (kg-m, ft-lb)

a 39.2 (4.0, 29) b 78.5 (8.0, 58) c 0 (0, 0) d 39.2 (4.0, 27) e 90 - 95 degrees (90 degree preferred)

f 90 - 95 degrees (90 degree preferred)

14. Install cylinder head outside bolts.

15. Install the following water hoses.

I Water hose for cylinder block. I Water hoses for heater.

EXIT

SEM977C

16. Install knock sensor harness connector.

MEC756B

17. Install starter motor.

SEM354D

18. Remove all traces of liquid gasket from mating surface of LH camshaft end bracket.

I Also remove traces of liquid gasket from mating surface of

cylinder head.

19. Apply liquid gasket to mating surface of LH camshaft end bracket as shown in illustration.

I Use Genuine Liquid Gasket or equivalent.

SEM075DA

EM-50

CYLINDER HEAD

Installation (Cont’d)

20. Install camshafts and camshaft brackets.

I Position camshaft. I Exhaust camshaft key at about 12 o’clock I Intake camshaft key at about 10 o’clock

Apply engine oil to bearings and cam surfaces of camshafts before installing them.

EXIT

SEM201DA

SEM098DA

SEM593G

SEM381F

I Position camshaft brackets as shown in illustration.

Apply engine oil to threads and seating surfaces of camshaft bracket bolts before installing them.

I Tightening procedure

STEP 1:

Intake camshaft

Tighten bolts9-10inthat order then tighten bolts 1-8innumerical order.

: 2 N·m (0.2 kg-m, 1.4 ft-lb)

Exhaust camshaft

Tighten bolts 11 - 12 in that order then tighten bolts1-10innumerical order.

: 2 N·m (0.2 kg-m, 1.4 ft-lb)

STEP 2:

Tighten bolts in the specified order.

: 6 N·m (0.6 kg-m, 4.3 ft-lb)

STEP 3:

Tighten bolts in the specified order.

Bolt type A B

: 10 - 12 N·m (1.0 - 1.2 kg-m, 7.2 - 8.7 ft-lb)

Bolt type C

: 18 - 25 N·m (1.8 - 2.6 kg-m, 13 - 19 ft-lb)

21. Install camshaft sprockets.

Line up mating marks on timing chain with mating marks on camshaft sprockets.

SEM696DA

IDX

EM-51

Installation (Cont’d)

SEM584D

CYLINDER HEAD

I Lock camshafts as shown in figure and tighten to specified

torque.

: 137 - 157 N·m (14.0 - 16.0 kg-m, 101 - 116 ft-lb)

Apply engine oil to threads and seating surfaces of camshaft sprocket bolts before installing them.

22. Install timing chain guide.

EXIT

SEM071D

23. Install distributor.

I Make sure that position of camshaft is as shown in figure.

SEM227D

I Make sure that No. 1 piston is set at TDC and that distribu-

tor is set at No. 1 cylinder spark position.

SEM594G

24. Install chain tensioner.

I Make sure the camshaft sprockets are tightened com-

pletely. Press cam stopper down and “press-in” sleeve until hook can be engaged on pin. When tensioner is bolted in position the hook will release automatically.

SEM990C

EM-52

CYLINDER HEAD

Installation (Cont’d)

I Make sure arrow “A” points toward engine front.

EXIT

SEM991C

SEM580D

SEM366D

25. Install oil filter bracket (SR20DE engine only) and power steering oil pump bracket.

26. Install intake manifold supports.

27. Remove all old liquid gasket from mating surfaces of rocker cover and cylinder head.

28. Apply a continuous bead of liquid gasket to mating surfaces of rocker cover gasket and cylinder head.

I Use Genuine Liquid Gasket or equivalent.

SEM595G

SEM596G

29. Install rocker cover.

1) Tighten bolts1-10-11-13-8inthat order to 8 to 10 N·m

(0.8 to 1.0 kg-m, 69 to 89 in-lb).

2) Tighten bolts 1 through 13 in numerical order to 8 to 10 N·m (0.8 to 1.0 kg-m, 70 to 89 in-lb).

30. Refit spark plugs and leads.

31. Install vacuum hoses, fuel hoses, wires, harness, connectors and so on.

32. Install power steering oil pump and alternator.

33. Install water pump pulley and drive belts.

34. Install intake manifold collector and brackets.

EM-53

IDX

Installation (Cont’d)

CYLINDER HEAD

35. Refit air duct to intake manifold.

36. Install radiator.

37. Refit hoses and refill with coolant. (Refer to MA-15.)

38. Install engine side cover and front RH wheel.

39. Install engine under covers.

EXIT

EM-54

ENGINE ASSEMBLY

Removal and Installation

EXIT

Removal and Installation

NCEM0022

1. Stopper

2. Bracket

3. Front insulator assembly

4. Center member

5. Pad

6. Right insulator assembly

7. Exhaust bracket

WARNING:

I Position vehicle on a flat and solid surface. I Place chocks at front and back of rear wheels. I Do not remove engine until exhaust system has com-

pletely cooled off, otherwise you may burn yourself and/or fire may break out in fuel line.

I Before disconnecting fuel hose, release pressure. Refer to

EC-50, “Fuel Pressure Release”.

I Before removing front axle from transaxle, place safety

stands under designated front supporting points. Refer to GI-47, “Garage Jack and Safety Stand”.

I Be sure to lift engine and transaxle in a safe manner. I For engines not equipped with engine slingers, attach

proper slingers and bolts described in PARTS CATALOG.

CAUTION:

I When lifting engine, be sure to clear surrounding parts.

Use special care near accelerator wire casing, brake lines and brake master cylinder.

8. Bracket

9. Rear insulator assembly

10. Left insulator assembly (A/T)

SEM518F

IDX

EM-55

Removal and Installation (Cont’d)

ENGINE ASSEMBLY

I In lifting the engine, always use engine slingers in a safe

manner.

I In removing drive shaft, be careful not to damage grease

seal of transaxle.

I Before separating engine and transaxle, remove the

crankshaft position sensor (OBD) from the assembly.

I Always be extra careful not to damage edge of crankshaft

position sensor (OBD) or ring gear teeth.

EXIT

SEM174D

REMOVAL

NCEM0022S01

1. Remove engine under covers and engine side cover.

2. Drain coolant from both cylinder block and radiator. Refer to MA-14, “Changing Engine Coolant”.

3. Drain engine oil.

4. Remove air cleaner assembly and duct.

5. Remove the battery and battery tray.

6. Disconnect the following:

I Vacuum hoses I Heater hoses I A/T cooler hoses I Power steering hoses I Fuel lines I Wires I Harnesses and connectors I Throttle cable I ASCD cable I A/T control cable

7. Remove the cooling fans, radiator and recovery tank.

8. Remove front LH and RH wheels and drive shafts. Refer to AX-10, “Drive Shaft”.

9. Remove front exhaust pipe.

10. Remove starter and intake manifold support.

11. Remove the drive belts.

12. Remove power steering oil pump and A/C compressor.

13. Set a suitable transmission jack under transaxle. Lift engine with engine slinger.

SEM092D

14. Remove center member.

15. Remove generator and adjusting bracket.

EM-56

ENGINE ASSEMBLY

Removal and Installation (Cont’d)

16. Remove engine mounting bolts from both sides, then slowly lower transmission jack.

EXIT

SEM040G

SEM195F

17. Remove engine with transaxle as shown.

INSTALLATION

1. Install in the reverse order of removal.

NCEM0022S02

EM-57

IDX

Components

CYLINDER BLOCK

EXIT

Components

NCEM0023

1. Rear oil seal retainer

2. Cylinder block

3. Water pump

4. Power steering oil pump adjusting bar

5. Front cover with oil pump

6. Oil strainer

7. Thrust bearing

8. Crankshaft

9. Connecting rod bushing

10. Piston rings

11. Piston

12. Piston pin

13. Connecting rod

14. Connecting rod bearing

15. Aluminum oil pan

16. Rear cover plate

17. Oil pan drain plug

18. Steel oil pan

SEM067GA

19. Baffle plate

20. Main bearing cap

21. Pilot converter

22. Drive plate

23. Reinforcement plate

24. Flywheel

25. Pilot bushing

26. Rear plate

27. Main bearing

EM-58

CYLINDER BLOCK

Removal and Installation

EXIT

SEM141F

SEM877B

Removal and Installation

CAUTION:

I When installing sliding parts (bearings, pistons, etc.),

lubricate contacting surfaces with new engine oil.

I Place removed parts such as bearings and bearing caps

in their proper order and direction.

I When installing connecting rod nuts and main bearing cap

bolts, apply new engine oil to threads and seating surfaces.

I Do not allow any magnetic materials to contact the ring

gear teeth of flywheel or drive plate.

Disassembly

PISTON AND CRANKSHAFT

1. Place engine on engine stand (ST0501S000).

2. Remove cylinder head and timing chain. Refer to EM-20.

3. Remove oil pan. Refer to EM-14.

4. Remove pistons with connecting rods.

I To disassemble piston and connecting rod, first remove snap

rings. Heat piston to 60 to 70°C (140 to 158°F) then use piston pin press to remove pin.

I When piston rings are not replaced, make sure that piston

rings are mounted in their original positions.

I When replacing piston rings, if there is no punchmark,

install with either side up.

5. Remove rear oil seal retainer.

6. Remove main bearing cap and crankshaft as shown.

I Bolts should be loosened in two or three steps.

NCEM0024

NCEM0025

NCEM0025S01

SEM068G

AEM023

Inspection

PISTON AND PISTON PIN CLEARANCE

1. Measure inner diameter of piston pin hole “dp”.

Standard diameter “dp”:

21.993 - 22.005 mm (0.8659 - 0.8663 in)

EM-59

NCEM0026

NCEM0026S01

IDX

Inspection (Cont’d)

AEM024

SEM024AA

CYLINDER BLOCK

2. Measure outer diameter of piston pin “Dp”.

Standard diameter “Dp”:

21.989 - 22.001 mm (0.8657 - 0.8622 in)

3. Calculate interference fit of piston pin to piston.

Dp − dp: 0.005 - 0.017 mm (0.0002 - 0.0007 in)

If it exceeds the above value, replace piston assembly with pin.

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:

Top and 2nd ring

0.1 mm (0.004 in)

If out of specification, replace piston ring. If clearance exceeds maximum limit with new ring, replace piston.

NCEM0026S02

EXIT

EM-60

CYLINDER BLOCK

Inspection (Cont’d)

EXIT

SEM822B

SEM038F

PISTON RING END GAP

End gap:

Top ring 0.20 - 0.39 mm (0.0079 - 0.0154 in) 2nd ring 0.35 - 0.59 mm (0.0138 - 0.0232 in) Oil ring 0.20 - 0.69 mm (0.0079 - 0.0272 in)

Max. limit of ring gap:

Top ring 0.53 mm (0.0209 in) 2nd ring 0.7 mm (0.028 in) Oil ring 0.95 mm (0.374 in)

If out of specification, replace piston ring. If gap exceeds maximum limit with a new ring, rebore cylinder and use oversized piston and piston rings. Refer to SDS, EM-78.

I When replacing the piston, check cylinder block surface for

scratches or seizure. If scratches or seizure are found, hone or replace the cylinder block.

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.

NCEM0026S03

NCEM0026S04

SEM003F

AEM156

CYLINDER BLOCK DISTORTION AND WEAR

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)

If out of specification, resurface it. The limit for cylinder block resurfacing is determined by the amount of 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:

211.25 - 211.35 mm (8.3169 - 8.3208 in)

If necessary, replace cylinder block.

NCEM0026S05

IDX

SEM008D

EM-61

Inspection (Cont’d)

CYLINDER BLOCK

EXIT

SEM363EA

SEM011D

SEM085G

PISTON-TO-BORE CLEARANCE

NCEM0026S06

1. Using a bore gauge, measure cylinder bore for wear, out-ofround and taper.

Standard inner diameter:

86.000 - 86.030 mm (3.3858 - 3.3870 in)

Wear limit:

0.20 mm (0.0079 in)

Out-of-round (X − Y) standard:

0.015 mm (0.0006 in)

Taper (A − B and A − C) standard:

0.010 mm (0.0004 in)

If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary.

2. Check for score and seizure. If seizure is found, hone it.

I If cylinder block and piston are replaced, match piston

grade with grade number on cylinder block upper surface.

3. Measure piston skirt diameter.

Piston diameter “A”: Refer to SDS, EM-78. Measuring point “a” (Distance from the top):

45.0 mm (1.772 in)

4. Check that piston-to-bore clearance is within specification.

Piston-to-bore clearance = bore measurement “C” − Piston diameter “A”:

0.010 - 0.030 mm (0.0004 - 0.0012 in)

5. Determine piston oversize according to amount of cylinder wear.

Oversize pistons are available for service. Refer to SDS, EM-78.

6. Cylinder bore size is determined by adding piston-to-bore clearance 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)

SEM069G

7. Install main bearing caps and tighten to the specified torque. This will prevent distortion of cylinder bores, otherwise cylinder bores may be distorted in final assembly.

8. Cut cylinder bores.

I When any cylinder needs boring, all other cylinders must

also be bored.

I 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.

EM-62

SEM316A

CYLINDER BLOCK

Inspection (Cont’d)

I Measurement should be done after cylinder bore cools

down.

CRANKSHAFT

1. Check crankshaft main and pin journals for score, wear or cracks.

2. With a micrometer, measure journals for taper and out-ofround.

Out-of-round (X − Y): Taper (A − B):

Main journal: Less than 0.005 mm (0.0002 in) Pin journal: Less than 0.003 mm (0.0001 in)

3. Measure crankshaft runout.

Runout (Total indicator reading):

Less than 0.05 mm (0.0020 in)

NCEM0026S07

EXIT

SEM434

SEM685D

BEARING CLEARANCE

I Use Method A or Method B. Method A is preferred because it

is more accurate.

Method A (Using bore gauge and micrometer)

Main bearing

1. Set main bearings in their proper positions on cylinder block and main bearing cap.

2. Install main bearing cap and main bearing beam to cylinder block.

Tighten all bolts in correct order in two or three stages. Refer to EM-68.

3. Measure inner diameter “A” of each main bearing.

NCEM0026S08

NCEM0026S0801

SEM070G

IDX

EM-63

Inspection (Cont’d)

AEM026

CYLINDER BLOCK

4. Measure outer diameter “Dm” of each crankshaft main journal.

5. Calculate main bearing clearance.

Main bearing clearance = A − Dm

Standard: 0.004 - 0.022 mm (0.0002 - 0.0009 in) Limit: 0.050 mm (0.0020 in)

If it exceeds the limit, replace bearing.

I If clearance cannot be adjusted within the standard of any

bearing, grind crankshaft main journal and use undersized bearing.

I When grinding crankshaft journal, confirm that “L” dimen-

sion in fillet roll is more than the specified limit.

“L”: 0.05 mm (0.0020 in)

I Refer to SDS, EM-80 for grinding crankshaft and available

service parts.

EXIT

SEM964

SEM313D

SEM013D

I 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.

b. Grade number of each crankshaft main journal is punched on

the respective crankshaft. These numbers are punched in either Arabic or Roman numerals.

c. Select main bearing with suitable thickness according to the

following table.

How to Select Main Bearings

NCEM0026S0803

(Identification mark and color)

Crankshaft main journal grade number

(A, Black)

Cylinder block main journal grade number 0123 0

(B, Brown)

(C, Green)

(D, Yellow)

SEM203D

(B, Brown)

(C, Green)

(D, Yellow)

(C, Green)

(D, Yellow)

(E, Blue)

(D, Yellow)

(E, Blue)

(F, Pink)

For example:

Cylinder block main journal grade number: 1

EM-64

(E, Blue)

(F, Pink)

(G, No color)

CYLINDER BLOCK

Inspection (Cont’d)

Crankshaft main journal grade number: 2 Main bearing grade number=1+2

= 3 (D, Yellow)

Connecting Rod Bearing (Big end)

1. Install connecting rod bearing to connecting rod and cap.

2. Install connecting rod cap to connecting rod.

Tighten bolts to the specified torque. Refer to EM-68.

3. Measure inner diameter “C” of each bearing.

NCEM0026S0802

EXIT

AEM027

AEM028

SEM013D

4. Measure outer diameter “Dp” of corresponding crankshaft pin journal.

5. Calculate connecting rod bearing clearance.

Connecting rod bearing clearance=C−Dp

Standard: 0.020 - 0.045 mm (0.0008 - 0.0018 in) Limit: 0.065 mm (0.0026 in)

If it exceeds the limit, replace bearing.

I If clearance cannot be adjusted within the standard of any

bearing, grind crankshaft journal and use undersized bearing. Refer to EM-63 for fillet roll remarks, grinding crankshaft and available service parts.

I If crankshaft is replaced with a new one, select connecting rod

bearing according to the following table.

Connecting rod bearing grade number:

These numbers are punched in either Arabic or Roman numerals.

Crank pin grade number Connecting rod bearing grade number

00 11 22

Identification color:

Grade 0; No color Grade 1; Black Grade 2; Brown

SEM204D

IDX

EM-65

Inspection (Cont’d)

CYLINDER BLOCK

Method B (Using Plastigage)

CAUTION:

I Do not turn crankshaft or connecting rod while Plastigage

is being inserted.

I If incorrect bearing clearance exists, use a thicker or

undersized main bearing to ensure specified clearance.

EM142

CONNECTING ROD BUSHING CLEARANCE (SMALL END)

1. Measure inner diameter “C” of bushing.

NCEM0026S09

EXIT

AEM029

AEM030

SEM062A

2. Measure outer diameter “Dp” of piston pin.

3. Calculate connecting rod bushing clearance.

Connecting rod bushing clearance=C−Dp

Standard:

0.005 - 0.017 mm (0.0002 - 0.0007 in)

Limit:

0.023 mm (0.0009 in)

If it exceeds the limit, replace connecting rod assembly or connecting rod bushing and/or piston set with pin.

REPLACEMENT OF CONNECTING ROD BUSHING (SMALL END)

1. Drive in small end bushing until it is flush with end surface of rod.

Be sure to align the oil holes.

2. Ream the bushing so that clearance with piston pin is within specification.

Clearance between connecting rod bushing and piston pin:

0.005 - 0.017 mm (0.0002 - 0.0007 in)

NCEM0026S10

REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T)

1. Remove pilot bushing or pilot converter using Tool or suitable tool.

NCEM0026S11

SEM916AA

EM-66

CYLINDER BLOCK

2. Install pilot bushing or pilot converter as shown.

Inspection (Cont’d)

EXIT

SEM163B

AEM100

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 0.20 mm (0.0079 in)

CAUTION:

I Be careful not to damage the ring gear teeth. I Check the drive plate for deformation or cracks. I Do not allow any magnetic materials to contact the ring

gear teeth.

I Do not resurface flywheel. Replace as necessary.

NCEM0026S12

SEM166B

SEM946C

Assembly

PISTON

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

2. Heat piston to 60 to 70°C (140 to 158°F) and assemble piston, piston pin, connecting rod and new snap ring.

I Align the direction of piston and connecting rod. I Numbers stamped on connecting rod and cap correspond

to each cylinder.

I After assembly, make sure connecting rod swings

smoothly.

NCEM0027

NCEM0027S01

EM-67

IDX

Assembly (Cont’d)

SEM601D

CYLINDER BLOCK

3. Set piston rings as shown.

CAUTION:

I When piston rings are not replaced, make sure that piston

rings are mounted in their original positions.

I Install new piston rings either side up if there is no punch

mark.

I Align piston rings so that end gaps are positioned as

shown.

EXIT

SEM160B

SEM685D

SEM069G

CRANKSHAFT

NCEM0027S02

1. Set main bearings in their proper positions on cylinder block and main bearing cap.

I Confirm that correct main bearings are selected by using

Method A or Method B. Refer to EM-63.

I Apply new engine oil to bearing surfaces.

2. Install crankshaft and main bearing caps, then tighten bolts to the specified torque.

I Prior to tightening bearing cap bolts, shift crankshaft back

and forth to properly seat the bearing cap.

I Apply new engine oil to threads and seating surfaces of

bearing cap bolts before installing them.

I Tightening procedure: a. Tighten all bolts to 7 to 12 N·m (0.7 to 1.3 kg-m, 61 to 112

ft-lb).

EM-68

SEM071G

CYLINDER BLOCK

Assembly (Cont’d)

b. Turn all bolts 70 to 80 degrees clockwise with Tool or

suitable angle wrench.

c. Loosen all bolts completely. d. Tighten all bolts to 33 to 38 N·m (3.3 to 3.9 kg-m, 24 to 28

ft-lb).

e. Turn all bolts 30 to 35 degrees clockwise with Tool or

suitable angle wrench.

I If an angle wrench is not available, mark all bearing cap

bolts on the side facing engine rear. Then, turn each bolt specified degrees clockwise. Confirm angle of degrees with a graduator, not by eye measurement.

I After securing bearing cap bolts, make sure crankshaft

turns smoothly by hand.

EXIT

SEM072G

SEM073G

SEM159B

3. Measure crankshaft end play.

Crankshaft end play:

Standard

0.10 - 0.26 mm (0.0039 - 0.0102 in)

Limit

0.30 mm (0.0118 in)

If beyond the limit, replace thrust bearing with new one.

4. Install connecting rod bearings in connecting rods and connecting rod caps.

I Confirm that correct bearings are used. Refer to EM-64. I Install bearings so that oil hole in connecting rod aligns

with oil hole of bearing.

I Apply new engine oil to bolt threads and bearing surfaces.

5. Install pistons with connecting rods.

a. Install them into corresponding cylinders with Tool.

I Make sure connecting rod does not scratch cylinder wall. I Make sure connecting rod bolts do scratch crankshaft pin

journals.

I Arrange so that front mark on piston head faces engine

front.

I Apply new engine oil to piston rings and sliding surface

of piston.

IDX

SEM554E

EM-69

Assembly (Cont’d)

SEM074G

CYLINDER BLOCK

b. Install connecting rod caps.

I Apply new engine oil to threads and seat surfaces.

Tighten connecting rod cap nuts using the following procedure:

a) Tighten nuts to 13.7 to 15.7 N·m (1.4 to 1.6 kg-m, 10 to 12

ft-lb).

b) Turn all nuts 60 to 65 degrees clockwise. If an angle

wrench is not available, tighten nuts to 38 to 44 N·m (3.9 to 4.5 kg-m, 28 to 33 ft-lb).

6. Measure connecting rod side clearance.

Connecting rod side clearance:

Standard

0.20 - 0.35 mm (0.0079 - 0.0138 in)

Limit

0.40 mm (0.0157 in)

If beyond the limit, replace connecting rod and/or crankshaft.

EXIT

SEM075G

7. Install rear oil seal retainer.

a. Before installing rear oil seal retainer, remove old liquid gasket

from mating surface.

I Also remove old liquid gasket from mating surface of cylinder

block.

SEM218D

b. Apply a continuous bead of liquid gasket to mating surface of

rear oil seal retainer.

I Use Genuine RTV silicone sealant part No. 999MP-A7007

or equivalent.

I Apply around inner side of bolt holes.

SEM219DA

EM-70

SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications

EXIT

General Specifications

Cylinder arrangement In-line 4 Displacement cm Bore and stroke mm (in) 86 x 86 (3.39 x 3.39) Valve arrangement DOHC Firing order 1-3-4-2

Number of piston rings

Number of main bearings 5 Compression ratio 9.5

Valve timing Unit: degree

(cu in) 1,998 (121.92)

Compression 2 Oil 1

NCEM0028

Compression pressure

EM120

abcdef

240° 232° 5° 47° 3° 57°

Compression Pressure

Unit: kPa (kg/cm2, psi)/300 rpm

Standard 1,275 (13, 185) Minimum 1,079 (11, 156) Differential limit between cylinders 98 (1.0, 14)

Cylinder Head

Standard Limit

Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)

Nominal cylinder head height “H” 136.9 - 137.1 (5.390 - 5.398)

NCEM0029

NCEM0030

Unit: mm (in)

SEM043F

Resurfacing limit 0.2 (0.008)*

*Total amount of cylinder head resurfacing plus cylinder block resurfacing

EM-71

IDX

Valve

SERVICE DATA AND SPECIFICATIONS (SDS)

EXIT

Valve

VALVE

Valve head diameter “D”

Valve length “L”

Valve stem diameter “d”

Valve seat angle “α”

Valve margin “T”

Valve margin “T” limit More than 0.5 (0.020) Valve stem end surface grinding limit Less than 0.2 (0.008)

Intake 34.0 - 34.3 (1.339 - 1.350) Exhaust 30.0 - 30.3 (1.181 - 1.193) Intake 97.04 - 97.16 (3.8205 - 3.8252) Exhaust 97.66 - 97.78 (3.8449 - 3.8496) Intake 5.965 - 5.980 (0.2348 - 0.2354) Exhaust 5.945 - 5.960 (0.2341 - 0.2346) Intake

45°15′ - 45°45′

Exhaust Intake 1.1 (0.043) Exhaust 1.3 (0.051)

NCEM0031

NCEM0031S01

Unit: mm (in)

SEM188A

VALVE SPRING

Free height mm (in) 47.53 (1.8713)

Pressure

Standard

N (kg, lb) at height mm (in)

Limit

Out-of-square mm (in) Less than 2.1 (0.083)

519 - 571 (53.0 - 58.2, 117 - 128)

at 27.0 (1.063)

491.8 (50.16, 110.6) at 27.0 (1.063)

HYDRAULIC LASH ADJUSTER (HLA)

HLA outer diameter 16.980 - 16.993 (0.6685 - 0.6690) HLA guide hole diameter 17.000 - 17.020 (0.6693 - 0.6701) Clearance between HLA and HLA guide hole 0.007 - 0.040 (0.0003 - 0.0016)

NCEM0031S02

NCEM0031S03

Unit: mm (in)

EM-72

SERVICE DATA AND SPECIFICATIONS (SDS)

Valve (Cont’d)

EXIT

VALVE GUIDE

Standard Service

Valve guide Outer diameter

Valve guide Inner diameter (Finished size)

Cylinder head valve guide hole diameter

Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)

Stem to guide clearance

Valve deflection limit 0.2 (0.008) Projection length “L” 14.0 - 14.2 (0.551 - 0.559)

Intake 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029) Exhaust 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029) Intake 6.000 - 6.018 (0.2362 - 0.2369) Exhaust 6.000 - 6.018 (0.2362 - 0.2369) Intake 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014) Exhaust 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014)

Standard Limit Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031) Exhaust 0.040 - 0.073 (0.0016 - 0.0029) 0.1 (0.004)

NCEM0031S04

Unit: mm (in)

SEM083D

VALVE SHIM CLEARANCE ADJUSTMENT

Valve shim clearance (cold) Intake & Exhaust

Shim thickness “T

” T1± 0.025 (0.001)

Less than 0.025 (0.001)

NCEM0031S06

Unit: mm (in)

SEM095D

IDX

EM-73

Valve (Cont’d)

SERVICE DATA AND SPECIFICATIONS (SDS)

EXIT

AVAILABLE SHIM

Thickness mm (in) Identification mark

2.800 (0.1102)

2.825 (0.1112)

2.850 (0.1122)

2.875 (0.1132)

2.900 (0.1142)

2.925 (0.1152)

2.950 (0.1161)

2.975 (0.1171)

3.000 (0.1181)

3.025 (0.1191)

3.050 (0.1201)

3.075 (0.1211)

3.100 (0.1220)

3.125 (0.1230)

3.150 (0.1240)

3.175 (0.1250)

3.200 (0.1260)

NCEM0031S07

AEM236

28 00

28 25

28 50

28 75

29 00

29 25

29 50

29 75

30 00

30 25

30 50

30 75

31 00

31 25

31 50

31 75

32 00

EM-74

SERVICE DATA AND SPECIFICATIONS (SDS)

Valve (Cont’d)

EXIT

VALVE SEAT

NCEM0031S05

Unit: mm (in)

Standard Service

In. 35.000 - 35.016 (1.3780 - 1.3786) 35.500 - 35.516 (1.3976 - 1.3983)

Cylinder head seat recess diameter (D)

Ex. 31.000 - 31.016 (1.2205 - 1.2211) 31.500 - 31.516 (1.2402 - 1.2408) In. 0.064 - 0.096 (0.0025 - 0.0038)

Valve seat interference fit

Ex. 0.064 - 0.096 (0.0025 - 0.0038) In. 35.080 - 35.096 (1.3811 - 1.3817) 35.580 - 35.596 (1.4008 - 1.4014)

Valve seat outer diameter (d)

Ex. 31.080 - 31.096 (1.2236 - 1.2242) 31.580 - 31.596 (1.2433 - 1.2439) In. 6.25 (0.2461)

Depth (H)

Ex. 6.25 (0.2461)

Height (h) 6.2 - 6.3 (0.244 - 0.248) 5.4 - 5.5 (0.213 - 0.217)

SEM651DE

IDX

EM-75

Valve (Cont’d)

SERVICE DATA AND SPECIFICATIONS (SDS)

EXIT

VALVE SEAT RESURFACE LIMIT

Depth (L) 42.74 - 43.26 (1.6827 - 1.7031)

Camshaft and Camshaft Bearing

Standard Limit

Camshaft journal to bearing clearance

Inner diameter of camshaft bearing 28.000 - 28.021 (1.1024 - 1.1032) —

Outer diameter of camshaft journal

Camshaft runout [TIR*] Less than 0.02 (0.0008) 0.1 (0.004) Camshaft sprocket runout [TIR*] Less than 0.25 (0.0098) — Camshaft end play 0.055 - 0.139 (0.0022 - 0.0055) 0.20 (0.0079)

0.045 - 0.090 (0.0018 - 0.0035)

0.030 - 0.071 (0.0012 - 0.0028) for engine serial number SR20-266590

27.935 - 27.955 (1.0998 - 1.1006)

27.950 - 27.970 (1.1004 - 1.1012) for engine serial number SR20-266590

0.15 (0.0059)

—

NCEM0031S08

Unit: mm (in)

AEM343

NCEM0032

Unit: mm (in)

Intake 37.550 - 37.740 (1.4783 - 1.4858)

Cam height “A”

Exhaust 37.920 - 38.110 (1.4929 - 1.5004)

Wear limit of cam height 0.2 (0.008)

Intake 9.4 (0.370)

Valve lift

Exhaust 8.8 (0.346)

*Total indicator reading

EM671

EM-76

SERVICE DATA AND SPECIFICATIONS (SDS)

Cylinder Block

EXIT

Cylinder Block

Surface flatness

Cylinder bore Inner diameter

Out-of-round (X − Y) Less than 0.015 (0.0006) Taper (A − B and A − C) Less than 0.010 (0.0004) Difference in inner diameter between cylin-

ders

Main journal inner diameter

Standard Less than 0.03 (0.0012) Limit 0.10 (0.0039)

Grade No. 1 86.000 - 86.010 (3.3858 - 3.3862)

Standard

Wear limit 0.20 (0.0079)

Limit Less than 0.05 (0.0020)

Grade No. 0 58.944 - 58.950 (2.3206 - 2.3209) Grade No. 1 58.950 - 58.956 (2.3209 - 2.3211) Grade No. 2 58.956 - 58.962 (2.3211 - 2.3213) Grade No. 3 58.962 - 58.968 (2.3213 - 2.3216)

Grade No. 2 86.010 - 86.020 (3.3862 - 3.3866) Grade No. 3 86.020 - 86.030 (3.3866 - 3.3870)

NCEM0033

Unit: mm (in)

SEM008D

SEM686DB

EM-77

IDX

SERVICE DATA AND SPECIFICATIONS (SDS)

Piston, Piston Ring and Piston pin

EXIT

Piston, Piston Ring and Piston pin

PISTON

Grade No. 1 85.980 - 85.990 (3.3850 - 3.3854)

Piston skirt diameter “A” Standard

“a” dimension 45.0 (1.772) Piston clearance to cylinder block 0.010 - 0.030 (0.0004 - 0.0012) Piston pin hole diameter 21.993 - 22.005 (0.8659 - 0.8663)

Grade No. 2 85.990 - 86.000 (3.3854 - 3.3858) Grade No. 3 86.000 - 86.010 (3.3858 - 3.3862)

0.20 (0.0079) oversize (Service) 86.180 - 86.210 (3.3929 - 3.3941)

NCEM0034

NCEM0034S01

Unit: mm (in)

SEM086G

PISTON RING

Standard 0.04 - 0.08 (0.0016 - 0.0031) Limit 0.1 (0.004) Standard 0.03 - 0.07 (0.0012 - 0.0028) Limit 0.1 (0.004) Standard 0.065 - 0.135 (0.0026 - 0.0053) Limit — Standard 0.20 - 0.39 (0.0079 - 0.0154) Limit 0.53 (0.0209) Standard 0.35 - 0.59 (0.0138 - 0.0232) Limit 0.7 (0.028) Standard 0.20 - 0.69 (0.0079 - 0.0272) Limit 0.95 (0.0374)

Side clearance

Ring end gap

Top

2nd

Oil

Top

2nd

Oil

PISTON PIN

Piston pin outer diameter 21.989 - 22.001 (0.8657 - 0.8622) Interference fit of piston pin to piston 0.002 - 0.006 (0.0001 - 0.0002)

Piston pin to connecting rod bushing clearance

Standard 0.005 - 0.017 (0.0002 - 0.0007) Limit 0.023 (0.0009)

NCEM0034S02

Unit: mm (in)

NCEM0034S03

Unit: mm (in)

* Values measured at ambient temperature of 20°C (68°F)

EM-78

SERVICE DATA AND SPECIFICATIONS (SDS)

Connecting Rod

EXIT

Connecting Rod

Center distance 136.25 - 136.35 (5.3642 - 5.3681) Bend [per 100 (3.94)] Limit 0.15 (0.0059) Torsion [per 100 (3.94)] Limit 0.30 (0.0118) Connecting rod small end inner diameter 24.980 - 25.000 (0.9835 - 0.9843) Piston pin bushing inner diameter* 22.000 - 22.012 (0.8661 - 0.8666) Connecting rod big end inner diameter 51.000 - 51.013 (2.0079 - 2.0084)

Standard 0.20 - 0.35 (0.0079 - 0.0138)

Side clearance

Limit 0.5 (0.020)

*After installing in connecting rod

NCEM0035

Unit: mm (in)

EM-79

IDX

Crankshaft

SERVICE DATA AND SPECIFICATIONS (SDS)

EXIT

Crankshaft

Grade No. 0 54.974 - 54.980 (2.1643 - 2.1646)

Main journal dia. “Dm”

Pin journal dia. “Dp”

Center distance “r” 42.96 - 43.04 (1.6913 - 1.6945)

Out-of-round (X − Y) Standard

Taper (A − B) Standard

Runout [TIR]

Free end play

Grade No. 1 54.968 - 54.974 (2.1641 - 2.1643) Grade No. 2 54.962 - 54.968 (2.1639 - 2.1641) Grade No. 3 54.956 - 54.962 (2.1636 - 2.1639) Grade No. 0 47.968 - 47.974 (1.8885 - 1.8887) Grade No. 1 47.962 - 47.968 (1.8883 - 1.8885) Grade No. 2 47.956 - 47.962 (1.8880 - 1.8883)

Main journal Less than 0.005 (0.0002) Pin journal Less than 0.003 (0.0001) Main journal Less than 0.005 (0.0002) Pin journal Less than 0.0025 (0.0001) Standard Less than 0.025 (0.0010) Limit Less than 0.05 (0.0020) Standard 0.10 - 0.26 (0.0039 - 0.0102) Limit 0.30 (0.0118)

NCEM0036

Unit: mm (in)

SEM954C

EM715

EM-80

SERVICE DATA AND SPECIFICATIONS (SDS)

Main Bearing

EXIT

STANDARD

Grade number Thickness “T” Width “W” Identification color (mark)

Main Bearing

0 1.977 - 1.980 (0.0778 - 0.0780) 1 1.980 - 1.983 (0.0780 - 0.0781) Brown (B) 2 1.983 - 1.986 (0.0781 - 0.0782) Green (C) 3 1.986 - 1.989 (0.0782 - 0.0783) Yellow (D) 4 1.989 - 1.992 (0.0783 - 0.0784) Blue (E) 5 1.992 - 1.995 (0.0784 - 0.0785) Pink (F) 6 1.995 - 1.998 (0.0785 - 0.0787) No color (G)

18.9 - 19.1 (0.744 - 0.752)

Black (A)

NCEM0037

SEM685D

NCEM0037S01

Unit: mm (in)

UNDERSIZE

Undersize Thickness “T” Main journal diameter “Dm”

0.25 (0.0098) 2.109 - 2.117 (0.0830 - 0.0833)

STANDARD SIZE

Grade number Thickness “T” Width “W” Identification color (mark)

0 1.500 - 1.503 (0.0591 - 0.0592) 1 1.503 - 1.506 (0.0592 - 0.0593) Black (B) 2 1.506 - 1.509 (0.0593 - 0.0594) Brown (C)

UNDERSIZE

Undersize Thickness “T” Crank pin journal diameter “Dp”

0.08 (0.0031) 1.541 - 1.549 (0.0607 - 0.0610)

0.12 (0.0047) 1.561 - 1.569 (0.0615 - 0.0618)

0.25 (0.0098) 1.626 - 1.634 (0.0640 - 0.0643)

Grind so that bearing clearance is the specified

Connecting Rod Bearing

16.9 - 17.1 (0.665 - 0.673)

Grind so that bearing clearance is the specified

value.

No color (A)

value.

NCEM0037S02

Unit: mm (in)

NCEM0038

NCEM0038S01

Unit: mm (in)

NCEM0038S02

Unit: mm (in)

IDX

EM-81

Bearing Clearance

SERVICE DATA AND SPECIFICATIONS (SDS)

EXIT

Bearing Clearance

Standard 0.004 - 0.022 (0.0002 - 0.0009)

Main bearing clearance

Limit 0.05 (0.0020) Standard 0.020 - 0.045 (0.0008 - 0.0018)

Connecting rod bearing clearance

Limit 0.065 (0.0026)

Miscellaneous Components

Camshaft sprocket runout limit [TIR] 0.25 (0.0098) Flywheel runout limit [TIR] 0.15 (0.0059) Drive plate runout limit [TIR] 0.2 (0.008)

NCEM0039

Unit: mm (in)

NCEM0040

Unit: mm (in)

EM-82

Infiniti G20 P11 (2000) Service Manual – ENGINE MECHANICAL

Specifications and Main Features

Frequently Asked Questions

User Manual

PRECAUTIONS

Parts Requiring Angular Tightening

Liquid Gasket Application Procedure

Special Service Tools

PREPARATION

Commercial Service Tools

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

Removal and Installation

OUTER COMPONENT PARTS

MEASUREMENT OF COMPRESSION PRESSURE

Components

OIL PAN

Removal

Installation

TIMING CHAIN

Components

Removal

Inspection

Installation

Replacement

OIL SEAL

VALVE OIL SEAL

FRONT OIL SEAL

REAR OIL SEAL

Components

CYLINDER HEAD

Removal

Disassembly

Inspection

CYLINDER HEAD DISTORTION

CAMSHAFT VISUAL CHECK

CAMSHAFT RUNOUT

CAMSHAFT CAM HEIGHT

CAMSHAFT JOURNAL CLEARANCE

CAMSHAFT END PLAY

CAMSHAFT SPROCKET RUNOUT

VALVE GUIDE CLEARANCE

VALVE GUIDE REPLACEMENT

VALVE SEATS

REPLACING VALVE SEAT FOR SERVICE PARTS

VALVE DIMENSIONS

HYDRAULIC LASH ADJUSTER

ROCKER ARM, SHIM AND ROCKER ARM GUIDE

Assembly

Installation

ENGINE ASSEMBLY

Removal and Installation

REMOVAL

INSTALLATION

Components

CYLINDER BLOCK

Removal and Installation

Disassembly

PISTON AND CRANKSHAFT

Inspection

PISTON AND PISTON PIN CLEARANCE

PISTON RING SIDE CLEARANCE

PISTON RING END GAP

CONNECTING ROD BEND AND TORSION

CYLINDER BLOCK DISTORTION AND WEAR

PISTON-TO-BORE CLEARANCE

CRANKSHAFT

BEARING CLEARANCE

CONNECTING ROD BUSHING CLEARANCE (SMALL END)

REPLACEMENT OF CONNECTING ROD BUSHING (SMALL END)

REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T)

FLYWHEEL/DRIVE PLATE RUNOUT

Assembly

PISTON

CRANKSHAFT

SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications

Compression pressure

Cylinder Head

Valve

Valve