Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Primera 2000.2005 Approved Nissan Note 2006 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 ......................................................................88
.
Valve Clearance ..................................................... 47
. PISTON TO CYLINDER BORE CLEARANCE ...89
INSPECTION ...................................................... 47
. OUTER DIAMETER OF CRANKSHAFT JOUR-
ADJUSTMENT ................................................... 49 . NAL .....................................................................90
.
TIMING CHAIN ......................................................... 50
. OUTER DIAMETER OF CRANKSHAFT PIN .....90 .
Removal and Installation ....................................... 50 . OUT-OF-ROUND AND TEPER OF CRANK-
REMOVAL .......................................................... 51
. SHAFT ................................................................90
.
INSPECTION AFTER REMOVAL ....................... 53 . CRANKSHAFT RUNOUT ...................................91 .
INSTALLATION ................................................... 53. OIL CLEARANCE OF CONNECTING ROD
INSPECTION AFTER INSTALLATION ............... 56 . BEARING ............................................................91 .
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 ..................................92 .
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 ..... 100 .
INSTALLATION ................................................... 62. CONNECTING ROD ......................................... 101 .
Disassembly and Assembly ................................... 63 . CRANKSHAFT .................................................. 101 .
DISASSEMBLY .................................................. 64 . MAIN BEARING ................................................ 101 .
ASSEMBLY ........................................................ 64
. CONNECTING ROD BEARING ........................ 102 .
INSPECTION AFTER DISASSEMBLY ............... 65 . MISCELLANEOUS COMPONENTS ................. 102 .
ENGINE ASSEMBLY ............................................... 70 . Tightening Torque ................................................ 103 .
Removal and Installation ....................................... 70 .
REMOVAL .......................................................... 71
. HR
INSTALLATION ................................................... 73.
INSPECTION AFTER INSTALLATION ............... 73 . PRECAUTIONS ...................................................... 105 .
CYLINDER BLOCK .................................................. 74 . Precautionsfor ProcedureswithoutCowl TopCover 105 .
Disassembly and Assembly ................................... 74 . Precautions for Draining Engine Coolant ............. 105 .
DISASSEMBLY .................................................. 75 . Precautions for Disconnecting Fuel Piping .......... 105 .
ASSEMBLY ........................................................ 77
. Precautions for Removal and Disassembly ......... 105 .
How to Select Piston and Bearing ......................... 82 . Precautions for Inspection, Repair and Replace-
DESCRIPTION ................................................... 82 . ment ..................................................................... 105
.
HOW TO SELECT PISTON ................................ 83 . Precautions for Assembly and Installation ........... 105 .
HOW TO SELECT MAIN BEARING ................... 84 . Parts Requiring Angle Tightening ........................ 105 .
Inspection After Disassembly ................................ 85 . Precautions For Liquid Gasket ............................. 106 .
CRANKSHAFT SIDE CLEARANCE ................... 85 . REMOVAL OF LIQUID GASKET ...................... 106 .
CONNECTING ROD SIDE CLEARANCE .......... 85 . LIQUID GASKET APPLICATION PROCEDURE.106
PISTON AND PISTON PIN CLEARANCE ......... 85 . PREPARATION ...................................................... 108 .
PISTON RING SIDE CLEARANCE .................... 86 . Special Service Tools ........................................... 108 .
PISTON RING END GAP ................................... 86 . Commercial Service Tools ................................... 110 .
CONNECTING ROD BEND AND TORSION ...... 87 . NOISE, VIBRATION AND HARSHNESS (NVH)
CONNECTING ROD BEARING HOUSING TROUBLESHOOTING ........................................... 112 .
DIAMETER (BIG END) ....................................... 87 . NVH Troubleshooting -- Engine Noise ................ 112 .
CONNECTING ROD BUSHING OIL CLEAR- Use the Chart Below to Help You Find the Cause
ANCE DIAMETER (SMALL END) ...................... 87 . of the Symptom. ................................................... 113 .
CYLINDER BLOCK DISTORTION ..................... 88 . DRIVE BELTS ......................................................... 114 .
INNER DIAMETER OF MAIN BEARING HOUS- Checking Drive Belts ............................................ 114 .
Tension Adjustment .............................................. 114 .
Removal and Installation ...................................... 115 .
EM-2
REMOVAL .........................................................115
. TIMING CHAIN ....................................................... 142
.
INSTALLATION .................................................115. Components ........................................................ 142
. A
Removal and Installation of Drive Belt Idler Pulley ..116 Removal and Installation ..................................... 143 .
REMOVAL .........................................................116
. REMOVAL ........................................................ 143
.
INSTALLATION .................................................117. INSPECTION AFTER REMOVAL .................... 146 . EM
AIR CLEANER AND AIR DUCT .............................118 . INSTALLATION ................................................ 146 .
Components .........................................................118
. INSPECTION AFTER INSTALLATION ............. 150 .
Removal and Installation ......................................118. CAMSHAFT ........................................................... 151
.
REMOVAL .........................................................118
. Components ........................................................ 151
. C
INSTALLATION .................................................119. Removal and Installation ..................................... 151 .
Changing Air Cleaner Filter ..................................119 . REMOVAL ........................................................ 151
.
REMOVAL .........................................................119
. INSPECTION AFTER REMOVAL .................... 157 . D
INSPECTION AFTER REMOVAL .....................119 . INSTALLATION ................................................ 161 .
INSTALLATION .................................................119. INSPECTION AFTER INSTALLATION ............. 165 .
INTAKE MANIFOLD .............................................. 120 . Valve Clearance .................................................. 166
. E
Components ........................................................ 120
. INSPECTION ................................................... 166 .
Removal and Installation ..................................... 121. ADJUSTMENT ................................................. 168 .
REMOVAL ........................................................ 121
. OIL SEAL ............................................................... 170
.
INSTALLATION ................................................ 122. Removal and Installation of Valve Oil Seal .......... 170 . F
EXHAUST MANIFOLD .......................................... 124 . REMOVAL ........................................................ 170
.
Components ........................................................ 124
. INSTALLATION ................................................ 170 .
Removal and Installation ..................................... 125. Removal and Installation of Front Oil Seal .......... 171 . G
REMOVAL ........................................................ 125
. REMOVAL ........................................................ 171
.
INSPECTION AFTER REMOVAL .................... 126 . INSTALLATION ................................................ 171 .
INSTALLATION ................................................ 126. Removal and Installation of Rear Oil Seal ........... 172 . H
OIL PAN AND OIL STRAINER .............................. 127 . REMOVAL ........................................................ 172
.
Components ........................................................ 127
. INSTALLATION ................................................ 172 .
Removal and Installation ..................................... 127. CYLINDER HEAD .................................................. 173 .
I
REMOVAL ........................................................ 127
. On-Vehicle Service .............................................. 173.
INSTALLATION ................................................ 128. CHECKING COMPRESSION PRESSURE ...... 173 .
INSPECTION AFTER INSTALLATION ............ 131 . Components ........................................................ 174
.
IGNITION COIL ...................................................... 132
. Removal and Installation ..................................... 174 . J
Components ........................................................ 132
. REMOVAL ........................................................ 174
.
Removal and Installation ..................................... 132. INSPECTION AFTER REMOVAL .................... 175 .
REMOVAL ........................................................ 132
. INSTALLATION ................................................ 176 . K
INSTALLATION ................................................ 132. INSPECTION AFTER INSTALLATION ............. 176 .
SPARK PLUG (PLATINUM-TIPPED TYPE) .......... 133 . Components ........................................................ 177
.
Components ........................................................ 133
. Disassembly and Assembly ................................. 178 . L
Removal and Installation ..................................... 133. DISASSEMBLY ................................................ 178 .
REMOVAL ........................................................ 133
. ASSEMBLY ...................................................... 178.
INSPECTION AFTER REMOVAL .................... 133 . Inspection After Disassembly .............................. 179 .
INSTALLATION ................................................ 134. VALVE DIMENSIONS ....................................... 179 . M
FUEL INJECTOR AND FUEL TUBE ..................... 135 . VALVE GUIDE CLEARANCE ........................... 179 .
Components ........................................................ 135
. VALVE GUIDE REPLACEMENT ...................... 180 .
Removal and Installation ..................................... 135. VALVE SEAT CONTACT .................................. 181 .
REMOVAL ........................................................ 135
. VALVE SEAT REPLACEMENT ........................ 181 .
INSTALLATION ................................................ 137. VALVE SPRING SQUARENESS ...................... 182 .
INSPECTION AFTER INSTALLATION ............ 139 . VALVE SPRING DIMENSIONS AND VALVE
ROCKER COVER .................................................. 140 . SPRING PRESSURE LOAD ............................ 182 .
Components ........................................................ 140
. ENGINE ASSEMBLY ............................................. 184 .
Removal and Installation ..................................... 140. Components ........................................................ 184
.
REMOVAL ........................................................ 140
. Removal and Installation ..................................... 184 .
INSTALLATION ................................................ 141. REMOVAL ........................................................ 185
.
INSTALLATION ................................................ 187 .
INSPECTION AFTER INSTALLATION ............. 188 .
CYLINDER BLOCK ............................................... 189 .
Components ........................................................ 189
.
Disassembly and Assembly ................................. 190 .
DISASSEMBLY ................................................ 190 .
EM-3
ASSEMBLY ...................................................... 193 . Precautions for Inspection, Repair and Replace-
How to Select Piston and Bearing ....................... 199 . ment ..................................................................... 227
.
DESCRIPTION ................................................. 199 . Precautions for Assembly and Installation ........... 227 .
HOW TO SELECT CONNECTING ROD BEAR- Parts Requiring Angular Tightening ..................... 227 .
ING ................................................................... 199
. Precautions For Liquid Gasket ............................. 228 .
HOW TO SELECT MAIN BEARING ................. 202 . REMOVAL OF LIQUID GASKET ...................... 228 .
Inspection After Disassembly .............................. 206 . LIQUID GASKET APPLICATION PROCEDURE.228
CRANKSHAFT END PLAY ............................... 206 . Precautions for Diesel Equipment ........................ 229 .
CONNECTING ROD SIDE CLEARANCE ........ 206 . CLEANLINESS ................................................. 229 .
PISTON TO PISTON PIN OIL CLEARANCE ... 206 . SPECIAL FEATURES ....................................... 231 .
PISTON RING SIDE CLEARANCE .................. 207 . PREPARATION ...................................................... 233 .
PISTON RING END GAP ................................. 207 . Special Service Tools ........................................... 233 .
CONNECTING ROD BEND AND TORSION .... 208 . Commercial Service Tools ................................... 236 .
CONNECTING ROD BIG END DIAMETER ..... 208 . IDENTIFICATION INFORMATION ......................... 238 .
CONNECTING ROD BUSHING OIL CLEAR- Engine Identification ............................................. 238 .
ANCE ................................................................ 208
. NOISE, VIBRATION AND HARSHNESS (NVH)
CYLINDER BLOCK DISTORTION ................... 209 . TROUBLESHOOTING ........................................... 239 .
MAIN BEARING HOUSING INNER DIAMETER 209 . NVH Troubleshooting --Engine Noise ................. 239 .
PISTON TO CYLINDER BORE CLEARANCE . 210 Use the Chart Below to Help You Find the Cause
CRANKSHAFT MAIN JOURNAL DIAMETER .. 211 . of the Symptom. ................................................... 240 .
CRANKSHAFT PIN JOURNAL DIAMETER ..... 211 . ENGINE ROOM COVER ........................................ 241 .
OUT-OF-ROUND AND TAPER OF CRANK- Removal and Installation ...................................... 241 .
SHAFT .............................................................. 211
. REMOVAL ......................................................... 241 .
CRANKSHAFT RUNOUT ................................. 211 . INSTALLATION ................................................. 241 .
CONNECTING ROD BEARING OIL CLEAR- DRIVE BELTS ......................................................... 242 .
ANCE ................................................................ 211
. Checking Drive Belts ............................................ 242 .
MAIN BEARING OIL CLEARANCE .................. 212 . Tension Adjustment .............................................. 242 .
MAIN BEARING CRUSH HEIGHT ................... 213 . MODELS WITH A/C COMPRESSOR ............... 242 .
CONNECTING ROD BEARING CRUSH MODELS WITHOUT A/C COMPRESSOR ....... 242 .
HEIGHT ............................................................ 213
. Removal and Installation ...................................... 243 .
MAIN BEARING CAP BOLT OUTER DIAMETER 213 . REMOVAL ......................................................... 243 .
CONNECTING ROD BOLT OUTER DIAMETER 214 . INSTALLATION ................................................. 243 .
FLYWHEEL DEFLECTION ............................... 214 . AIR CLEANER AND AIR DUCT ............................245 .
SERVICE DATA AND SPECIFICATIONS (SDS) ... 215 . Removal and Installation ...................................... 245 .
Standard and Limit ............................................... 215 . REMOVAL ......................................................... 245 .
GENERAL SPECIFICATIONS .......................... 215 . INSTALLATION ................................................. 245 .
DRIVE BELT ..................................................... 215 . Changing Air Cleaner Filter .................................. 246 .
EXHAUST MANIFOLD ..................................... 215 . REMOVAL ......................................................... 246 .
SPARK PLUG (PLATINUM-TIPPED TYPE) ..... 215 . INSTALLATION ................................................. 246 .
CYLINDER HEAD ............................................ 215 . CHARGE AIR COOLER ......................................... 247 .
VALVE ............................................................... 216
. Removal and Installation (For 50kW) ................... 247 .
CAMSHAFT AND CAMSHAFT BEARING ....... 220 . REMOVAL ......................................................... 247 .
CYLINDER BLOCK .......................................... 220 . INSPECTION AFTER REMOVAL ..................... 248 .
PISTON, PISTON RING AND PISTON PIN ..... 221 . INSTALLATION ................................................. 248 .
CONNECTING ROD ........................................ 222 . Removal and Installation (For 65kW) ................... 249 .
CRANKSHAFT ................................................. 222 . REMOVAL ......................................................... 249 .
MAIN BEARING ............................................... 224 . INSPECTION AFTER REMOVAL ..................... 250 .
CONNECTING ROD BEARING ....................... 225 . INSTALLATION ................................................. 250 .
EGR UNIT ............................................................... 251
.
K9K Removal and Installation ...................................... 251 .
REMOVAL ......................................................... 251 .
APPLICATION NOTICE ......................................... 226 . INSTALLATION ................................................. 252 .
How to Check Vehicle Type ................................. 226 . EXHAUST MANIFOLD, TURBOCHARGER, CATA-
PRECAUTIONS ...................................................... 227
. LYST ....................................................................... 253
.
Precautions for Drain Coolant ............................. 227 . Removal and Installation ...................................... 253 .
Precautions for Disconnecting Fuel Piping .......... 227 . REMOVAL ......................................................... 253 .
Precautions for Removal and Disassembly ......... 227 . INSTALLATION ................................................. 254 .
EM-4
INSPECTION AFTER INSTALLATION ............ 254 . UPPER ENGINE .............................................. 282 .
Disassembly and Assembly ................................ 255 . BOTTOM ENGINE ........................................... 282 . A
DISASSEMBLY ................................................ 255 . Standard Replacement ........................................ 283 .
INSPECTION AFTER DISASSEMBLY ............ 255 . PREPARING USED ENGINE ........................... 283 .
ASSEMBLY ...................................................... 256 . Disassembly ........................................................ 284 . EM
OIL PAN ................................................................. 257
. REMOVING THE UPPER ENGINE .................. 284 .
Removal and Installation ..................................... 257 . POSITIONING THE BELT AT THE TIMING
REMOVAL ........................................................ 257. POINT .............................................................. 285
.
INSPECTION AFTER REMOVAL .................... 259 . DISASSEMBLY OF THE CYLINDER HEAD .... 288 . C
INSTALLATION ................................................ 259 . Cleaning .............................................................. 291
.
INSPECTION AFTER INSTALLATION ............ 259 . Inspection ............................................................ 291
.
GLOW PLUG ......................................................... 260 . GASKET FACE ................................................ 291 . D
Removal and Installation ..................................... 260 . CAMSHAFT END PLAY ................................... 291 .
REMOVAL ........................................................ 260. Valve Clearance .................................................. 292 .
INSTALLATION ................................................ 260 . CHECKING AND ADJUSTING THE VALVE E
VACUUM PUMP .................................................... 261 . CLEARANCE ................................................... 292 .
Removal and Installation ..................................... 261 . Assembly ............................................................. 293
.
INSPECTION BEFORE REMOVAL ................. 261 . ASSEMBLY OF THE CYLINDER HEAD .......... 293 .
REMOVAL ........................................................ 261. Disassembly of The Bottom Engine .................... 297 . F
INSTALLATION ................................................ 261 . REMOVAL ........................................................ 297 .
HIGH PRESSURE PIPES ...................................... 262 . Assembly ............................................................. 301
.
Removal and Installation ..................................... 262 . INSTALLATION OF OIL JETS .......................... 301 . G
REMOVAL ........................................................ 262. METHOD FOR INSTALLING THE OIL COOLER
INSTALLATION ................................................ 263 . AND OIL FILTER .............................................. 302 .
FUEL INJECTOR ................................................... 266 . Removing The Piston Pins .................................. 302 . H
Removal and Installation ..................................... 266 . CONNECTING ROD BEARING ....................... 303 .
REMOVAL ........................................................ 266. ON THE CONNECTING ROD BODY ............... 303 .
INSTALLATION ................................................ 266 . ON THE CONNECTING ROD CAP ................. 304 .
I
INJECTOR RAIL .................................................... 267 . INSTALLATION OF MAIN BEARING ............... 306 .
Removal and Installation ..................................... 267 . ON THE CYLINDER BLOCK ........................... 306 .
REMOVAL ........................................................ 267. ON THE BEARING CAPS ................................ 307 .
INSTALLATION ................................................ 267 . INSTALLATION OF NO. 1 BEARING ............... 308 . J
HIGH PRESSURE PUMP ...................................... 268 . CONNECTING RODS / PISTON ASSEMBLY . 308
Removal and Installation ..................................... 268 . DIRECTION FOR INSTALLATION THE SNAP
REMOVAL ........................................................ 268. RINGS ON THE PISTON ................................. 308 . K
INSTALLATION ................................................ 269 . INSTALLATION OF THE SNAP RINGS ........... 308 .
ROCKER COVER .................................................. 270 . CHECKING PISTON PROTRUSION ............... 309 .
Removal and Installation ..................................... 270 . INSTALLATION OF REAR OIL SEAL RETAINER L
REMOVAL ........................................................ 270. AND OIL PUMP ................................................ 310 .
INSTALLATION ................................................ 271 . INSTALLATION OF THE CRANKSHAFT SEAL
TIMING BELT ......................................................... 272
. GASKETS ........................................................ 311 .
Removal and Installation ..................................... 272 . INSTALLATION OF THE CYLINDER HEAD .... 315 . M
REMOVAL ........................................................ 272. TIMING ADJUSTMENT .................................... 316 .
INSTALLATION ................................................ 275 . BASIC INSPECTION ............................................. 321 .
CYLINDER HEAD .................................................. 276 . Cylinder Head ...................................................... 321 .
Removal and Installation ..................................... 276 . CYLINDER HEAD TIGHTENING PROCEDURE 321 .
REMOVAL ........................................................ 276. THICKNESS OF THE CYLINDER HEAD GAS-
INSTALLATION ................................................ 277 . KET .................................................................. 321
.
Disassembly and Assembly ................................ 277 . INSPECTION OF THE PISTON PROTRUSION 321 .
DISASSEMBLY ................................................ 277 . VALVE .............................................................. 322
.
INSPECTION AFTER DISASSEMBLY ............ 277 . VALVE SEAT .................................................... 322 .
ASSEMBLY ...................................................... 278 . VALVE GUIDE .................................................. 322 .
ENGINE ASSEMBLY ............................................. 279 . VALVE SPRING ................................................ 324 .
Removal and Installation ..................................... 279 . PISTON ............................................................ 324.
REMOVAL ........................................................ 280. INSPECTION OF VALVE CLEARANCE .......... 324 .
INSTALLATION ................................................ 281 . CAMSHAFT ...................................................... 325 .
INSPECTION AFTER INSTALLATION ............ 281 . Piston ................................................................... 326
.
OVERHAUL ........................................................... 282. PISTON MARKING .......................................... 326 .
Tightening Torques .............................................. 282 . TABLE OF PISTON PIN HEIGHT .................... 326 .
EM-5
MEASURING THE PISTON DIAMETER .......... 326 . Cylinder Block ...................................................... 329
.
PISTON RING .................................................. 327 . TABLE OF CYLINDER BLOCK MAIN BEARING
PISTON RING END GAP ................................. 327 . HOUSING INNER DIAMETERS ....................... 329 .
Connecting Rod ................................................... 327
. MATCHING THE MAIN BEARING .................... 330 .
DIRECTION OF INSTALLATION OF THE CON- Main Bearing and Cap ......................................... 330 .
NECTING ROD IN RELATION TO THE PISTON 328 . MAIN BEARING ................................................ 330 .
DIRECTION FOR INSTALLATION THE SNAP CONNECTING ROD BEARING ........................ 331 .
RINGS ON THE PISTON ................................. 328 . Preparing the engine to be on the stand .............. 331 .
Crankshaft ........................................................... 328
. Parts To Be Replaced After Removal .................. 332 .
WORKING OUT THE CLASS OF MAIN BEAR- Installation of Thread Inserts ................................ 333 .
ING (ORIGINAL FITMENT) .............................. 329 .
EM-6
PRECAUTIONS
[CR]
PRECAUTIONS
[CR] PFP:00001
A
Precautions for Draining Coolant BBS002MS
q Drain coolant only after the engine has cooled down.
EM
Precautions for Disconnecting Fuel Piping BBS002MT
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 BBS002MU
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 BBS002MV
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 BBS002MW 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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