Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Micra 2003-2006 Approved 05k12e EM
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ENGINE MECHANICAL
B ENGINE
A
SECTION
ENGINE MECHANICAL
EM EM
C
D
E
CONTENTS
CR INTAKE MANIFOLD ................................................ 22 . F
Removal and Installation ....................................... 22 .
PRECAUTIONS ......................................................... 7 . REMOVAL .......................................................... 22 .
Precautions for Draining Coolant ............................ 7 . INSTALLATION .................................................. 23 . G
Precautions for Disconnecting Fuel Piping ............. 7 . EXHAUST MANIFOLD AND THREE WAY CATA-
Precautions for Removal and Disassembly ............ 7 . LYST ......................................................................... 24
.
Precautions for Inspections, Repairs, and Replace- Removal and Installation ....................................... 24 .
ment ........................................................................ 7
. H
REMOVAL .......................................................... 24 .
Precautions for Assembling and Installing .............. 7 . INSPECTION AFTER REMOVAL ...................... 25 .
Parts Requiring Angle Tightening ............................ 7 . INSTALLATION .................................................. 25 .
Precautions for Liquid Gasket ................................. 8 . OIL PAN AND OIL STRAINER ................................ 26 . I
REMOVAL OF LIQUID GASKET SEALING ......... 8 . Removal and Installation ....................................... 26 .
LIQUID GASKET APPLICATION PROCEDURE 8 ..... REMOVAL .......................................................... 26 .
PREPARATION .......................................................... 9 . INSTALLATION .................................................. 27 . J
Special Service Tools .............................................. 9 . INSPECTION AFTER INSTALLATION ............... 28 .
Commercial Service Tools ......................................11 . IGNITION COIL ........................................................ 29 .
NOISE, VIBRATION AND HARSHNESS (NVH) Removal and Installation ....................................... 29 .
TROUBLESHOOTING ............................................. 12 . K
REMOVAL .......................................................... 29 .
NVH Troubleshooting --Engine Noise .................. 12 . INSTALLATION .................................................. 29 .
Use the Chart Below to Help You Find the Cause SPARK PLUG (PLATINUM-TIPPED TYPE) ............ 30 .
of the Symptom. .................................................... 13 . Removal and Installation ....................................... 30 . L
DRIVE BELTS .......................................................... 14. REMOVAL .......................................................... 30 .
Checking drive Belts ............................................. 14 . INSPECTION AFTER REMOVAL ...................... 30 .
Tension Adjustment ............................................... 14 . INSTALLATION .................................................. 31 . M
ALTERNATOR AND A/C COMPRESSOR BELT FUEL INJECTOR AND FUEL TUBE ....................... 32 .
(WITH A/C MODELS) ........................................ 15 . Removal and Installation ....................................... 32 .
ALTERNATOR BELT (WITHOUT A/C MODELS).. 15 . REMOVAL .......................................................... 32 .
WATER PUMP BELT ......................................... 16 . INSTALLATION .................................................. 33 .
Removal and Installation ....................................... 16 . INSPECTION AFTER INSTALLATION ............... 34 .
REMOVAL .......................................................... 16 . ROCKER COVER .................................................... 35 .
INSTALLATION .................................................. 16 . Removal and Installation ....................................... 35 .
Removal and Installation of Drive Belt Idler Pulley 16 ... REMOVAL .......................................................... 35 .
REMOVAL .......................................................... 17 . INSTALLATION .................................................. 36 .
INSTALLATION .................................................. 17 . CAMSHAFT ............................................................. 38 .
AIR CLEANER AND AIR DUCT .............................. 18 . Removal and Installation ....................................... 38 .
Removal and Installation ....................................... 18 . REMOVAL .......................................................... 38 .
REMOVAL .......................................................... 18 . INSTALLATION .................................................. 41 .
INSTALLATION .................................................. 19 . INSPECTION AFTER REMOVAL ...................... 44 .
Changing Air Cleaner Filter ................................... 21 .
REMOVAL .......................................................... 21 .
INSTALLATION .................................................. 21 .
EM-1
INSPECTION AFTER INSTALLATION ............... 47 . ING ......................................................................89
.
Valve Clearance ..................................................... 47
. PISTON TO CYLINDER BORE CLEARANCE ...89
INSPECTION ...................................................... 47
. OUTER DIAMETER OF CRANKSHAFT JOUR-
ADJUSTMENT ................................................... 49 . NAL .....................................................................91
.
TIMING CHAIN ......................................................... 50
. OUTER DIAMETER OF CRANKSHAFT PIN .....91 .
Removal and Installation ....................................... 50 . OUT-OF-ROUND AND TEPER OF CRANK-
REMOVAL .......................................................... 51
. SHAFT ................................................................91
.
INSPECTION AFTER REMOVAL ....................... 53 . CRANKSHAFT RUNOUT ...................................91 .
INSTALLATION ................................................... 53. OIL CLEARANCE OF CONNECTING ROD
INSPECTION AFTER INSTALLATION ............... 56 . BEARING ............................................................92 .
OIL SEAL ................................................................. 57
. OIL CLEARANCE OF MAIN BEARING ..............92 .
Removal and Installation of Valve Oil Seal ............ 57 . CRUSH HEIGHT OF MAIN BEARING OR CON-
REMOVAL .......................................................... 57
. NECTING ROD BEARING ..................................93 .
INSTALLATION ................................................... 57. FLYWHEEL RUNOUT ........................................93 .
Removal and Installation of Front Oil Seal ............ 57 . SERVICE DATA AND SPECIFICATIONS (SDS) .....94 .
REMOVAL .......................................................... 57
. Standard and Limit .................................................94 .
INSTALLATION ................................................... 58. GENERAL SPECIFICATIONS ............................94 .
Removal and Installation of Rear Oil Seal ............. 58 . INTAKE MANIFOLD AND EXHAUST MANI-
REMOVAL .......................................................... 58
. FOLD ..................................................................94
.
INSTALLATION ................................................... 58. DRIVE BELTS .....................................................95 .
CYLINDER HEAD .................................................... 60 . SPARK PLUG .....................................................95 .
On Vehicle Inspection ............................................ 60. CYLINDER HEAD ...............................................95 .
COMPRESSION PRESSURE INSPECTION ..... 60 . VALVE .................................................................96
.
Removal and Installation ....................................... 61 . CAMSHAFT AND CAMSHAFT BEARING ..........99 .
REMOVAL .......................................................... 61
. CYLINDER BLOCK .............................................99 .
INSPECTION AFTER REMOVAL ....................... 62 . PISTON, PISTON RING AND PISTON PIN ..... 101 .
INSTALLATION ................................................... 62. CONNECTING ROD ......................................... 101 .
Disassembly and Assembly ................................... 63 . CRANKSHAFT .................................................. 102 .
DISASSEMBLY .................................................. 64 . MAIN BEARING ................................................ 102 .
ASSEMBLY ........................................................ 64
. CONNECTING ROD BEARING ........................ 103 .
INSPECTION AFTER DISASSEMBLY ............... 65 . MISCELLANEOUS COMPONENTS ................. 103 .
ENGINE ASSEMBLY ............................................... 70 . Tightening Torque ................................................ 104 .
Removal and Installation ....................................... 70 .
REMOVAL .......................................................... 71
. HR
INSTALLATION ................................................... 73.
INSPECTION AFTER INSTALLATION ............... 73 . PRECAUTIONS ...................................................... 106 .
CYLINDER BLOCK .................................................. 74 . Precautionsfor ProcedureswithoutCowl TopCover 106 .
Disassembly and Assembly ................................... 74 . Precautions for Draining Engine Coolant ............. 106 .
DISASSEMBLY .................................................. 75 . Precautions for Disconnecting Fuel Piping .......... 106 .
ASSEMBLY ........................................................ 77
. Precautions for Removal and Disassembly ......... 106 .
How to Select Piston and Bearing ......................... 83 . Precautions for Inspection, Repair and Replace-
DESCRIPTION ................................................... 83 . ment ..................................................................... 106
.
HOW TO SELECT PISTON ................................ 83 . Precautions for Assembly and Installation ........... 106 .
HOW TO SELECT MAIN BEARING ................... 84 . Parts Requiring Angle Tightening ........................ 106 .
Inspection After Disassembly ................................ 85 . Precautions For Liquid Gasket ............................. 107 .
CRANKSHAFT SIDE CLEARANCE ................... 85 . REMOVAL OF LIQUID GASKET ...................... 107 .
CONNECTING ROD SIDE CLEARANCE .......... 86 . LIQUID GASKET APPLICATION PROCEDURE.107
PISTON AND PISTON PIN CLEARANCE ......... 86 . PREPARATION ...................................................... 109 .
PISTON RING SIDE CLEARANCE .................... 86 . Special Service Tools ........................................... 109 .
PISTON RING END GAP ................................... 87 . Commercial Service Tools ................................... 111 .
CONNECTING ROD BEND AND TORSION ...... 87 . NOISE, VIBRATION AND HARSHNESS (NVH)
CONNECTING ROD BEARING HOUSING TROUBLESHOOTING ........................................... 113 .
DIAMETER (BIG END) ....................................... 88 . NVH Troubleshooting -- Engine Noise ................ 113 .
CONNECTING ROD BUSHING OIL CLEAR- Use the Chart Below to Help You Find the Cause
ANCE DIAMETER (SMALL END) ...................... 88 . of the Symptom. ................................................... 114 .
CYLINDER BLOCK DISTORTION ..................... 89 . DRIVE BELTS ......................................................... 115 .
INNER DIAMETER OF MAIN BEARING HOUS- Checking Drive Belts ............................................ 115 .
Tension Adjustment .............................................. 115 .
Removal and Installation ...................................... 116 .
EM-2
REMOVAL .........................................................116
. TIMING CHAIN ....................................................... 143
.
INSTALLATION .................................................117. Components ........................................................ 143
. A
Removal and Installation of Drive Belt Idler Pulley ..117 Removal and Installation ..................................... 144 .
REMOVAL .........................................................117
. REMOVAL ........................................................ 144
.
INSTALLATION .................................................118. INSPECTION AFTER REMOVAL .................... 147 . EM
AIR CLEANER AND AIR DUCT .............................119 . INSTALLATION ................................................ 147 .
Components .........................................................119
. INSPECTION AFTER INSTALLATION ............. 151 .
Removal and Installation ......................................119. CAMSHAFT ........................................................... 152
.
REMOVAL .........................................................119
. Components ........................................................ 152
. C
INSTALLATION ................................................ 120. Removal and Installation ..................................... 152 .
Changing Air Cleaner Filter ................................. 120 . REMOVAL ........................................................ 152
.
REMOVAL ........................................................ 120
. INSPECTION AFTER REMOVAL .................... 158 . D
INSPECTION AFTER REMOVAL .................... 120 . INSTALLATION ................................................ 162 .
INSTALLATION ................................................ 120. INSPECTION AFTER INSTALLATION ............. 166 .
INTAKE MANIFOLD .............................................. 121 . Valve Clearance .................................................. 167
. E
Components ........................................................ 121
. INSPECTION ................................................... 167 .
Removal and Installation ..................................... 122. ADJUSTMENT ................................................. 169 .
REMOVAL ........................................................ 122
. OIL SEAL ............................................................... 171
.
INSTALLATION ................................................ 123. Removal and Installation of Valve Oil Seal .......... 171 . F
EXHAUST MANIFOLD .......................................... 125 . REMOVAL ........................................................ 171
.
Components ........................................................ 125
. INSTALLATION ................................................ 171 .
Removal and Installation ..................................... 125. Removal and Installation of Front Oil Seal .......... 172 . G
REMOVAL ........................................................ 125
. REMOVAL ........................................................ 172
.
INSPECTION AFTER REMOVAL .................... 126 . INSTALLATION ................................................ 172 .
INSTALLATION ................................................ 126. Removal and Installation of Rear Oil Seal ........... 173 . H
OIL PAN AND OIL STRAINER .............................. 128 . REMOVAL ........................................................ 173
.
Components ........................................................ 128
. INSTALLATION ................................................ 173 .
Removal and Installation ..................................... 128. CYLINDER HEAD .................................................. 174 .
I
REMOVAL ........................................................ 128
. On-Vehicle Service .............................................. 174.
INSTALLATION ................................................ 129. CHECKING COMPRESSION PRESSURE ...... 174 .
INSPECTION AFTER INSTALLATION ............ 132 . Components ........................................................ 175
.
IGNITION COIL ...................................................... 133
. Removal and Installation ..................................... 175 . J
Components ........................................................ 133
. REMOVAL ........................................................ 175
.
Removal and Installation ..................................... 133. INSPECTION AFTER REMOVAL .................... 176 .
REMOVAL ........................................................ 133
. INSTALLATION ................................................ 177 . K
INSTALLATION ................................................ 133. INSPECTION AFTER INSTALLATION ............. 177 .
SPARK PLUG (PLATINUM-TIPPED TYPE) .......... 134 . Components ........................................................ 179
.
Components ........................................................ 134
. Disassembly and Assembly ................................. 179 . L
Removal and Installation ..................................... 134. DISASSEMBLY ................................................ 179 .
REMOVAL ........................................................ 134
. ASSEMBLY ...................................................... 180.
INSPECTION AFTER REMOVAL .................... 134 . Inspection After Disassembly .............................. 181 .
INSTALLATION ................................................ 135. VALVE DIMENSIONS ....................................... 181 . M
FUEL INJECTOR AND FUEL TUBE ..................... 136 . VALVE GUIDE CLEARANCE ........................... 181 .
Components ........................................................ 136
. VALVE GUIDE REPLACEMENT ...................... 181 .
Removal and Installation ..................................... 136. VALVE SEAT CONTACT .................................. 183 .
REMOVAL ........................................................ 136
. VALVE SEAT REPLACEMENT ........................ 183 .
INSTALLATION ................................................ 138. VALVE SPRING SQUARENESS ...................... 184 .
INSPECTION AFTER INSTALLATION ............ 140 . VALVE SPRING DIMENSIONS AND VALVE
ROCKER COVER .................................................. 141 . SPRING PRESSURE LOAD ............................ 184 .
Components ........................................................ 141
. ENGINE ASSEMBLY ............................................. 185 .
Removal and Installation ..................................... 141. Components ........................................................ 185
.
REMOVAL ........................................................ 141
. Removal and Installation ..................................... 185 .
INSTALLATION ................................................ 142. REMOVAL ........................................................ 186
.
INSTALLATION ................................................ 188 .
INSPECTION AFTER INSTALLATION ............. 188 .
CYLINDER BLOCK ............................................... 190 .
Components ........................................................ 190
.
Disassembly and Assembly ................................. 191 .
DISASSEMBLY ................................................ 191 .
EM-3
ASSEMBLY ...................................................... 194 . Precautions for Assembly and Installation ........... 227 .
How to Select Piston and Bearing ....................... 200 . Parts Requiring Angular Tightening ..................... 227 .
DESCRIPTION ................................................. 200 . Precautions For Liquid Gasket ............................. 228 .
HOW TO SELECT CONNECTING ROD BEAR- REMOVAL OF LIQUID GASKET ...................... 228 .
ING ................................................................... 200
. LIQUID GASKET APPLICATION PROCEDURE.228
HOW TO SELECT MAIN BEARING ................. 203 . Cleanliness Instructions Which Must Be Followed
Inspection After Disassembly .............................. 206 . When Working On The High Pressure Direct Injec-
CRANKSHAFT END PLAY ............................... 206 . tion System .......................................................... 228
.
CONNECTING ROD SIDE CLEARANCE ........ 206 . RISKS RELATING TO CONTAMINATION ........ 228 .
PISTON TO PISTON PIN OIL CLEARANCE ... 206 . The Sources Of Contamination ............................ 229 .
PISTON RING SIDE CLEARANCE .................. 207 . Precautions To Be Followed Before Any Work Is
PISTON RING END GAP ................................. 207 . Carried Out On The Injection System .................. 229 .
CONNECTING ROD BEND AND TORSION .... 208 . Cleaning Precautions To Be Followed Before Car-
CONNECTING ROD BIG END DIAMETER ..... 208 . rying Out Any Work On The Fuel System ............ 229 .
CONNECTING ROD BUSHING OIL CLEAR- Precautions To Be Followed During The Operation.229
ANCE ................................................................ 208
. Instructions For Fitting The Plugs ........................ 231 .
CYLINDER BLOCK DISTORTION ................... 209 . PREPARATION ...................................................... 233 .
MAIN BEARING HOUSING INNER DIAMETER 209 . Special Service Tools ........................................... 233.
PISTON TO CYLINDER BORE CLEARANCE . 210 Commercial Service Tools ................................... 236 .
CRANKSHAFT MAIN JOURNAL DIAMETER .. 211 . IDENTIFICATION INFORMATION ......................... 238 .
CRANKSHAFT PIN JOURNAL DIAMETER ..... 211 . Engine Identification ............................................. 238
.
OUT-OF-ROUND AND TAPER OF CRANK- NOISE, VIBRATION AND HARSHNESS (NVH)
SHAFT .............................................................. 211
. TROUBLESHOOTING ........................................... 239 .
CRANKSHAFT RUNOUT ................................. 211 . NVH Troubleshooting --Engine Noise ................. 239 .
CONNECTING ROD BEARING OIL CLEAR- Use the Chart Below to Help You Find the Cause
ANCE ................................................................ 211
. of the Symptom. ................................................... 240
.
MAIN BEARING OIL CLEARANCE .................. 212 . ENGINE ROOM COVER ........................................ 241 .
MAIN BEARING CRUSH HEIGHT ................... 213 . Removal and Installation ...................................... 241 .
CONNECTING ROD BEARING CRUSH REMOVAL ......................................................... 243
.
HEIGHT ............................................................ 213
. INSTALLATION ................................................. 243.
MAIN BEARING CAP BOLT OUTER DIAMETER 213 . DRIVE BELTS ......................................................... 244
.
CONNECTING ROD BOLT OUTER DIAMETER 214 . Checking Drive Belts ............................................ 244.
FLYWHEEL DEFLECTION ............................... 214 . Tension Adjustment .............................................. 244.
SERVICE DATA AND SPECIFICATIONS (SDS) ... 215 . MODELS WITH A/C COMPRESSOR ............... 244 .
Standard and Limit ............................................... 215 . MODELS WITHOUT A/C COMPRESSOR ....... 244 .
GENERAL SPECIFICATIONS .......................... 215 . Removal and Installation ...................................... 245 .
DRIVE BELT ..................................................... 215 . REMOVAL ......................................................... 245
.
EXHAUST MANIFOLD ..................................... 215 . INSTALLATION ................................................. 245.
SPARK PLUG (PLATINUM-TIPPED TYPE) ..... 215 . AIR CLEANER AND AIR DUCT ............................247 .
CYLINDER HEAD ............................................ 215 . Removal and Installation (For Euro3 48kW/60kW).247
VALVE ............................................................... 216
. REMOVAL ......................................................... 247
.
CAMSHAFT AND CAMSHAFT BEARING ....... 220 . INSTALLATION ................................................. 247.
CYLINDER BLOCK .......................................... 220 . Removal and Installation (For Euro4 50kW/63kW).248
PISTON, PISTON RING AND PISTON PIN ..... 221 . REMOVAL ......................................................... 248
.
CONNECTING ROD ........................................ 222 . INSTALLATION ................................................. 248.
CRANKSHAFT ................................................. 222 . Changing Air Cleaner Filter .................................. 249 .
MAIN BEARING ............................................... 224 . REMOVAL ......................................................... 249
.
CONNECTING ROD BEARING ....................... 224 . INSTALLATION ................................................. 249.
CHARGE AIR COOLER ......................................... 250 .
K9K Removal and Installation (For Euro3 48kW/60kW).250
Removal and Installation (For Euro4 50kW) ........ 251 .
APPLICATION NOTICE ......................................... 226 . Removal and Installation (For Euro4 63kW) ........ 252 .
How to Check Vehicle Type ................................. 226 . REMOVAL ......................................................... 252
.
PRECAUTIONS ...................................................... 227 . INSPECTION AFTER REMOVAL ..................... 253 .
Precautions for Drain Coolant ............................. 227 . INSTALLATION ................................................. 253.
Precautions for Disconnecting Fuel Piping .......... 227 . EGR UNIT ............................................................... 254
.
Precautions for Removal and Disassembly ......... 227 . Removal and Installation (For Euro3 48kW/60kW).254
Precautions for Inspection, Repair and Replace- REMOVAL ......................................................... 254
.
ment ..................................................................... 227
.
EM-4
INSTALLATION ................................................ 255 . ENGINE ASSEMBLY ............................................. 280 .
Removal and Installation (For Euro4 50kW/63kW) 256 . Removal and Installation (For Euro3 48kW/60kW) 280 . A
REMOVAL ........................................................ 256 . Removal and Installation (For Euro4 50kW/63kW) 281 .
INSTALLATION ................................................ 257 . REMOVAL ........................................................ 281 .
EXHAUST MANIFOLD, TURBOCHARGER, CATA- INSTALLATION ................................................ 283 . EM
LYST ...................................................................... 258
. INSPECTION AFTER INSTALLATION ............. 283 .
Removal and Installation (For Euro3 48kW/60kW) 258 . OVERHAUL ........................................................... 285.
REMOVAL ........................................................ 258 . Tightening Torques .............................................. 285 .
INSTALLATION ................................................ 259 . UPPER ENGINE .............................................. 285 . C
INSPECTION AFTER INSTALLATION ............ 259 . BOTTOM ENGINE ........................................... 285 .
Disassembly and Assembly ................................ 260 . Standard Replacement ........................................ 286 .
DISASSEMBLY ................................................ 260 . PREPARING USED ENGINE ........................... 286 . D
INSPECTION AFTER DISASSEMBLY ............ 260 . Disassembly ........................................................ 287
.
ASSEMBLY ...................................................... 261 . REMOVING THE UPPER ENGINE .................. 287 .
Removal and Installation (For Euro4 50kW/63kW) 261 . POSITIONING THE BELT AT THE TIMING E
REMOVAL ........................................................ 261 . POINT .............................................................. 288
.
INSTALLATION ................................................ 262 . DISASSEMBLY OF THE CYLINDER HEAD .... 291 .
INSPECTION AFTER INSTALLATION ............ 262 . Cleaning .............................................................. 294
.
Disassembly and Assembly ................................ 263 . Inspection ............................................................ 294
. F
DISASSEMBLY ................................................ 263 . GASKET FACE ................................................ 294 .
INSPECTION AFTER DISASSEMBLY ............ 263 . CAMSHAFT END PLAY ................................... 294 .
ASSEMBLY ...................................................... 264 . Valve Clearance .................................................. 295 . G
OIL PAN ................................................................. 265
. CHECKING AND ADJUSTING THE VALVE
Removal and Installation ..................................... 265 . CLEARANCE ................................................... 295 .
REMOVAL ........................................................ 265 . Assembly ............................................................. 296
. H
INSPECTION AFTER REMOVAL .................... 267 . ASSEMBLY OF THE CYLINDER HEAD .......... 296 .
INSTALLATION ................................................ 267 . Disassembly of The Bottom Engine .................... 300 .
INSPECTION AFTER INSTALLATION ............ 267 . REMOVAL ........................................................ 300 .
I
GLOW PLUG ......................................................... 268 . Assembly ............................................................. 304
.
Removal and Installation ..................................... 268 . INSTALLATION OF OIL JETS .......................... 304 .
REMOVAL ........................................................ 268 . METHOD FOR INSTALLING THE OIL COOLER
INSTALLATION ................................................ 268 . AND OIL FILTER .............................................. 305 . J
VACUUM PUMP .................................................... 269 . Removing The Piston Pins .................................. 305 .
Removal and Installation (For Euro3 48kW/60kW) 269 . CONNECTING ROD BEARING ....................... 306 .
INSPECTION BEFORE REMOVAL ................. 269 . ON THE CONNECTING ROD BODY ............... 306 . K
REMOVAL ........................................................ 269 . ON THE CONNECTING ROD CAP ................. 307 .
INSTALLATION ................................................ 269 . INSTALLATION OF MAIN BEARING ............... 309 .
Removal and Installation (For Euro4 50kW/63kW) 270 . ON THE CYLINDER BLOCK ........................... 309 . L
INSPECTION BEFORE REMOVAL ................. 270 . ON THE BEARING CAPS ................................ 310 .
REMOVAL ........................................................ 270 . INSTALLATION OF NO. 1 BEARING ............... 311 .
INSTALLATION ................................................ 270 . CONNECTING RODS / PISTON ASSEMBLY . 311
ROCKER COVER .................................................. 271 . DIRECTION FOR INSTALLATION THE SNAP M
Removal and Installation ..................................... 271 . RINGS ON THE PISTON ................................. 311 .
REMOVAL ........................................................ 271 . INSTALLATION OF THE SNAP RINGS ........... 311 .
INSTALLATION ................................................ 272 . CHECKING PISTON PROTRUSION ............... 312 .
TIMING BELT ......................................................... 273 . INSTALLATION OF REAR OIL SEAL RETAINER
Removal and Installation ..................................... 273 . AND OIL PUMP ................................................ 313 .
REMOVAL ........................................................ 273 . INSTALLATION OF THE CRANKSHAFT SEAL
INSTALLATION ................................................ 276 . GASKETS ........................................................ 314 .
CYLINDER HEAD .................................................. 277 . INSTALLATION OF THE CYLINDER HEAD .... 318 .
Removal and Installation ..................................... 277 . TIMING ADJUSTMENT .................................... 319 .
REMOVAL ........................................................ 277 . BASIC INSPECTION ............................................. 324 .
INSTALLATION ................................................ 278 . Cylinder Head ...................................................... 324
.
Disassembly and Assembly ................................ 278 . CYLINDER HEAD TIGHTENING PROCEDURE 324 .
DISASSEMBLY ................................................ 278 . THICKNESS OF THE CYLINDER HEAD GAS-
INSPECTION AFTER DISASSEMBLY ............ 278 . KET .................................................................. 324
.
ASSEMBLY ...................................................... 279 . INSPECTION OF THE PISTON PROTRUSION 324 .
VALVE .............................................................. 325
.
VALVE SEAT .................................................... 325 .
EM-5
VALVE GUIDE .................................................. 325 . RINGS ON THE PISTON .................................. 331 .
VALVE SPRING ................................................ 327 . Crankshaft ............................................................ 331
.
PISTON ............................................................ 327. WORKING OUT THE CLASS OF MAIN BEAR-
INSPECTION OF VALVE CLEARANCE ........... 327 . ING (ORIGINAL FITMENT) .............................. 332 .
CAMSHAFT ...................................................... 328 . Cylinder Block ...................................................... 332
.
Piston ................................................................... 329
. TABLE OF CYLINDER BLOCK MAIN BEARING
PISTON MARKING .......................................... 329 . HOUSING INNER DIAMETERS ....................... 332 .
TABLE OF PISTON PIN HEIGHT ..................... 329 . MATCHING THE MAIN BEARING .................... 333 .
MEASURING THE PISTON DIAMETER .......... 329 . Main Bearing and Cap ......................................... 333 .
PISTON RING .................................................. 330 . MAIN BEARING ................................................ 333 .
PISTON RING END GAP ................................. 330 . CONNECTING ROD BEARING ........................ 334 .
Connecting Rod ................................................... 330 . Preparing the engine to be on the stand .............. 334 .
DIRECTION OF INSTALLATION OF THE CON- Parts To Be Replaced After Removal .................. 335 .
NECTING ROD IN RELATION TO THE PISTON 331 . Installation of Thread Inserts ................................ 336 .
DIRECTION FOR INSTALLATION THE SNAP
EM-6
PRECAUTIONS
[CR]
PRECAUTIONS
[CR] PFP:00001
A
Precautions for Draining Coolant EBS00OEB
q Drain coolant only after the engine has cooled down.
EM
Precautions for Disconnecting Fuel Piping EBS00OHR
q Before starting work, make sure no fire or spark producing items are in the work area.
q Release fuel pressure before disassembly. C
q After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly EBS00OED
D
q Use correct special service tool in the specified position. Always pay attention to safety.
q Be careful not to damage surface accuracy of mating or sliding surfaces.
q To prevent foreign material from entering the engine, close openings with appropriate tape as necessary. E
q Arrange disassembled parts in their normal positions in order to simplify locating the cause of damage or
excessive wear and to insure correct reassembly.
q The removal order of nuts and bolts should in principle move diagonally from the outside. Locations for F
which order is stipulated should follow that order.
Precautions for Inspections, Repairs, and Replacement EBS00OEE
G
q Thoroughly inspect each part following inspection procedure, then correct or replace as necessary.
Inspect new parts in the same way, and replace if necessary.
Precautions for Assembling and Installing EBS00OEF H
q Always use a torque wrench when tightening nuts and bolts.
q Unless otherwise specified, tighten nuts and bolts from inside to outside in crisscross pattern. Tighten
them gradually and evenly in two to three steps. I
q Always replace gasket, packing, oil seals, and O-rings with new ones.
q Thoroughly wash, clean, and blow dry each part. Be sure that engine oil and coolant passages are free of
clogs. J
q Remove any dirt and lint on sliding and mating surfaces. Before assembly, apply ample amount of engine
oil to sliding surfaces.
q If coolant was drained, bleed air from the system. K
q Follow the procedure below to make sure there are no fuel leaks.
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