Infiniti I30 A33 (2000) Service Manual – ENGINE MECHANICAL

Download

ENGINE MECHANICAL

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.....................................................7

NVH Troubleshooting - Engine Noise .........................8

OUTER COMPONENT PARTS.......................................9

Removal and Installation.............................................9

TIGHTENING PROCEDURES

MEASUREMENT OF COMPRESSION PRESSURE....12

OIL PAN.........................................................................13

Components...............................................................13

Removal.....................................................................13

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

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

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

POSITION FOR APPLYING LIQUID GASKET

Removal.....................................................................22

Inspection...................................................................30

Installation..................................................................30

OIL SEAL.......................................................................35

Replacement..............................................................35

VALVE OIL SEAL OIL SEAL INSTALLATION DIRECTION FRONT OIL SEAL REAR OIL SEAL

CYLINDER HEAD..........................................................38

Components...............................................................38

Removal.....................................................................39

Disassembly...............................................................39

Inspection...................................................................41

CYLINDER HEAD DISTORTION CAMSHAFT VISUAL CHECK CAMSHAFT RUNOUT CAMSHAFT CAM HEIGHT CAMSHAFT JOURNAL CLEARANCE CAMSHAFT END PLAY

.....................................................35

....................................................36

......................................................37

...................................11

.....................36

...............................41

....................................41

..............................................41

.......................................41

........................42

............................................42

SECTION

CONTENTS

CAMSHAFT SPROCKET RUNOUT VALVE GUIDE CLEARANCE VALVE GUIDE REPLACEMENT VALVE SEATS REPLACING VALVE SEAT FOR SERVICE PARTS VALVE DIMENSIONS VALVE SPRING VALVE LIFTER

Assembly ...................................................................46

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

Valve Clearance.........................................................51

CHECKING ADJUSTING

ENGINE ASSEMBLY.....................................................56

Removal and Installation...........................................56

REMOVAL INSTALLATION

CYLINDER BLOCK.......................................................59

Components...............................................................59

............20

Removal and Installation...........................................60

Disassembly...............................................................60

PISTON AND CRANKSHAFT

Inspection...................................................................60

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) DRIVE PLATE RUNOUT

Assembly ...................................................................68

PISTON CRANKSHAFT REPLACING PILOT CONVERTER

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

...........................42

....................................43

................................43

.........................................................44

....44

...............................................45

.......................................................45

........................................................45

.............................................................51

............................................................53

...............................................................57

........................................................58

....................................60

..................60

............................61

..........................................61

...............62

...........62

..............................63

.........................................................64

...........................................64

..........................................................67

..........................................67

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

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

............................70

IDX

CONTENTS (Cont’d)

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

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

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

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

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

VALVE VALVE CLEARANCE AVAILABLE SHIMS VALVE SPRING VALVE LIFTER VALVE GUIDE

Valve Seat..................................................................75

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

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

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

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

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

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

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

Piston, Piston Ring and Piston Pin ...........................78

AVAILABLE PISTON PISTON RING PISTON PIN

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

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

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

UNDERSIZE

Available Connecting Rod Bearing............................82

CONNECTING ROD BEARING UNDERSIZE

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

BEARING CLEARANCE

............................................................79

............................................................81

............................................................82

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

.........................................................79

.................................82

...........................................82

EM-2

PRECAUTIONS

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 d) Crankshaft pulley bolt

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 all traces of 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 Be sure liquid gasket diameter is as specified.

NHEM0001

NHEM0002

SEM164F

AEM080

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.

IDX

EM-3

Special Service Tools

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

KV10106500 (—) Engine stand shaft

KV10117000 (J41262) Engine sub-attachment

Description

Disassembling and assembling

NT042

NT028

KV10117000 has been replaced with KV10117001 (KV10117000 is no longer in production, but it is usable).

NHEM0003

KV10117001 (—) Engine sub-attachment

ST10120000 (J24239-01) Cylinder head bolt wrench

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

NT373

Installing on the cylinder block

NT372

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

EM-4

Tool number (Kent-Moore No.) Tool name

(J39386) Valve oil seal drift

KV101151S0 (J38972) Lifter stopper set 1 KV10115110 (J38972-1) Camshaft pliers 2 KV10115120 (J38972-2) Lifter stopper

EM03470000 (J8037) Piston ring compressor

Description

NT024

NT041

PREPARATION

Special Service Tools (Cont’d)

Installing valve oil seal

Changing shims

Installing piston assembly into cylinder bore

ST16610001 (J23907) Pilot bushing puller

KV10111100 (J37228) Seal cutter

WS39930000 (—) Tube presser

KV10112100 (BT8653-A) Angle wrench

NT044

NT045

NT046

NT052

Removing crankshaft pilot bushing

Removing steel oil pan and rear timing chain case

Pressing the tube of liquid gasket

Tightening bolts for bearing cap, cylinder head, etc.

NT014

IDX

EM-5

Commercial Service Tools

PREPARATION

Tool number (Kent-Moore No.) Tool name

Spark plug wrench

Valve seat cutter set

Piston ring expander

Valve guide drift

Description

NT047

NT048

NT030

Commercial Service Tools

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 = 5.5 mm (0.217 in) dia.

NHEM0004

Valve guide reamer

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

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

NT015

NT016

AEM488

Reaming valve guide 1 or hole for oversize valve guide 2

Intake & Exhaust: d

= 6.0 mm (0.236 in) dia.

= 10.2 mm (0.402 in) dia.

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

a = J-43897-18 (18 mm dia.) for zirconia oxygen sensor b = J-43897-12 (12 mm dia.) for titania oxygen sensor

Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads

AEM489

EM-6

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NHEM0005

EM-7

IDX

SEM646F

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting — Engine Noise

Location of

noise

Top of engine Rocker cover Cylinder head

Crankshaft pulley Cylinder block (Side of engine) Oil pan

Type of

noise

warm-up

Ticking or clicking

Rattle C A — A B C

Slap or knock

Slap or rap

Knock A B C B B B

Knock A B — A B C

NVH Troubleshooting — Engine Noise

Use the chart 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 engine.

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

Operating condition of engine

Before

C A —A B—

— A —B B—

A ——BBA

After

warm-up

When

starting

When

idling

When racing

While

driving

Source of

noise

Tappet noise

Camshaft bearing noise

Piston pin noise

Piston slap noise

Connecting rod bearing noise

Main bearing noise

NHEM0005S01

Check item

Valve clearance EM-53

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

Reference

page

EM-41, 42

EM-60, 67

EM-61, 61, 62, 63

EM-67, 66

EM-64, 64

Front of engine Timing chain cover

Front of engine

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

Tapping or ticking

Squeaking or fizzing

Creaking A B ABAB

Squall Creak

A A—BBB

A B —B—C

A B—BAB

EM-8

Timing chain and chain tensioner noise

Other drive belts (Sticking or slipping)

Other drive belts (Slipping)

Water pump noise

Timing chain cracks and wear Timing chain tensioner operation

Drive belts deflection

Idler pulley bearing operation

Water pump operation

EM-30, 19

MA section (“Checking Drive Belts”, “ENGINE MAINTENANCE”)

LC section (“Water Pump Inspection”, “ENGINE COOLING SYSTEM”)

OUTER COMPONENT PARTS

Removal and Installation

NHEM0006

1. Intake manifold collector support

2. Intake manifold collector

3. Fuel damper and fuel feed hose assembly

4. Injector

5. Fuel tube assembly

6. Fuel pressure regulator

7. Ignition coil with power transistor

8. Ornament cover

SEM579G

9. Intake manifold

10. Throttle body

11. IACV-AAC valve

12. EVAP canister purge volume control solenoid valve

IDX

EM-9

Removal and Installation (Cont’d)

OUTER COMPONENT PARTS

1. EGR valve

2. EGR temperature sensor

3. Camshaft position sensor (PHASE)

4. Thermostat with water inlet

5. Exhaust manifold

6. Water outlet

7. EGR guide tube

SEM580G

8. Water control valve

9. Water connector

10. Cylinder block water outlet

EM-10

OUTER COMPONENT PARTS

Removal and Installation (Cont’d)

SEM950F

SEM951F

TIGHTENING PROCEDURES Intake Manifold

I Tighten in numerical order shown in the figure.

1. Tighten all bolts and nuts to 5 to 10 N·m (0.5 to 1.0 kg-m, 44 to 86 in-lb).

2. Finally tighten all bolts and nuts to 26 to 31 N·m (2.7 to 3.2 kg-m, 20 to 23 ft-lb).

I Tightenall bolts and nuts to the final torque, evenly dividing the

tightening into at least five steps.

Fuel Tube

I Tighten in numerical order shown in the figure.

1. Tighten all bolts to 9.3 to 10.8 N·m (0.95 to 1.1 kg-m, 79 to 95 in-lb).

2. Then tighten all bolts to 21 to 26 N·m (2.1 to 2.7 kg-m, 15 to 20 ft-lb).

Fuel Pressure Regulator

Tighten fuel pressure regulator to 2.9 to 3.8 N·m (0.3 to 0.39 kg-m,

26.0 to 33.9 in-lb).

I Tighten screws evenly several times to have the fuel pres-

sure regulator tightened at the specified torque.

I Always replace O-ring with new ones. I Lubricate O-ring with new engine oil.

NHEM0006S01

NHEM0006S0101

NHEM0006S0102

NHEM0006S0103

SEM952F

SEM953F

Throttle Body

I Tighten in numerical order shown in the figure.

1. Tighten all bolts to 8.8 to 10.8 N·m (0.9 to 1.1 kg-m, 79 to 95 in-lb).

2. Then tighten all bolts to 17.7 to 21.6 N·m (1.8 to 2.2 kg-m, 13 to 16 ft-lb).

Intake Manifold Collector

Tightenbolts and nuts to 11 to 15 N·m (1.1 to 1.6 kg-m, 8 to 11 ft-lb) in numerical order shown in the figure.

NHEM0006S0105

NHEM0006S0107

IDX

SEM954F

EM-11

MEASUREMENT OF COMPRESSION PRESSURE

1. Warm up engine.

2. Turn ignition switch OFF.

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

4. Disconnect ignition coil with power transistor harness connectors, then remove ignition coils.

5. Remove all spark plugs.

6. Remove fuse for fuel injector.

SEM087G

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 as shown above.

I Always use a fully-charged battery to obtain specified

engine speed.

NHEM0007

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

SEM909E

SEM387C

Standard Minimum

1,275 (13.0, 185)/300 981 (10.0, 142)/300 98 (1.0, 14)/300

Difference limit between

cylinders

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.

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-72 and 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.

EM-12

OIL PAN

Components

Removal

CAUTION:

When removing the aluminum oil pan from engine, first remove the crankshaft position sensors (POS and REF) from the assembly. Be careful not to damage sensor edges and signal plate teeth.

1. Remove engine undercover.

2. Drain engine oil.

NHEM0008

SEM006G

NHEM0009

SEM956F

SEM957F

3. Remove steel oil pan bolts.

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

deformed.

IDX

EM-13

Removal (Cont’d)

OIL PAN

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

SEM960F

5. Remove oil strainer.

SEM809E

6. Remove front exhaust tube and its support. Refer to FE-11, “Removal and Installation”.

SEM834FA

7. Set a suitable transmission jack under transaxle and hoist engine with engine slinger.

8. Remove crankshaft position sensors (POS and REF) from oil pan.

9. Remove front and rear engine mounting nuts and bolts.

10. Remove center member.

SEM811E

EM-14

SEM812E

OIL PAN

11. Remove drive belts.

12. Remove air compressor and bracket.

13. Remove rear cover plate.

Removal (Cont’d)

SEM813E

SEM184F

SEM815E

14. Remove aluminum oil pan bolts in numerical order.

15. Remove four engine-to-transaxle bolts.

16. Remove aluminum oil pan.

a. Insert an appropriate size tool into the notch of aluminum oil

pan as shown in the figure.

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

deformed.

b. Pry off aluminum oil pan by moving the tool up and down. c. Remove aluminum oil pan.

IDX

SEM155F

EM-15

Removal (Cont’d)

OIL PAN

17. Remove O-rings from cylinder block and oil pump body.

SEM819E

MEM108A

SEM964E

Installation

NHEM0010

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 surface of cyl-

inder block, front cover and steel oil pan.

I Remove old liquid gasket from the bolt hole and thread.

b. Apply sealant to front cover gasket and rear oil seal retainer

gasket.

c. 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.

SEM159F

SEM185FA

d. Apply liquid gasket to inner sealing surface as shown in figure.

I Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197 in)

or 4.5 to 5.5 mm (0.177 to 0.217 in) wide.

I Attaching should be done within 5 minutes after coating.

EM-16

SEM819E

OIL PAN

Installation (Cont’d)

e. Install O-rings, cylinder block and oil pump body.

f. Install aluminum oil pan.

I Tighten bolts in numerical order. I Wait at least 30 minutes before refilling engine oil.

SEM186F

SEM822E

SEM812E

2. Install the four engine-to-transaxle bolts. For tightening torque, refer to AT-284, “Installation”.

3. Install rear cover plate.

4. Install air compressor and bracket. Refer to HA-112, “Removal and Installation”.

5. Install drive belts.

6. Install center member.

7. Install front and rear engine mounting insulator nuts and bolts.

8. Install crankshaft position sensors (POS and REF) and front heated oxygen sensor (left bank) harness clamp.

I Make sure that crankshaft position sensor (POS) and front

heated oxygen sensor (left bank) harness clamp are installed correctly as shown in figure.

9. Install front exhaust tube and its support.

10. Install oil strainer.

IDX

SEM222F

EM-17

Installation (Cont’d)

OIL PAN

11. Install steel oil pan.

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

faces.

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

minum oil pan.

SEM958F

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.

SEM159F

I Be sure liquid gasket is 4.5 to 5.5 mm (0.177 to 0.217 in)

wide.

I Attaching should be done within 5 minutes after coating.

SEM959F

c. Install steel oil pan.

I Tighten in numerical order shown in the figure. I Wait at least 30 minutes before refilling engine oil.

SEM956F

EM-18

TIMING CHAIN

Components

NHEM0011

1. Rear timing chain case

2. Left camshaft chain tensioner

3. Internal chain guide

4. Camshaft chain

5. Right camshaft chain tensioner

6. Timing chain tensioner

7. Slack side chain guide

8. Timing chain

9. Crankshaft sprocket

10. Lower chain guide

11. Upper chain guide

12. Front timing chain case

13. Crankshaft pulley

SEM277G

14. Water pump cover

15. Chain tensioner cover

16. Exhaust camshaft sprocket 2ND

17. Intake camshaft sprocket 2ND

18. Camshaft sprocket 1ST

19. Water pump

IDX

EM-19

Components (Cont’d)

TIMING CHAIN

POSITION FOR APPLYING LIQUID GASKET

Refer to “Installation” in “OIL PAN”, EM-16.

I Before installation, wipe off the protruding sealant.

=NHEM0011S01

EM-20

TIMING CHAIN

Components (Cont’d)

EM-21

IDX

SEM443FA

Components (Cont’d)

TIMING CHAIN

CAUTION:

I After removing timing chain, do not turn crankshaft and

camshaft separately, or valves will strike piston heads.

I When installing camshafts, chain tensioners, 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 cylinder head, camshaft sprockets, crankshaft pulley, and camshaft brackets.

I Before disconnecting fuel hose, release fuel pressure.

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

I When removing the oil pans, oil pump assembly and tim-

ing chain from engine, first remove the camshaft position sensor (PHASE) and the crankshaft position sensors (REF)/(POS) from the assembly. Be careful not to damage sensor edges.

I Do not spill engine coolant on drive belts.

Removal

1. Drain engine oil.

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

3. Drain coolant by removing cylinder block drain plugs. Refer to MA-14, “Changing Engine Coolant”.

4. Remove left side ornament cover.

5. Remove air duct to intake manifold, collector, blow-by hose, vacuum hoses, fuel hoses, wires, harness, connectors and so on.

6. Remove the following.

I Vacuum hoses I Water hoses I EVAP canister purge hose I Blow-by hose

7. Remove RH and LH ignition coils.

NHEM0012

SMA040D

EM-22

TIMING CHAIN

8. Remove EGR guide tube.

Removal (Cont’d)

SEM961F

SEM962F

9. Remove intake manifold collector supports and intake manifold collector (RH cylinder head only).

10. Remove fuel tube assembly. Referto EC-52, “InjectorRemoval and Installation”.

IDX

SEM963F

EM-23

Removal (Cont’d)

TIMING CHAIN

11. Remove intake manifold in reverse order of installation. Refer to “TIGHTENING PROCEDURES”, EM-11.

SEM964F

12. Remove RH and LH rocker covers from cylinder head.

SEM910E

13. Remove engine undercover.

14. Remove front RH wheel and engine side cover.

15. Remove drive belts and idler pulley bracket.

16. Remove power steering oil pump belt and power steering oil pump assembly.

SEM911E

EM-24

TIMING CHAIN

Removal (Cont’d)

17. Remove camshaft position sensor (PHASE) and crankshaft position sensors (REF)/(POS).

SEM912E

SEM913E

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

19. Loosen crankshaft pulley bolt. (At this time remove oil pan rear cover plate and set a suitable tool to ring gear so that crankshaft cannot rotate.)

I Be careful not to damage the signal plate teeth.

SEM965F

IDX

EM-25

Removal (Cont’d)

TIMING CHAIN

20. Remove crankshaft pulley with a suitable puller.

SEM915E

21. Remove air compressor and bracket.

22. Remove front exhaust tube and its support.

23. Hang engine at right and left side engine slingers with a suitable hoist.

24. Remove right side engine mounting, mounting bracket and nuts.

25. Remove center member assembly.

26. Remove upper and lower oil pans.

I For procedures described in steps 21 through 26, refer to

“Removal”, EM-13.

SEM812E

27. Remove water pump cover.

SEM916E

28. Remove front timing chain case bolts.

I Loosen bolts in numerical order as shown in the figure.

SEM917EA

EM-26

SEM156F

TIMING CHAIN

Removal (Cont’d)

29. Remove front timing chain case.

I Do not scratch sealing surfaces.

30. Remove internal chain guide.

31. Remove upper chain guide.

32. Remove timing chain tensioner and slack side chain guide.

SEM919E

SEM966F

I Remove timing chain tensioner. (Push piston and insert a suit-

able pin into pinhole.)

EM-27

IDX

Removal (Cont’d)

TIMING CHAIN

33. Remove RH & LH camshaft sprocket 1ST bolts.

34. Remove camshaft sprockets 1ST on both sides, crankshaft sprocket and timing chain.

I Apply paint to timing chain and camshaft sprockets 1ST

for alignment during installation.

SEM004G

35. Attach a suitable stopper pin to RH and LH camshaft chain tensioners.

SEM927EA

36. Remove exhaust camshaft sprocket 2ND bolts on both sides.

I Apply paint to timing chain and camshaft sprockets 2ND

for alignment during installation.

SEM922E

EM-28

SEM160F

TIMING CHAIN

Removal (Cont’d)

37. Remove exhaust camshaft sprockets 2ND, intake camshaft sprockets 2ND and camshaft chains on both sides.

38. Remove lower chain guide.

SEM924E

SEM925E

SEM161F

39. Use a scraper to remove all traces of liquid gasket from front timing chain case.

I Remove old liquid gasket from the bolt hole and thread.

40. Use a scraper to remove all traces of liquid gasket from water pump cover.

IDX

SEM926E

EM-29

Inspection

TIMING CHAIN

SEM928E

SEM929E

Inspection

NHEM0013

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

Installation

NHEM0014

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 on compression stroke.

SEM930E

3. Install lower chain guide on dowel pin, with front mark on the guide facing upside.

SEM931E

EM-30

TIMING CHAIN

Installation (Cont’d)

4. Align the marks on RH and LH intake camshaft sprockets 2ND, exhaust camshaft sprockets 2ND and camshaft chain, as shown.

5. Put LH camshaft dowel pin into camshaft sprocket dowel groove and install these on camshaft. Tighten LH exhaust camshaft sprocket 2ND bolt.

6. Put RH camshaft dowel pin in camshaft sprocket dowel groove and install sprocket on camshaft.

7. Tighten RH exhaust camshaft sprocket 2ND bolt.

I Make sure that the timing marks on RH and LH intake

camshaft sprockets 2ND are aligned with the camshaft chain mark.

I Lubricate threads and seat surfaces of camshaft sprocket

bolts with new engine oil.

SEM162F

SEM932E

SEM934E

I Be careful not to confuse intake and exhaust camshaft

sprockets 2ND (their thicknesses are different).

8. Remove RH and LH camshaft chain tensioner stopper pins.

EM-31

IDX

Installation (Cont’d)

TIMING CHAIN

9. Align mating mark on crankshaft sprocket with matchmark on chain as shown.

10. Attach lower timing chain on the water pump sprocket.

11. Install RH and LH camshaft sprockets 1ST onto camshafts by matching sprocket dowel grooves with camshaft.

12. Tighten RH and LH camshaft sprocket 1ST bolts.

I Lubricate threads and seat surfaces of the bolts with new

engine oil.

13. Install timing chain. Make sure that mating marks on crankshaft sprocket and RH and LH camshaft sprockets are aligned with matchmarks on timing chain.

SEM163F

14. Install internal chain guide.

15. Install upper chain guide and slack side chain guide.

SEM919E

16. Install timing chain tensioner, then remove the stopper pin.

I When installing the timing chain tensioner, engine oil

should be applied to the oil hole and tensioner.

17. Apply liquid gasket to front timing chain case.

I Refer to “POSITION FOR APPLYING LIQUID GASKET”,

EM-20.

I Before installation, wipe off the protruding sealant.

SEM967F

EM-32

TIMING CHAIN

Installation (Cont’d)

18. Install rear case pin into dowel pin hole on front timing chain case.

19. Tighten bolts to the specified torque in order shown in the figure.

I Leave the bolts unattended for 30 minutes or more after

tightening.

SEM938E

SEM941EA

20. Apply liquid gasket to water pump cover.

I Apply a continuous bead of liquid gasket to mating surface of

water pump cover. Refer to LC-12, “Water Pump Installation”.

21. Install water pump cover.

22. Apply liquid gasket to RH and LH rocker covers.

I Use genuine liquid gasket or equivalent. I Refer to “POSITION FOR APPLYING LIQUID GASKET”,

EM-20.

23. Install RH and LH rocker covers.

Rocker cover tightening procedure:

I Tighten in numerical order as shown in the figure.

a. Tighten bolts 1 to 10 in that order to 6.9 to 8.8 N·m (0.7 to 0.9

kg-m, 61 to 78 in-lb).

b. Then tighten bolts 1 to 10 as indicated in figure to 6.9 to 8.8

N·m (0.7 to 0.9 kg-m, 61 to 78 in-lb).

SEM942EB

IDX

EM-33

Installation (Cont’d)

TIMING CHAIN

24. Install intake manifold. Tighten intake manifold nuts and bolts.

Refer to “TIGHTENING PROCEDURES”, EM-11.

25. Install fuel tube assembly.

26. Install intake manifold collector gasket.

27. Install intake manifold collector supports and intake manifold collector bolt.

28. Install EGR guide tube.

29. Install RH and LH ignition coils.

30. Install rocker cover ornament on left side.

SEM944E

31. Install crankshaft pulley to crankshaft.

I Lubricate thread and seat surface of the bolt with new

engine oil.

a. Tighten to 39 to 49 N·m (4.0 to 5.0 kg-m, 29 to 36 ft-lb). b. Put a paint mark on the crankshaft pulley. c. Again tighten by turning 60° to 66°, about the angle from one

hexagon bolt head corner to another.

SEM968F

SEM963E

SEM222F

32. Install camshaft position sensor (PHASE), crankshaft position sensors (REF)/(POS) and front heated oxygen sensor (left bank) harness clamp.

I Make sure that crankshaft position sensor (POS) and front

heated oxygen sensor (left bank) harness clamp are installed correctly as shown in figure.

33. Reinstall removed parts in reverse order of removal.

I When installing fuel tube assembly. Refer to EC-52, “Injector

Removal and Installation”.

I After starting engine, keep idling for three minutes. Then

rev engine up to 3,000 rpm under no load to purge air from the high-pressure chamber of the chain tensioners. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.

EM-34

OIL SEAL

Replacement

SEM948E

Replacement

CAUTION:

When removing the oil pans, oil pump assembly and timing chain from engine, first remove the camshaft position sensor (PHASE) and the crankshaft position sensors (REF)/(POS) from the assembly. Be careful not to damage sensor edges.

VALVE OIL SEAL

1. Remove LH ornament cover.

2. Remove RH and LH ignition coils.

3. Remove EGR guide tube.

4. Remove intake manifold collector supports and intake manifold collector (RH cylinder head only).

5. Remove RH and LH rocker covers from cylinder head.

6. Remove camshaft position sensor (PHASE) and crankshaft position sensors (REF)/(POS).

7. Remove oil pan. Refer to “Removal”, EM-13.

8. Remove timing chain. Refer to “Removal, EM-22.

9. Remove camshaft brackets and camshaft. Refer to “Disassembly”, EM-39.

10. Remove valve lifters and shims.

11. Remove valve spring with Tool.

12. Reinstall any parts removed in reverse order of removal.

Before removing valve spring, fix valve as follows. Method A: Piston concerned should be set at TDC to prevent valve from falling.

NHEM0015

NHEM0015S01

SEM826E

Method B: Remove spark plug, then 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

Method C: Install spark plug with suitable washer into spark plug hole from combustion chamber side.

, 71 psi).

IDX

SEM983D

EM-35

Replacement (Cont’d)

OIL SEAL

13. Remove valve oil seal.

SEM827E

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

SEM828E

SEM715A

OIL SEAL INSTALLATION DIRECTION

I Install new oil seal in the direction shown in the figure.

FRONT OIL SEAL

1. Remove the following parts:

I Engine undercover I Front RH wheel and engine side cover I Drive belts I Crankshaft position sensor (REF) I Crankshaft pulley

Be careful not to damage sensor edge.

NHEM0015S02

NHEM0015S03

SEM829E

2. Remove front oil seal using a suitable tool.

Be careful not to scratch front cover.

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

EM-36

OIL SEAL

Replacement (Cont’d)

SEM830E

SEM831E

REAR OIL SEAL

1. Remove transaxle. Refer to AT-283.

2. Remove flywheel or drive plate.

3. Remove oil pan. Refer to EM-13.

4. Remove rear oil seal retainer.

5. Remove old liquid gasket using scraper.

I Remove old liquid gasket from the bolt hole and thread.

6. Apply liquid gasket to rear oil seal retainer.

NHEM0015S04

SEM832EA

IDX

EM-37

Components

CYLINDER HEAD

Components

NHEM0016

1. Oil filler cap

2. Rocker cover

3. Camshaft bracket

4. Camshaft

5. PCV valve

6. Cylinder head

7. Blow-by hose

8. Spark plug

9. Valve

10. Valve spring seat

SEM278G

11. Valve spring

12. Valve spring retainer

13. Valve collet

14. Valve lifter

15. Shim

EM-38

CYLINDER HEAD

Components (Cont’d)

CAUTION:

I When installing camshafts, chain tensioners, oil seals, or

other sliding parts, lubricate contacting surfaces with new engine oil.

I Apply new engine oil to threads and seat surfaces when

installing cylinder head, camshaft sprocket, crankshaft pulley, and camshaft bracket.

I Attach tags to valve lifters so as not to mix them up.

SEM167F

Removal

I This removal is the same procedure as that for timing

chain. Refer to “Removal”, EM-22.

I Apply paint to camshaft sprockets for alignment during

installation.

Disassembly

1. Remove rear timing chain case bolts.

2. Remove rear timing chain case.

NHEM0017

NHEM0018

SEM279G

SEM856E

3. Remove intake and exhaust camshafts and camshaft brackets.

I Equally loosen camshaft bracket bolts in several steps in the

numerical order shown in the figure.

For reinstallation, be sure to put marks on camshaft bracket before removal.

4. Remove valve component parts. Refer to “VALVE OIL SEAL”, EM-35.

EM-39

IDX

Disassembly (Cont’d)

CYLINDER HEAD

SEM857E

5. Remove RH and LH camshaft chain tensioners from cylinder head.

SEM489F

6. Remove cylinder head bolts.

I Cylinder head bolts should be loosened in two or three

steps.

I A warped or cracked cylinder head could result from

removing in incorrect order.

SEM859E

SEM860E

EM-40

SEM863E

CYLINDER HEAD

Disassembly (Cont’d)

7. Remove cylinder head.

SEM861E

Inspection

CYLINDER HEAD DISTORTION

Clean surface of cylinder head. Use a reliable straightedge and feeler gauge to check the flatness of cylinder head surface. Check along six positions shown in the figure.

Head surface flatness: Limit 0.1 mm (0.004 in)

If beyond the specified limit, resurface or replace it.

The limit for cylinder head resurfacing is determined by the cylinder block resurfacing.

Resurfacing limit:

Amount of cylinder head resurfacing is “A”. Amount of cylinder block resurfacing is “B”.

The maximum limit: 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)

CAMSHAFT VISUAL CHECK

Check camshaft for scratches, seizure and wear.

CAMSHAFT RUNOUT

1. Measure camshaft runout at A and B as shown in the figure.

Runout (Total indicator reading):

Limit 0.05 mm (0.0020 in)

2. If it exceeds the limit, replace camshaft.

NHEM0019

NHEM0019S01

NHEM0019S02

NHEM0019S03

SEM191F

SEM549A

CAMSHAFT CAM HEIGHT

1. Measure camshaft cam height.

Standard cam height:

Intake 43.940 - 44.130 mm (1.7299 - 1.7374 in) Exhaust 44.465 - 44.655 mm (1.7506 - 1.7581 in)

Cam wear limit:

0.2 mm (0.008 in)

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

EM-41

NHEM0019S04

IDX

Inspection (Cont’d)

CYLINDER HEAD

SEM862E

SEM012A

CAMSHAFT JOURNAL CLEARANCE

NHEM0019S05

1. Install camshaft bracket and tighten bolts to the specified torque.

2. Measure inner diameter “A” of camshaft bearing.

Standard inner diameter:

No. 1: 26.000 - 26.021 mm (1.0236 - 1.0244 in) No. 2, 3, 4: 23.500 - 23.521 mm (0.9252 - 0.9260 in)

3. Measure outer diameter of camshaft journal.

Standard outer diameter:

No. 1: 25.935 - 25.955 mm (1.0211 - 1.0218 in) No. 2, 3, 4: 23.445 - 23.465 mm (0.9230 - 0.9238 in)

4. If clearance exceeds the limit, replace camshaft and/or cylinder head.

Camshaft journal clearance:

Standard

No. 1: 0.045 - 0.086 mm (0.0018 - 0.0034 in) No. 2, 3, 4: 0.035 - 0.076 mm (0.0014 - 0.0030 in)

Limit

0.15 mm (0.0059 in)

SEM864E

SEM865E

CAMSHAFT END PLAY

1. Install camshaft in cylinder head.

2. Measure camshaft end play.

Camshaft end play:

Standard

0.115 - 0.188 mm (0.0045 - 0.0074 in)

Limit

0.24 mm (0.0094 in)

CAMSHAFT SPROCKET RUNOUT

1. Install sprocket on camshaft.

2. Measure camshaft sprocket runout.

Runout (Total indicator reading):

Less than 0.15 mm (0.0059 in)

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

NHEM0019S06

NHEM0019S07

EM-42

CYLINDER HEAD

Inspection (Cont’d)

SEM178F

SEM938C

VALVE GUIDE CLEARANCE

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

Valve deflection limit (Dial gauge reading):

Intake 0.24 mm (0.0094 in) Exhaust 0.28 mm (0.0110 in)

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 limit:

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

c. If it exceeds the limit, replace valve or valve guide.

VALVE GUIDE REPLACEMENT

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

NHEM0019S08

NHEM0019S09

SEM008A

SEM931C

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.

3. Ream cylinder head valve guide hole.

Valve guide hole diameter (for service parts):

10.185 - 10.196 mm (0.4010 - 0.4014 in)

IDX

SEM932C

EM-43

Inspection (Cont’d)

SEM950E

CYLINDER HEAD

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

Projection “L”:

12.6 - 12.8 mm (0.496 - 0.504 in)

5. Ream valve guide.

Finished size:

6.000 - 6.018 mm (0.2362 - 0.2369 in)

VALVE SEATS

Check valve seats for any evidence of pitting at valve contact surface, and reseat or replace if it has worn out excessively.

I Before repairing valve seats, check valve and valve guide

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

I Use both hands to cut uniformly.

NHEM0019S10

SEM934C

SEM795A

SEM892B

REPLACING VALVE SEAT FOR SERVICE PARTS

NHEM0019S11

1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess in cylinder head. Set the machine depth stop to ensure this.

2. Ream cylinder head recess for service valve seat.

Oversize [0.5 mm (0.020 in)]:

Intake 37.500 - 37.516 mm (1.4764 - 1.4770 in) Exhaust 32.700 - 32.716 mm (1.2874 - 1.2880 in)

Be sure to ream in circles concentric to the valve guide center. This will enable valve seat to fit correctly.

3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil.

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

5. Cut or grind valve seat using suitable tool to the specified dimensions as shown in SDS (EM-75).

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

7. Check valve seating condition.

Seat face angle “α”: 45° Contacting width “W”:

Intake 1.09 - 1.31 mm (0.0429 - 0.0516 in) Exhaust 1.29 - 1.51 mm (0.0508 - 0.0594 in)

EM-44

SEM621F

CYLINDER HEAD

Inspection (Cont’d)

8. Use a depth gauge to measure the distance between the mounting surface of the cylinder head spring seat and the valve stem end. If the distance is shorter than specified, repeat step 5 above to adjust it. If it is longer, replace the valve seat with a new one.

Valve seat resurface limit “L”:

Intake 41.07 - 41.67 mm (1.6169 - 1.6405 in) Exhaust 41.00 - 41.60 mm (1.6142 - 1.6378 in)

VALVE DIMENSIONS

Check dimensions of each valve. For dimensions, 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.

NHEM0019S12

SEM188A

SEM288A

EM113

VALVE SPRING Squareness

1. Measure dimension “S”.

Out-of-square “S”:

Less than 2.0 mm (0.079 in)

2. If it exceeds the limit, replace spring.

Pressure

Check valve spring pressure at specified spring height.

Pressure:

Standard

202 N (20.6 kg, 45.4 lb) at height 37.0 mm (1.457 in)

Limit

More than 436 N (44.5 kg, 98.1 lb) at height 28.2 mm (1.110 in)

If it exceeds the limit, replace spring.

VALVE LIFTER

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

NHEM0019S13

NHEM0019S1301

NHEM0019S1302

NHEM0019S14

IDX

SEM960E

EM-45

Inspection (Cont’d)

CYLINDER HEAD

2. Check diameter of valve lifter and valve lifter guide bore.

Valve lifter outer diameter:

34.960 - 34.975 mm (1.3764 - 1.3770 in)

SEM961E

Lifter guide bore diameter:

35.000 - 35.021 mm (1.3780 - 1.3788 in)

SEM867E

SEM085D

SEM891E

Assembly

NHEM0020

1. Install valve component parts.

I Always use new valve oil seal. Refer to “VALVE OIL

SEAL”, EM-35.

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

pitch side toward cylinder head side (paint mark).

I After installing valve component parts, tap valve stem tip with

plastic hammer to assure a proper fit.

Installation

NHEM0021

1. Before installing rear timing chain case, remove old liquid gasket from mating surface using a scraper.

I Also remove old liquid gasket from mating surface of cylinder

block.

I Remove old liquid gasket from the bolt hole and thread.

SEM161F

EM-46

SEM892E

CYLINDER HEAD

Installation (Cont’d)

2. Before installing cam bracket, remove old liquid gasket from mating surface using a scraper.

3. Remove O-rings from cylinder block.

4. Turn crankshaft until No. 1 piston is set at approximately 240° before TDC on compression stroke to prevent interference of valves and pistons.

SEM875E

SEM876E

5. Install cylinder heads with new gaskets.

I Do not rotate crankshaft and camshaft separately, or

valves will strike piston heads.

CAUTION:

Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between d1 and d2 exceeds the limit, replace them with new ones.

Limit (d1 − d2):

0.11 mm (0.0043 in)

I Lubricate threads and seat surfaces of the bolts with new

engine oil.

IDX

SEM957E

EM-47

Installation (Cont’d)

CYLINDER HEAD

I Tightening procedure:

a. Tighten all bolts to 98 N·m (10 kg-m, 72 ft-lb). b. Completely loosen all bolts. c. Tighten all bolts to 34 to 44 N·m (3.5 to 4.5 kg-m, 25 to 33

ft-lb).

d. Turn all bolts 90 to 95 degrees clockwise. e. Turn all bolts 90 to 95 degrees clockwise.

I Tighten in numerical order shown in the figure.

SEM877EA

SEM878EA

6. Install cylinder head outside bolts.

SEM879EA

7. Install camshaft chain tensioners on both sides of cylinder head.

SEM490F

8. Install exhaust and intake camshafts and camshaft brackets.

I Intake camshaft has a drill mark on camshaft sprocket

mounting flange. Install it on the intake side.

SEM652F

EM-48

CYLINDER HEAD

Installation (Cont’d)

I Identification marks are present on camshafts.

SEM653F

SEM888EA

SEM884EB

Bank INT/EXH ID mark Drill mark

Paint mark

M1 M2

INT R3 Yes Yes No

EXH R3 No No Yes

INT L3 Yes Yes No

EXH L3 No No Yes

I Position camshaft

RH exhaust camshaft dowel pin at about 10 o’clock LH exhaust camshaft dowel pin at about 2 o’clock

9. Before installing camshaft brackets, apply sealant to mating surface of No. 1 journal head.

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

or equivalent.

I Refer to “POSITION FOR APPLYING LIQUID GASKET”,

EM-20.

I Install camshaft brackets in their original positions. I Tighten camshaft bracket bolts gradually in two or three

stages.

I If any part of valve assembly or camshaft is replaced,

check valve clearance according to reference data. After completing assembly check valve clearance. Refer to “CHECKING” and “ADJUSTING” in “Valve Clearance”, EM-51 and 53.

Reference data valve clearance (Cold):

Intake

0.26 - 0.34 mm (0.010 - 0.013 in)

Exhaust

0.29 - 0.37 mm (0.011 - 0.015 in)

I Lubricate threads and seat surfaces of camshaft bracket

bolts with new engine oil before installing them.

I Align stamp mark as shown in the figure.

SEM188F

IDX

EM-49

Installation (Cont’d)

CYLINDER HEAD

I Tighten the camshaft brackets in the following steps.

Step Tightening torque Tightening order

SEM885EA

SEM886EA

1 1.96 N·m (0.2 kg-m, 17 in-lb)

2 6 N·m (0.6 kg-m, 52 in-lb) Tighten in the numerical order.

9.02 - 11.8 N·m (0.92 - 1.20 kg-m,

79.9 - 104.2 in-lb)

Tighten in the order of 7 to 10,

then tighten 1 to 6.

Tighten in the numerical order.

10. Install O-rings to cylinder block.

SEM887E

11. Apply sealant to the hatched portion of rear timing chain case.

I Apply continuous bead of liquid gasket to mating surface of

rear timing chain case. Refer to “POSITION FOR APPLYING LIQUID GASKET”, EM-20.

I Before installation, wipe off the protruding sealant.

EM-50

CYLINDER HEAD

Installation (Cont’d)

12. Align rear timing chain case with dowel pins, then install on cylinder head and block.

13. Tighten rear chain case bolts.

a. Tighten bolts in numerical order shown in the figure. b. Repeat above step a. I This installation is the same procedure as that for timing chain.

Refer to “Installation”, EM-30.

SEM890EA

SEM868E

Valve Clearance

CHECKING

Check valve clearance while engine is cold and not running.

1. Remove intake manifold collector.

2. Remove rocker cover ornament.

3. Remove RH and LH rocker covers.

4. Remove all spark plugs.

5. Set No. 1 cylinder at TDC on its compression stroke.

I Align pointer with TDC mark on crankshaft pulley. I 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°) andalign as above.

NHEM0022

NHEM0022S01

EM-51

IDX

Valve Clearance (Cont’d)

CYLINDER HEAD

6. Check only those valves shown in the figure.

Valve

SEM893E

SEM139D

Crank position

No. 1 TDC qqq q

No. 1 No. 2 No. 3 No. 4 No. 5 No. 6

INT EXH INT EXH INT EXH INT EXH INT EXH INT EXH

I Using a feeler gauge, measure clearance between valve lifter

and camshaft.

I Record any valve clearance measurements which are out of

specification. They will be used later to determine the required replacement adjusting shim.

Valve clearance for checking (Cold):

Intake

0.26 - 0.34 mm (0.010 - 0.013 in)

Exhaust

0.29 - 0.37 mm (0.011 - 0.015 in)

7. Turn crankshaft 240° and align as above.

8. Set No. 3 cylinder at TDC on its compression stroke.

9. Check only those valves shown in the figure.

SEM894E

Valve

Crank position

No. 3 TDC qq qq

No. 1 No. 2 No. 3 No. 4 No. 5 No. 6

INT EXH INT EXH INT EXH INT EXH INT EXH INT EXH

EM-52

CYLINDER HEAD

Valve Clearance (Cont’d)

10. Turn crankshaft 240° and align as above.

11. Set No. 5 cylinder at TDC on its compression stroke.

12. Check only those valves shown in the figure.

SEM958E

Valve

Crank position

No. 5 TDC qqqq

13. If all valve clearances are within specification, install the following parts.

I Intake manifold collector I RH and LH rocker covers I All spark plugs I Rocker cover ornament

No. 1 No. 2 No. 3 No. 4 No. 5 No. 6

INT EXH INT EXH INT EXH INT EXH INT EXH INT EXH

ADJUSTING

Adjust valve clearance while engine is cold.

1. Turn crankshaft, to position cam lobe on camshaft of valve that must be adjusted upward.

2. Place Tool (A) around camshaft as shown in figure.

Before placing Tool (A), rotate notch toward center of cylinder head (See figure.), to simplify shim removal later.

CAUTION:

Be careful not to damage cam surface with Tool (A).

NHEM0022S02

SEM557EB

SEM869E

SEM870E

3. Rotate Tool (A) (See figure.) so that valve lifter is pushed down.

4. Place Tool (B) between camshaft and the edge of the valve lifter to retain valve lifter.

CAUTION:

I Tool (B) must be placed as close to camshaft bracket as

possible.

I Be careful not to damage cam surface with Tool (B).

5. Remove Tool (A).

IDX

EM-53

Valve Clearance (Cont’d)

SEM871E

SEM872E

CYLINDER HEAD

6. Blow air into the hole to separate adjusting shim from valve lifter.

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

8. Determine replacement adjusting shim size following formula.

I Using a micrometer determine thickness of removed shim. I Calculate thickness of new adjusting shim so valve clearance

comes within specified values. R = Thickness of removed shim N = Thickness of new shim M = Measured valve clearance

Intake:

N=R+[M−0.30 mm (0.0118 in)]

Exhaust:

N=R+[M−0.33 mm (0.0130 in)]

Shims are available in 64 sizes from 2.32 mm (0.0913 in) to 2.95 mm (0.1161 in), in steps of 0.01 mm (0.0004 in).

I Select new shim with thickness as close as possible to calcu-

lated value.

SEM145D

SEM873E

9. Install new shim using a suitable tool.

I Install with the surface on which the thickness is stamped

facing down.

SEM146D

EM-54

CYLINDER HEAD

Valve Clearance (Cont’d)

10. Place Tool (A) as mentioned in steps 2 and 3.

11. Remove Tool (B).

12. Remove Tool (A).

13. Recheck valve clearance.

Valve clearance:

Unit: mm (in)

Cold Hot* (reference data)

Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016)

SEM874E

Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.308 - 0.432 (0.012 - 0.017)

*: Approximately 80°C (176°F)

EM-55

IDX

Removal and Installation

ENGINE ASSEMBLY

Removal and Installation

NHEM0023

1. Front upper engine slinger

2. RH engine mounting

3. Mounting bracket

4. Rear engine mounting (Fluid type)

5. Center member

6. Front engine mounting (Fluid type)

7. LH engine mounting

8. Rear engine slinger

9. Insulator

WARNING:

I Situate 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 For safety during subsequent steps, the tension of wires

should be slackened against the engine.

SEM308GA

EM-56

ENGINE ASSEMBLY

Removal and Installation (Cont’d)

I Before disconnecting fuel hose, release fuel pressure

from fuel line. 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 hoist 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 careful not to strike adjacent parts,

especially the following: Accelerator wire casing, brake lines, and brake master cylinder.

I In hoisting 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 (POS) from the assembly.

I Always pay extra attention not to damage edge of crank-

shaft position sensor (POS) or ring gear teeth.

SEM971F

REMOVAL

1. Remove engine undercover and hood.

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

3. Remove vacuum hoses, fuel hoses, wires, harnesses, connectors and so on.

4. Remove front exhaust tubes, ball joints and drive shafts.

5. Remove radiator and fans.

6. Remove drive belts.

7. Remove alternator, compressor and power steering oil pump from engine.

8. Set a suitable transmission jack under transaxle. Hoist engine with engine slinger.

9. Remove LH engine mounting.

10. Disconnect control cable from transaxle.

11. Remove RH engine mounting.

NHEM0023S01

SEM836EA

IDX

EM-57

Removal and Installation (Cont’d)

ENGINE ASSEMBLY

12. Remove center member and then slowly lower transmission jack.

SEM837E

13. Remove engine with transaxle as shown.

SEM972F

SEM307G

INSTALLATION

NHEM0023S02

Installation is in the reverse order of removal. Install the electronically-controlled engine mount harness to match the following values. (Models with electronically-controlled engine mounts)

Front (A — B):

170 mm (6.69 in)

Rear (C — D):

130 mm (5.12 in)

EM-58

CYLINDER BLOCK

Components

NHEM0024

1. Rear oil seal retainer

2. Cylinder block

3. Knock sensor

4. Upper main bearing

5. Lower main bearing

6. Water drain plug (LH side)

7. Water drain plug (RH side)

8. Water drain plug (Water pump side)

9. Main bearing cap

10. Main bearing beam

11. Crankshaft

12. Pilot bushing or pilot converter

13. Drive plate with signal plate

14. Drive plate reinforcement

15. Oil ring

16. Piston pin

17. Connecting rod bearing

18. Connecting rod

19. Piston

20. Top ring

21. 2nd ring

SEM076GA

IDX

EM-59

Removal and Installation

CYLINDER BLOCK

SEM180FA

SEM190FA

Removal and Installation

NHEM0025

CAUTION:

I When installing bearings, pistons, or other sliding parts,

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 signal

plate teeth of flywheel or drive plate.

Disassembly

PISTON AND CRANKSHAFT

NHEM0026

NHEM0026S01

1. Remove engine. Refer to “Removal and Installation”, EM-56.

2. Place engine on a work stand.

3. Drain coolant and oil.

4. Remove oil pan. Refer to “Removal”, EM-13.

5. Remove timing chain. Refer to “Removal”, EM-22.

6. Remove cylinder head. Refer to “Removal”, EM-39.

7. Remove pistons with connecting rods. I When disassembling piston and connecting rod, remove snap

ring first, then heat piston to 60 to 70°C (140 to 158°F).

8. Remove rear oil seal retainer.

CAUTION:

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.

SEM965A

SEM842E

AEM023

9. Loosen bolts in numerical order as shown and remove main bearing beam, bearing cap and crankshaft.

I Before removing bearing beam and bearing cap, measure

crankshaft end play. Refer to EM-68.

I Bolts should be loosened in two or three steps.

Inspection

PISTON AND PISTON PIN CLEARANCE

NHEM0027

NHEM0027S01

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

Standard diameter “dp”:

Grade No. 0

21.993 - 21.999 mm (0.8659 - 0.8661 in)

Grade No. 1

21.999 - 22.005 mm (0.8661 - 0.8663 in)

EM-60

AEM024

SEM024AA

CYLINDER BLOCK

Inspection (Cont’d)

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

Standard diameter “Dp”:

Grade No. 0

21.989 - 21.995 mm (0.8657 - 0.8659 in)

Grade No. 1

21.995 - 22.001 mm (0.8659 - 0.8662 in)

3. Calculate interference fit of piston pin to piston.

Dp − dp = 0.002 - 0.06 mm (0.0001 - 0.0024 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)

Oil ring

0.015 - 0.185 mm (0.0006 - 0.0073 in)

Max. limit of side clearance:

Top ring 0.11 mm (0.0043 in) 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.

NHEM0027S02

SEM599A

PISTON RING END GAP

End gap:

Top ring 0.22 - 0.32 mm (0.0087 - 0.0126 in) 2nd ring 0.32 - 0.47 mm (0.0126 - 0.0185 in) Oil ring 0.20 - 0.60 mm (0.0079 - 0.0236 in)

Max. limit of ring gap:

Top ring 0.55 mm (0.0217 in) 2nd ring 0.85 mm (0.0335 in) Oil ring 0.95 mm (0.0374 in)

If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, do the following. Rebore cylinder and use oversized piston and piston rings.

Refer to SDS (EM-78).

I When replacing the piston, check the cylinder block surface for

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

NHEM0027S03

IDX

EM-61

Inspection (Cont’d)

CYLINDER BLOCK

SEM038F

SEM003F

SEM123C

CONNECTING ROD BEND AND TORSION

NHEM0027S04

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.

CYLINDER BLOCK DISTORTION AND WEAR

NHEM0027S05

I 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 the figure.

Distortion limit: 0.10 mm (0.0039 in)

I If out of specification, resurface it. The limit for cylinder block

resurfacing is determined by cylinder head resurfacing in engine.

Resurfacing limit: 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:

214.95 - 215.05 mm (8.4626 - 8.4665 in) Refer to SDS (EM-77).

I If necessary, replace cylinder block.

EM-62

CYLINDER BLOCK

Inspection (Cont’d)

SEM843E

SEM321AA

PISTON-TO-BORE CLEARANCE

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

Cylinder bore inner diameter

Grade No. Standard inner diameter Wear limit

No. 1 93.000 - 93.010 mm (3.6614 - 3.6618 in)

0.20 mm (0.0079 in)No. 2 93.011 - 93.020 mm (3.6618 - 3.6622 in)

No. 3 93.021 - 93.030 mm (3.6622 - 3.6626 in)

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

Out-of-round (X − Y):

Limit 0.015 mm (0.0006 in)

Taper (A −B−C):

Limit 0.015 mm (0.0006 in)

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

I If both cylinder block and piston are replaced with new

ones, select piston of the same grade number punched on cylinder block rear position. These numbers are punched in either Arabic or Roman numerals.

NHEM0027S06

SEM174F

SEM258C

3. Measure piston skirt diameter.

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

45.4 mm (1.787 in)

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

Piston-to-bore clearance “B”:

0.010 - 0.032 mm (0.0004 - 0.0013 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)

7. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted in final assembly.

IDX

EM-63

Inspection (Cont’d)

CYLINDER BLOCK

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 in diameter at a time.

9. Hone cylinders to obtain specified piston-to-bore clearance.

10. Measure finished cylinder bore for out-of-round and taper.

I Measurement should be done after cylinder bore cools

down.

SEM316A

CRANKSHAFT

NHEM0027S07

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):

Standard

0.002 mm (0.0001 in)

Taper (A − B):

Standard

0.002 mm (0.0001 in)

3. Measure crankshaft runout.

Runout (Total indicator reading):

Limit 0.10 mm (0.0039 in)

SEM346D

SEM175F

BEARING CLEARANCE

NHEM0027S08

I Use either of the following two methods, however, method “A”

gives more reliable results and is preferable.

Method A (Using bore gauge & micrometer)

Main bearing

NHEM0027S0801

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

EM-64

SEM845E

AEM033

CYLINDER BLOCK

Inspection (Cont’d)

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

Tighten all bolts in correct order.

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

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

5. Calculate main bearing clearance.

Main bearing clearance = A − Dm

Standard: 0.035 - 0.045 mm (0.0014 - 0.0018 in) (Actual clearance)

Limit: 0.065 mm (0.0026 in)

I If it exceeds the limit, replace bearing. I If clearance cannot be adjusted using any standard bearing

grade, grind crankshaft journal and use undersized bearing.

a. When grinding crankshaft journal, confirm that “L” dimension in

fillet roll is more than the specified limit.

“L”: 0.1 mm (0.004 in)

b. Refer to SDS for grinding crankshaft and available service

parts.

SEM964

SEM176F

6. If crankshaft or cylinder block is replaced with a new one, 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 Alphabet. Refer to SDS, EM-77. If measured diameter is out of grade punched, decide suitable grade using table in SDS.

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

the respective crankshaft. These numbers are punched in either Arabic or Alphabet. Refer to SDS, EM-80. If measured diameter is out of grade punched, decide suitable grade using table in SDS.

c. Select main bearing with suitable thickness according to the

following table. Refer to “SDS”, EM-81, for available main bearings.

IDX

SEM847E

EM-65

Inspection (Cont’d)

CYLINDER BLOCK

AEM027

AEM034

SEM280G

Connecting Rod Bearing (Big end)

NHEM0027S0802

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

2. Install connecting rod cap to connecting rod.

Tighten bolts to the specified torque.

3. Measure inner diameter “C” of connecting rod.

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

5. Calculate connecting rod bearing clearance.

Connecting rod bearing clearance=C−Dp

Standard: 0.034 - 0.059 mm (0.0013 - 0.0023 in) (Actual clearance)

Limit: 0.070 mm (0.0028 in)

6. If it exceeds the limit, replace bearing.

7. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearing. Refer to “BEARING CLEARANCE — Main bearing”, EM-64.

EM-66

CYLINDER BLOCK

Inspection (Cont’d)

8. If crankshaft is replaced with a new one, select connecting rod bearing according to the following table.

Connecting rod bearing grade number (Identification color):

These numbers are punched in either Arabic or Roman numerals.

SEM848E

EM142

SEM673E

SEM062A

SEM077G

Crankshaft pin journal grade

number

0 0 (Black) 1 1 (Brown) 2 2 (Green)

Method B (Using plastigage)

CAUTION:

I Do not turn crankshaft or connecting rod while plastigage

is being inserted.

I When bearing clearance exceeds the specified limit,

ensure that the proper bearing has been installed. If incorrect bearing clearance exists, use a thicker or undersized main bearing to ensure specified clearance.

Connecting rod bearing grade number

CONNECTING ROD BUSHING CLEARANCE (SMALL END)

1. Measure inner diameter “C” of bushing.

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: 0.030 mm (0.0012 in)

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

NHEM0027S09

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. After driving in small end bushing, ream the bushing. This is to ensure the clearance between connecting rod bushing and piston pin is the specified value.

Clearance between connecting rod bushing and piston pin: 0.005 - 0.017 mm (0.0002 - 0.0007 in)

DRIVE PLATE RUNOUT

Runout (Total indicator reading):

Less than 0.15 mm (0.0059 in)

CAUTION:

I The signal plate is built into the drive plate assembly. Be

careful not to damage the signal plate, especially the teeth.

I Check the drive plate and signal plate for deformation or

cracks.

I Keep any magnetized objects away from the signal plate.

NHEM0027S10

NHEM0027S11

IDX

EM-67

Inspection (Cont’d)

CYLINDER BLOCK

I Do not allow any magnetic materials to contact the signal

plate teeth.

SEM838F

SEM965E

Assembly

PISTON

NHEM0028

NHEM0028S01

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.

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 When replacing piston rings, these without punchmarks,

present, piston rings can be mounted with either side up.

I Align piston rings so that end gaps are positioned as

shown in the figure.

SEM160B

SEM175F

CRANKSHAFT

NHEM0028S02

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

I Confirm that correct main bearings are used. Refer to

“Inspection” of this section.

EM-68

SEM177F

SEM851E

SEM852E

CYLINDER BLOCK

Assembly (Cont’d)

2. Instructions for re-use of main bearing cap bolts.

I A plastic zone tightening method is used for tightening

main bearing cap bolts. Measure d1 and d2 as shown in the figure. d2: Select minimum diameter in the measuring area. If the difference between d1 and d2 exceeds the limit, replace the bolts with new ones.

Limit (d1 - d2): 0.11 mm (0.0043 in)

3. After installing crankshaft, main bearing cap, main bearing beam and bearing cap bolts, tighten bearing cap bolts in numerical order as shown.

I Tightening procedure

a) Tighten all bolts to 32 to 38 N·m (3.3 to 3.9 kg-m, 24 to 28

ft-lb).

b) Turn all bolts 90 to 95 degrees clockwise with angle

wrench.

I Prior to tightening bearing cap bolts, place bearing beam

in its proper position by shifting crankshaft in the axial direction.

I After securing bearing cap bolts, make sure crankshaft

turns smoothly by hand.

I Lubricate threads and seat surfaces of the bolts with new

engine oil.

4. Measure crankshaft end play.

Crankshaft end play:

Standard

0.10 - 0.25 mm (0.0039 - 0.0098 in)

Limit

0.30 mm (0.0118 in)

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

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

I Confirm that correct bearings are used.

SEM973F

SEM620

6. Install pistons with connecting rods.

a. Install them into corresponding cylinders with Tool.

I Be careful not to scratch cylinder wall with the connecting

rod.

I Arrange so that front mark on piston head faces toward

engine front.

EM-69

IDX

Assembly (Cont’d)

SEM956E

CYLINDER BLOCK

b. A plastic zone tightening method is used for tightening con-

necting rod bolts and nuts. Check the old bolts for deformation before re-using them.

I Ensure that the connecting rod nut can be screwed

smoothly as far as the bolt thread end.

I If this is not possible, use slide calipers to measure the

outside diameter of the narrowest thread part of the bolt at 16 mm (0.63 in) from the thread end. Replace the connecting rod bolt and nut, if under the limit.

Standard: 7.90 - 8.00 mm (0.3110 - 0.3150 in) Limit: 7.75 mm (0.3051 in)

c. Install connecting rod caps.

I Lubricate threads and seat surfaces with new engine oil.

Tighten connecting rod bearing cap nuts to the specified torque.

Connecting rod bearing nut:

(1) Tighten nuts to 19 to 21 N·m (1.9 to 2.1 kg-m, 14 to 15 ft-lb).

(2) Turn nuts 90 to 95 degrees clockwise with angle wrench.

SEM953E

SEM954E

SEM005G

7. 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.

8. Install rear oil seal retainer.

REPLACING PILOT CONVERTER

1. Remove pilot converter using tool or suitable tool.

2. Install pilot converter as shown.

NHEM0028S04

SEM537E

EM-70

SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications

Cylinder arrangement V-6 Displacement cm Bore and stroke mm (in) 93 x 73.3 (3.66 x 2.886) Valve arrangement DOHC Firing order 1-2-3-4-5-6

Number of piston rings

Number of main bearings 4 Compression ratio 10.0

(cu in) 2,988 (182.33)

Compression 2 Oil 1

Compression Pressure

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

Standard 1,275 (13.0, 185)

Compression pressure

Minimum 981 (10.0, 142) Differential limit between cylinders 98 (1.0, 14)

NHEM0029

NHEM0030

Cylinder number

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

Cylinder Head

Standard Limit

SEM713A

NHEM0031

Unit: mm (in)

SEM949E

IDX

EM-71

Valve

SERVICE DATA AND SPECIFICATIONS (SDS)

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 36.0 - 36.3 (1.417 - 1.429) Exhaust 31.2 - 31.5 (1.228 - 1.240) Intake 97.32 - 97.82 (3.8315 - 3.8512) Exhaust 94.85 - 95.35 (3.7342 - 3.7539) 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 0.95 - 1.25 (0.0374 - 0.0492) Exhaust 1.15 - 1.45 (0.0453 - 0.0571)

NHEM0032

NHEM0032S01

Unit: mm (in)

SEM188

VALVE CLEARANCE

Cold Hot* (reference data) Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016) Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.308 - 0.432 (0.012 - 0.017)

*: Approximately 80°C (176°F)

AVAILABLE SHIMS

Thickness mm (in) Identification mark

2.32 (0.0913) 232

2.33 (0.0917) 233

2.34 (0.0921) 234

2.35 (0.0925) 235

2.36 (0.0929) 236

2.37 (0.0933) 237

2.38 (0.0937) 238

2.39 (0.0941) 239

2.40 (0.0945) 240

2.41 (0.0949) 241

NHEM0032S02

Unit: mm (in)

NHEM0032S03

EM-72

Thickness mm (in) Identification mark

SERVICE DATA AND SPECIFICATIONS (SDS)

2.42 (0.0953) 242

2.43 (0.0957) 243

2.44 (0.0961) 244

2.45 (0.0965) 245

2.46 (0.0969) 246

2.47 (0.0972) 247

2.48 (0.0976) 248

2.49 (0.0980) 249

2.50 (0.0984) 250

2.51 (0.0988) 251

2.52 (0.0992) 252

2.53 (0.0996) 253

2.54 (0.1000) 254

2.55 (0.1004) 255

2.56 (0.1008) 256

2.57 (0.1012) 257

2.58 (0.1016) 258

2.59 (0.1020) 259

2.60 (0.1024) 260

2.61 (0.1028) 261

2.62 (0.1031) 262

2.63 (0.1035) 263

2.64 (0.1039) 264

2.65 (0.1043) 265

2.66 (0.1047) 266

2.67 (0.1051) 267

2.68 (0.1055) 268

2.69 (0.1059) 269

2.70 (0.1063) 270

2.71 (0.1067) 271

2.72 (0.1071) 272

2.73 (0.1075) 273

2.74 (0.1079) 274

2.75 (0.1083) 275

2.76 (0.1087) 276

2.77 (0.1091) 277

2.78 (0.1094) 278

2.79 (0.1098) 279

2.80 (0.1102) 280

2.81 (0.1106) 281

Valve (Cont’d)

IDX

EM-73

Valve (Cont’d)

SERVICE DATA AND SPECIFICATIONS (SDS)

Thickness mm (in) Identification mark

2.82 (0.1110) 282

2.83 (0.1114) 283

2.84 (0.1118) 284

2.85 (0.1122) 285

2.86 (0.1126) 286

2.87 (0.1130) 287

2.88 (0.1134) 288

2.89 (0.1138) 289

2.90 (0.1142) 290

2.91 (0.1146) 291

2.92 (0.1150) 292

2.93 (0.1154) 293

2.94 (0.1157) 294

2.95 (0.1161) 295

VALVE SPRING

Free height mm (in) 47.10 (1.8543)

Standard 202 (20.6, 45.4) at 37.0 (1.457)

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

Limit 436 (44.5, 98.1) at 28.2 (1.110)

Out-of-square mm (in) Less than 2.0 (0.079)

VALVE LIFTER

Valve lifter outer diameter 34.960 - 34.975 (1.3764 - 1.3770) Lifter guide inner diameter 35.000 - 35.021 (1.3780 - 1.3788) Clearance between lifter and lifter guide 0.025 - 0.061 (0.0010 - 0.0024)

SEM966E

NHEM0032S04

NHEM0032S05

Unit: mm (in)

EM-74

SERVICE DATA AND SPECIFICATIONS (SDS)

Valve (Cont’d)

VALVE GUIDE

Standard Service Valve guide Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029) Valve guide Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369) Cylinder head valve guide hole diameter 9.960 - 9.978 (0.3921 - 0.3928) 10.185 - 10.196 (0.4010 - 0.4014) Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)

Standard Max. tolerance

Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031)

Stem to guide clearance

Exhaust 0.040 - 0.073 (0.0016 - 0.0029) 0.1 (0.004) Intake — 0.24 (0.0094)

Valve deflection limit

Exhaust — 0.28 (0.0110)

Projection length “L” 12.6 - 12.8 (0.496 - 0.504)

NHEM0032S06

Unit: mm (in)

SEM950E

Valve Seat

NHEM0033

Unit: mm (in)

IDX

EM-75

SEM021EA

SERVICE DATA AND SPECIFICATIONS (SDS)

Valve Seat (Cont’d)

Standard Service

Intake 37.000 - 37.016 (1.4567 - 1.4573) 37.500 - 37.516 (1.4764 - 1.4770)

Cylinder head seat recess diameter (D)

Exhaust 32.200 - 32.216 (1.2677 - 1.2683) 32.700 - 32.716 (1.2874 - 1.2880) Intake 0.081 - 0.113 (0.0032 - 0.0044)

Valve seat interference fit

Exhaust 0.064 - 0.096 (0.0025 - 0.0038) Intake 37.097 - 37.113 (1.4605 - 1.4611) 37.597 - 37.613 (1.4802 - 1.4808)

Valve seat outer diameter (d)

Exhaust 32.280 - 32.296 (1.2709 - 1.2715) 32.780 - 32.796 (1.2905 - 1.2912) Intake 5.9 - 6.0 (0.232 - 0.236) 5.05 - 5.15 (0.1988 - 0.2028)

Height (h)

Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.95 - 5.05 (0.1949 - 0.1988)

Depth (H) 5.9 - 6.1 (0.232 - 0.240)

Intake 41.07 - 41.67 (1.6169 - 1.6405)

Depth (L)

Exhaust 41.00 - 41.60 (1.6142 - 1.6378)

SEM621F

Camshaft and Camshaft Bearing

Standard Limit

Camshaft journal to bearing clearance

Inner diameter of camshaft bearing

Outer diameter of camshaft journal

Camshaft runout [TIR*] Less than 0.02 (0.0008) 0.05 (0.0020) Camshaft sprocket runout [TIR*] Less than 0.15 (0.0059) — Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) 0.24 (0.0094)

*: Total indicator reading

0.045 - 0.086 (0.0018 - 0.0034)

0.035 - 0.076 (0.0014 - 0.0030)

26.000 - 26.021 (1.0236 - 1.0244)

23.500 - 23.521 (0.9252 - 0.9260)

25.935 - 25.955 (1.0211 - 1.0218)

23.445 - 23.465 (0.9230 - 0.9238)

No. 1

No. 2, 3, 4

No. 1

No. 2, 3, 4

No. 1

No. 2, 3, 4

0.15 (0.0059)

—

NHEM0034

Unit: mm (in)

EM-76

SERVICE DATA AND SPECIFICATIONS (SDS)

Camshaft and Camshaft Bearing (Cont’d)

EM671

Cam height “A”

Intake 43.940 - 44.130 (1.7299 - 1.7374) Exhaust 44.465 - 44.655 (1.7506 - 1.7581)

Wear limit of cam height 0.2 (0.008)

Valve timing

abcdef

232 224 3 41 3 49

Cylinder Block

Unit: degree

NHEM0035

Unit: mm (in)

Surface flatness

Cylinder bore Inner diameter

Out-of-round (X − Y) Less than 0.015 (0.0006) Taper (A −B−C) Less than 0.015 (0.0006)

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

Grade No. 1 93.000 - 93.010 (3.6614 - 3.6618)

Standard

Wear limit 0.20 (0.0079)

Grade No. 2 93.011 - 93.020 (3.6618 - 3.6622) Grade No. 3 93.021 - 93.030 (3.6622 - 3.6626)

EM-77

SEM022EA

IDX

Cylinder Block (Cont’d)

SERVICE DATA AND SPECIFICATIONS (SDS)

Grade No. A Grade No. B Grade No. C Grade No. D Grade No. E Grade No. F Grade No. G Grade No. H Grade No. J Grade No. K

Main journal inner diameter grade (Without bearing)

Difference in inner diameter between cylinders

Grade No. L Grade No. M Grade No. N Grade No. P Grade No. R Grade No. S Grade No. T Grade No. U Grade No. V Grade No. W Grade No. X Grade No. Y Grade No. 4 Grade No. 7

Standard Less than 0.03 (0.0012)

AVAILABLE PISTON

63.993 - 63.994 (2.5194 - 2.5194)

63.994 - 63.995 (2.5194 - 2.5195)

63.995 - 63.996 (2.5195 - 2.5195)

63.996 - 63.997 (2.5195 - 2.5196)

63.997 - 63.998 (2.5196 - 2.5196)

63.998 - 63.999 (2.5196 - 2.5196)

63.999 - 64.000 (2.5196 - 2.5197)

64.000 - 64.001 (2.5197 - 2.5197)

64.001 - 64.002 (2.5197 - 2.5198)

64.002 - 64.003 (2.5198 - 2.5198)

64.003 - 64.004 (2.5198 - 2.5198)

64.004 - 64.005 (2.5198 - 2.5199)

64.005 - 64.006 (2.5199 - 2.5199)

64.006 - 64.007 (2.5199 - 2.5200)

64.007 - 64.008 (2.5200 - 2.5200)

64.008 - 64.009 (2.5200 - 2.5200)

64.009 - 64.010 (2.5200 - 2.5201)

64.010 - 64.011 (2.5201 - 2.5201)

64.011 - 64.012 (2.5201 - 2.5202)

64.012 - 64.013 (2.5202 - 2.5202)

64.013 - 64.014 (2.5202 - 2.5202)

64.014 - 64.015 (2.5202 - 2.5203)

64.015 - 64.016 (2.5203 - 2.5203)

64.016 - 64.017 (2.5203 - 2.5203)

Piston, Piston Ring and Piston Pin

NHEM0036

NHEM0036S01

Unit: mm (in)

Grade No. 1 92.979 - 92.988 (3.6606 - 3.6609) Grade No. 2 92.988 - 93.000 (3.6609 - 3.6614)

Piston skirt diameter “A” Standard

Grade No. 3 93.000 - 93.009 (3.6614 - 3.6618)

0.20 (0.0079) oversize (Service) 93.179 - 93.209 (3.6685 - 3.6696)

“a” dimension 45.4 (1.787)

Grade No. 0 21.993 - 21.999 (0.8659 - 0.8661)

Piston pin hole diameter

Grade No. 1 21.999 - 22.005 (0.8661 - 0.8663)

Piston clearance to cylinder block 0.010 - 0.032 (0.0004 - 0.0013)

SEM882E

EM-78

SERVICE DATA AND SPECIFICATIONS (SDS)

Piston, Piston Ring and Piston Pin (Cont’d)

PISTON RING

Standard Limit

Top 0.040 - 0.080 (0.0016 - 0.0031) 0.11 (0.0043)

Side clearance

End gap

2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.1 (0.004) Oil ring 0.015 - 0.185 (0.0006 - 0.0073) — Top 0.22 - 0.32 (0.0087 - 0.0126) 0.55 (0.0217) 2nd 0.32 - 0.47 (0.0126 - 0.0185) 0.85 (0.0335) Oil (rail ring) 0.20 - 0.60 (0.0079 - 0.0236) 0.95 (0.0374)

PISTON PIN

Piston pin outer diameter

Interference fit of piston pin to piston 0.002 - 0.006 (0.0001 - 0.0002)

Piston pin to connecting rod bushing clearance

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

Grade No. 0 21.989 - 21.995 (0.8657 - 0.8659) Grade No. 1 21.995 - 22.001 (0.8659 - 0.8662)

Standard 0.005 - 0.017 (0.0002 - 0.0007) Limit 0.030 (0.0012)

Connecting Rod

Center distance 147.60 - 147.70 (5.8110 - 5.8149) 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 23.980 - 24.000 (0.9441 - 0.9449)

Piston pin bushing inner diameter*

Connecting rod big end inner diameter 48.000 - 48.013 (1.8898 - 1.8903)

Side clearance

Grade No. 0 22.000 - 22.006 (0.8661 - 0.8664) Grade No. 1 22.006 - 22.012 (0.8664 - 0.8666)

Standard 0.20 - 0.35 (0.0079 - 0.0138) Limit 0.40 (0.0157)

=NHEM0036S02

Unit: mm (in)

NHEM0036S03

Unit: mm (in)

NHEM0037

Unit: mm (in)

*: After installing in connecting rod

IDX

EM-79

Crankshaft

SERVICE DATA AND SPECIFICATIONS (SDS)

Crankshaft

Grade No. A Grade No. B Grade No. C Grade No. D Grade No. E Grade No. F Grade No. G Grade No. H Grade No. J Grade No. K Grade No. L

Main journal dia. “Dm” grade

Pin journal dia. “Dp”

Center distance “r” 36.61 - 36.69 (1.4413 - 1.4445) Out-of-round (X − Y) Standard Less than 0.002 (0.0001) Taper (A − B) Standard Less than 0.002 (0.0001) Runout [TIR*] Limit Less than 0.10 (0.0039)

Free end play

Grade No. M Grade No. N Grade No. P Grade No. R Grade No. S Grade No. T Grade No. U Grade No. V Grade No. W Grade No. X Grade No. Y Grade No. 4 Grade No. 7

Grade No. 0 44.968 - 44.974 (1.7704 - 1.7706) Grade No. 1 44.962 - 44.968 (1.7702 - 1.7704) Grade No. 2 44.956 - 44.962 (1.7699 - 1.7702)

Standard 0.10 - 0.25 (0.0039 - 0.0098) Limit 0.30 (0.0118)

59.975 - 59.974 (2.3612 - 2.3612)

59.974 - 59.973 (2.3612 - 2.3611)

59.973 - 59.972 (2.3611 - 2.3611)

59.972 - 59.971 (2.3611 - 2.3611)

59.971 - 59.970 (2.3611 - 2.3610)

59.970 - 59.969 (2.3610 - 2.3610)

59.969 - 59.968 (2.3610 - 2.3609)

59.968 - 59.967 (2.3609 - 2.3609)

59.967 - 59.966 (2.3609 - 2.3609)

59.966 - 59.965 (2.3609 - 2.3608)

59.965 - 59.964 (2.3608 - 2.3608)

59.964 - 59.963 (2.3608 - 2.3607)

59.963 - 59.962 (2.3607 - 2.3607)

59.962 - 59.961 (2.3607 - 2.3607)

59.961 - 59.960 (2.3607 - 2.3606)

59.960 - 59.959 (2.3606 - 2.3606)

59.959 - 59.958 (2.3606 - 2.3605)

59.958 - 59.957 (2.3605 - 2.3605)

59.957 - 59.956 (2.3605 - 2.3605)

59.956 - 59.955 (2.3605 - 2.3604)

59.955 - 59.954 (2.3604 - 2.3604)

59.954 - 59.953 (2.3604 - 2.3603)

59.953 - 59.952 (2.3603 - 2.3603)

59.952 - 59.951 (2.3603 - 2.3603)

NHEM0038

Unit: mm (in)

*: Total indicator reading

SEM645

EM-80

EM715

SERVICE DATA AND SPECIFICATIONS (SDS)

Available Main Bearing

Grade number Thickness “T” mm (in)

0 2.000 - 2.003 (0.0787 - 0.0789) 1 2.003 - 2.006 (0.0789 - 0.0790) Brown 2 2.006 - 2.009 (0.0790 - 0.0791) Green 3 2.009 - 2.012 (0.0791 - 0.0792) Yellow 4 2.012 - 2.015 (0.0792 - 0.0793) Blue 5 2.015 - 2.018 (0.0793 - 0.0794) Pink 6 2.018 - 2.021 (0.0794 - 0.0796) Purple 7 2.021 - 2.024 (0.0796 - 0.0797) White

UPP 2.003 - 2.006 (0.0789 - 0.0790)

LWR 2.000 - 2.003 (0.0787 - 0.0789) UPR 2.006 - 2.009 (0.0790 - 0.0791)

LWR 2.003 - 2.006 (0.0789 - 0.0790)

UPR 2.009 - 2.012 (0.0791 - 0.0792)

LWR 2.006 - 2.009 (0.0790 - 0.0791) UPR 2.012 - 2.015 (0.0792 - 0.0793)

LWR 2.009 - 2.012 (0.0791 - 0.0792) UPR 2.015 - 2.018 (0.0793 - 0.0794)

LWR 2.012 - 2.015 (0.0792 - 0.0793) UPR 2.018 - 2.021 (0.0794 - 0.0796)

LWR 2.015 - 2.018 (0.0793 - 0.0794) UPR 2.021 - 2.024 (0.0796 - 0.0797)

LWR 2.018 - 2.021 (0.0794 - 0.0796)

Available Main Bearing

Width “W”

mm (in)

19.9 - 20.1

(0.783 - 0.791)

Identification color

(UPR/LWR)

Brown/Black

Green/Brown

Yellow/Green

Blue/Yellow

Purple/Pink

White/Purple

Black

Pink/Blue

SEM175F

NHEM0039

Remarks

Grade is the same for upper and lower bearings.

Grade is different for upper and lower bearings.

UNDERSIZE

Thickness Main journal diameter “Dm”

0.25 (0.0098) 2.132 - 2.140 (0.0839 - 0.0843)

EM-81

NHEM0039S01

Unit: mm (in)

Grind so that bearing clearance is the specified value.

IDX

SERVICE DATA AND SPECIFICATIONS (SDS)

Available Connecting Rod Bearing

CONNECTING ROD BEARING

Grade number Thickness “T” mm (in) Identification color (mark)

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

UNDERSIZE

Thickness Crank pin journal diameter “Dp”

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

Grind so that bearing clearance is the specified value.

Miscellaneous Components

Drive plate runout [TIR]* Less than 0.15 (0.0059)

*: Total indicator reading

BEARING CLEARANCE

Main bearing clearance

Connecting rod bearing clearance

Standard 0.035 - 0.045 (0.0014 - 0.0018)* Limit 0.065 (0.0026) Standard 0.034 - 0.059 (0.0013 - 0.0023)* Limit 0.070 (0.0028)

NHEM0040

NHEM0040S01

NHEM0040S02

Unit: mm (in)

NHEM0041

Unit: mm (in)

NHEM0041S01

Unit: mm (in)

*: Actual clearance

EM-82

Infiniti I30 A33 (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

OUTER COMPONENT PARTS

Removal and Installation

MEASUREMENT OF COMPRESSION PRESSURE

OIL PAN

Components

Removal

Installation

TIMING CHAIN

Components

POSITION FOR APPLYING LIQUID GASKET

Removal

Inspection

Installation

OIL SEAL

Replacement

VALVE OIL SEAL

OIL SEAL INSTALLATION DIRECTION

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

VALVE LIFTER

Assembly

Installation

Valve Clearance

CHECKING

ADJUSTING

Removal and Installation

ENGINE ASSEMBLY

REMOVAL

INSTALLATION

CYLINDER BLOCK

Components

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)

DRIVE PLATE RUNOUT

Assembly

PISTON

CRANKSHAFT

REPLACING PILOT CONVERTER

SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications