Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Primera 2000.2005 Approved Nissan Primera 2005 em
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ENGINE MECHANICAL
B ENGINE
A
EM
SECTION
ENGINE MECHANICAL C
D
E
CONTENTS
QG INSTALLATION .................................................. 20 . F
Disassembly and Assembly ................................. .. 21 .
PRECAUTIONS ......................................................... 6 . INTAKE MANIFOLD COLLECTOR .................... 21 .
Precautions for Drain Coolant ................................. 6 . THROTTLE POSITION SENSOR ...................... 22 . G
Precautions for Disconnecting Fuel Piping ............. 6 . EXHAUST MANIFOLD AND CATALYTIC CON-
Precautions for Removal and Disassembly ............ 6 . VERTER ................................................................... 23
.
Precautions for Inspection, Repair and Replace- Removal and Installation ....................................... 23 .
ment ........................................................................ 6
. H
REMOVAL .......................................................... 24
.
Precautions for Assembly and Installation .............. 6 . INSPECTION AFTER REMOVAL ...................... 25 .
Parts Requiring Angular Tightening ........................ 6 . INSTALLATION .................................................. 25 .
Precautions for Liquid Gasket ................................. 7 . Disassembly and Assembly ................................. .. 26 . I
REMOVAL OF LIQUID GASKET SEALING ......... 7 . QG16DE ENGINE MODELS ............................ .. 26 .
LIQUID GASKET APPLICATION PROCEDURE 7 ..... QG18DE ENGINE MODELS ............................ .. 26 .
PREPARATION .......................................................... 8 . OIL PAN AND OIL STRAINER ................................ 27 . J
Special Service Tools .............................................. 8 . Removal and Installation ....................................... 27 .
Commercial Service Tools ..................................... 10 . REMOVAL .......................................................... 27
.
NOISE, VIBRATION, AND HARSHNESS (NVH) INSTALLATION .................................................. 28 .
TROUBLESHOOTING ............................................. 12 . K
INSPECTION AFTER INSTALLATION ............... 28 .
NVH Troubleshooting --Engine Noise .................. 12 . IGNITION COIL ........................................................ 29
.
Use the Chart Below to Help You Find the Cause Removal and Installation ....................................... 29 .
of the Symptom. .................................................... 13 . REMOVAL .......................................................... 29
. L
DRIVE BELTS .......................................................... 14 . INSTALLATION .................................................. 29 .
Checking Drive Belts ............................................. 14 . SPARK PLUG (CONVENTIONAL) .......................... 30 .
Tension Adjustment ............................................... 15 . Removal and Installation ....................................... 30 . M
POWER STEERING PUMP AND WATER PUMP REMOVAL .......................................................... 30
.
BELT .................................................................. 15
. INSPECTION AFTER REMOVAL ...................... 30 .
ALTERNATOR AND AIR CONDITIONER COM- INSTALLATION .................................................. 30 .
PRESSOR BELT ................................................ 15 . FUEL INJECTOR AND FUEL TUBE ....................... 31 .
Removal and Installation ....................................... 16 . Removal and Installation ....................................... 31 .
REMOVAL .......................................................... 16 . REMOVAL .......................................................... 31
.
INSTALLATION .................................................. 16 . INSTALLATION .................................................. 32 .
AIR CLEANER AND AIR DUCT .............................. 17 . INSPECTION AFTER INSTALLATION ............... 33 .
Removal and Installation ....................................... 17 . ROCKER COVER .................................................... 34 .
REMOVAL .......................................................... 17 . Removal and Installation ....................................... 34 .
INSTALLATION .................................................. 17 . REMOVAL .......................................................... 34
.
Changing Air Cleaner Element .............................. 18 . INSTALLATION .................................................. 35 .
INTAKE MANIFOLD ................................................ 19 . CAMSHAFT ............................................................. 36
.
Removal and Installation ....................................... 19 . Removal and Installation ....................................... 36 .
REMOVAL .......................................................... 19 . REMOVAL .......................................................... 36
.
INSPECTION AFTER REMOVAL ...................... 20 . INSTALLATION .................................................. 39 .
EM-1
INSPECTION AFTER REMOVAL ....................... 42 . ING .................................................................... ..89
.
Valve Clearance ..................................................... 44. PISTON TO CYLINDER BORE CLEARANCE ...89
INSPECTION ...................................................... 44 . OUTER DIAMETER OF CRANKSHAFT JOUR-
ADJUSTMENT ................................................... 46 . NAL .....................................................................90
.
TIMING CHAIN ......................................................... 49 . OUTER DIAMETER OF CRANKSHAFT PIN .....90 .
Removal and Installation ....................................... 49 . OUT-OF-ROUND AND TAPER OF CRANK-
REMOVAL .......................................................... 50 . SHAFT ................................................................91
.
INSPECTION AFTER REMOVAL ....................... 53 . CRANKSHAFT RUNOUT ...................................91 .
INSTALLATION ................................................... 53 . OIL CLEARANCE OF CONNECTING ROD
INSPECTION AFTER INSTALLATION .............. 55 . BEARING ............................................................91 .
CYLINDER HEAD .................................................... 57 . OIL CLEARANCE OF MAIN BEARING ..............92 .
On-Vehicle Service ................................................ 57 . CRUSH HEIGHT OF MAIN BEARING ...............92 .
CHECKING COMPRESSION PRESSURE ........ 57 . FLYWHEEL RUNOUT ........................................92 .
Removal and Installation ....................................... 58 . SERVICE DATA AND SPECIFICATIONS (SDS) .....93 .
REMOVAL .......................................................... 58 . Standard and Limit ............................................... ..93 .
INSTALLATION ................................................... 59 . GENERAL SPECIFICATIONS .......................... ..93 .
Disassembly and Assembly ................................... 60 . INTAKE MANIFOLD AND EXHAUST MANI-
DISASSEMBLY .................................................. 60 . FOLD ..................................................................93
.
ASSEMBLY ........................................................ 61 . DRIVE BELTS .....................................................94 .
Inspection After Disassembly ................................ 62 . SPARK PLUG .....................................................94 .
CYLINDER HEAD DISTORTION ....................... 62 . CYLINDER HEAD ...............................................94 .
VALVE DIMENSIONS ......................................... 62 . VALVE .................................................................94
.
VALVE GUIDE CLEARANCE ............................. 62 . CAMSHAFT AND CAMSHAFT BEARING ..........98 .
VALVE GUIDE REPLACEMENT ........................ 62 . CYLINDER BLOCK .............................................99 .
VALVE SEAT CONTACT .................................... 64 . PISTON, PISTON RING AND PISTON PIN ..... 100 .
VALVE SEAT REPLACEMENT .......................... 64 . CONNECTING ROD ......................................... 101 .
VALVE SPRING SQUARENESS ........................ 65 . CRANKSHAFT .................................................. 101 .
VALVE SPRING DIMENSIONS AND VALVE MAIN BEARING ................................................ 101 .
SPRING PRESSURE LOAD .............................. 65 . CONNECTING ROD BEARING ........................ 102 .
ENGINE ASSEMBLY ............................................... 66 . MISCELLANEOUS COMPONENTS ................. 102 .
Removal and Installation ....................................... 66 . Tightening Torque ................................................ 102 .
REMOVAL .......................................................... 67 .
INSTALLATION ................................................... 68 . QR
INSPECTION AFTER INSTALLATION ............... 68 .
CYLINDER BLOCK .................................................. 70 . PRECAUTIONS ...................................................... 104 .
Disassembly and Assembly ................................... 70 . Precautions for Drain Coolant .............................. 104 .
DISASSEMBLY .................................................. 71 . Precautions for Disconnecting Fuel Piping .......... 104 .
ASSEMBLY ........................................................ 75 . Precautions for Removal and Disassembly ......... 104 .
How to Select Piston and Bearing ......................... 80 . Precautions for Inspection, Repair and Replace-
DESCRIPTION ................................................... 80 . ment ..................................................................... 104
.
HOW TO SELECT PISTON ................................ 80 . Precautions for Assembly and Installation ........... 104 .
HOW TO SELECT CONNECTING ROD BEAR- Parts Requiring Angular Tightening ..................... 104 .
ING ..................................................................... 82
. Precautions for Liquid Gasket .............................. 105 .
HOW TO SELECT MAIN BEARING ................... 83 . REMOVAL OF LIQUID GASKET SEALING ..... 105 .
Inspection After Disassembly ................................ 84 . LIQUID GASKET APPLICATION PROCEDURE.105
CRANKSHAFT SIDE CLEARANCE ................... 84 . PREPARATION ...................................................... 106 .
CONNECTING ROD SIDE CLEARANCE .......... 85 . Special Service Tools ........................................... 106 .
PISTON AND PISTON PIN CLEARANCE ......... 85 . Commercial Service Tools ................................... 107 .
PISTON RING SIDE CLEARANCE .................... 86 . NOISE, VIBRATION, AND HARSHNESS (NVH)
PISTON RING END GAP ................................... 86 . TROUBLESHOOTING ........................................... 110 .
CONNECTING ROD BEND AND TORSION ...... 87 . NVH Troubleshooting --Engine Noise ................. 110 .
CONNECTING ROD BEARING (BIG END) ....... 87 . Use the Chart Below to Help You Find the Cause
CONNECTING ROD BUSHING OIL CLEAR- of the Symptom. ................................................... 111 .
ANCE (SMALL END) .......................................... 88 . DRIVE BELTS ......................................................... 112 .
CYLINDER BLOCK DISTORTION ..................... 89 . Checking Drive Belts ............................................ 112 .
INNER DIAMETER OF MAIN BEARING HOUS- Tension Adjustment .............................................. 112 .
Removal and Installation ...................................... 112 .
REMOVAL ......................................................... 112 .
EM-2
INSTALLATION .................................................112 . CYLINDER HEAD .................................................. 152 .
Removal and Installation of Auxiliary Drive Belt On-Vehicle Service .............................................. 152 . A
Auto- tensioner .....................................................113. CHECKING COMPRESSION PRESSURE ...... 152 .
REMOVAL .........................................................113 . Removal and Installation ..................................... 153 .
INSTALLATION .................................................113 . REMOVAL ........................................................ 153 . EM
AIR CLEANER AND AIR DUCT .............................114 . INSPECTION AFTER REMOVAL .................... 154 .
Removal and Installation ......................................114 . INSTALLATION ................................................ 154 .
REMOVAL .........................................................114 . Disassembly and Assembly ................................. 155 .
INSTALLATION .................................................115 . DISASSEMBLY ................................................ 155 . C
CHANGING AIR CLEANER ELEMENT ............115 . ASSEMBLY ...................................................... 156 .
INTAKE MANIFOLD ...............................................116 . Inspection After Disassembly .............................. 156 .
Removal and Installation ......................................116 . CYLINDER HEAD DISTORTION ..................... 156 . D
REMOVAL .........................................................116 . VALVE DIMENSIONS ....................................... 157 .
INSTALLATION .................................................118 . VALVE GUIDE CLEARANCE ........................... 157 .
INSPECTION AFTER INSTALLATION .............119 . VALVE GUIDE REPLACEMENT ...................... 157 . E
EXHAUST MANIFOLD AND THREE WAY CATA- VALVE SEAT CONTACT .................................. 158 .
LYST ...................................................................... 121
. VALVE SEAT REPLACEMENT ........................ 158 .
Removal and Installation ..................................... 121 . VALVE SPRING SQUARENESS ...................... 160 .
REMOVAL ........................................................ 121 . VALVE SPRING DIMENSIONS AND VALVE F
INSPECTION AFTER REMOVAL .................... 122 . SPRING PRESSURE LOAD ............................ 160 .
INSTALLATION ................................................ 122 . ENGINE ASSEMBLY ............................................. 161 .
OIL PAN AND OIL STRAINER .............................. 123 . Removal and Installation ..................................... 161 . G
Removal and Installation ..................................... 123 . REMOVAL ........................................................ 162 .
REMOVAL ........................................................ 123 . INSTALLATION ................................................ 163 .
INSPECTION AFTER REMOVAL .................... 124 . INSPECTION AFTER INSTALLATION ............. 164 . H
INSTALLATION ................................................ 124 . CYLINDER BLOCK ............................................... 165 .
INSPECTION AFTER INSTALLATION ............ 125 . Disassembly and Assembly ................................. 165 .
IGNITION COIL ...................................................... 126 . DISASSEMBLY ................................................ 166 .
I
Removal and Installation ..................................... 126 . ASSEMBLY ...................................................... 170 .
REMOVAL ........................................................ 126 . How to Select Piston and Bearing ....................... 174 .
INSTALLATION ................................................ 126 . DESCRIPTION ................................................. 174 .
SPARK PLUG (CONVENTIONAL) ........................ 127 . HOW TO SELECT PISTON ............................. 175 . J
Removal and Installation ..................................... 127 . HOW TO SELECT CONNECTING ROD BEAR-
REMOVAL ........................................................ 127 . ING ................................................................... 176
.
INSPECTION AFTER REMOVAL .................... 127 . HOW TO SELECT MAIN BEARING ................. 178 . K
INSTALLATION ................................................ 127 . Inspection After Disassembly .............................. 181 .
FUEL INJECTOR AND FUEL TUBE ..................... 128 . CRANKSHAFT SIDE CLEARANCE ................. 181 .
Removal and Installation ..................................... 128 . CONNECTING ROD SIDE CLEARANCE ........ 182 .
L
REMOVAL ........................................................ 128 . PISTON AND PISTON PIN CLEARANCE ....... 182 .
INSTALLATION ................................................ 129 . PISTON RING SIDE CLEARANCE .................. 183 .
INSPECTION AFTER INSTALLATION ............ 130 . PISTON RING END GAP ................................. 183 .
ROCKER COVER .................................................. 131 . CONNECTING ROD BEND AND TORSION ... 184 . M
Removal and Installation ..................................... 131 . CONNECTING ROD BEARING (BIG END) ..... 184 .
REMOVAL ........................................................ 131 . CONNECTING ROD BUSHING OIL CLEAR-
INSTALLATION ................................................ 131 . ANCE (SMALL END) ........................................ 184 .
CAMSHAFT ........................................................... 133 . CYLINDER BLOCK DISTORTION ................... 185 .
Removal and Installation ..................................... 133 . INNER DIAMETER OF MAIN BEARING HOUS-
REMOVAL ........................................................ 133 . ING ................................................................... 186
.
INSTALLATION ................................................ 135 . PISTON TO CYLINDER BORE CLEARANCE . 186
INSPECTION AFTER REMOVAL .................... 138 . OUTER DIAMETER OF CRANKSHAFT JOUR-
Valve Clearance .................................................. 140 . NAL .................................................................. 187
.
INSPECTION ................................................... 140 . OUTER DIAMETER OF CRANKSHAFT PIN ... 187 .
ADJUSTMENT ................................................. 141 . OUT-OF-ROUND AND TAPER OF CRANK-
TIMING CHAIN ...................................................... 143 . SHAFT .............................................................. 187
.
Removal and Installation ..................................... 143 . CRANKSHAFT RUNOUT ................................. 188 .
REMOVAL ........................................................ 144 . OIL CLEARANCE OF CONNECTING ROD
INSPECTION AFTER REMOVAL .................... 147 .
INSTALLATION ................................................ 148 .
EM-3
BEARING ......................................................... 188
. AIR CLEANER AND AIR DUCT ............................ 213 .
OIL CLEARANCE OF MAIN BEARING ............ 188 . Removal and Installation ...................................... 213 .
CRUSH HEIGHT OF MAIN BEARING ............. 189 . REMOVAL ......................................................... 213
.
OUTER DIAMETER OF LOWER CYLINDER INSTALLATION ................................................. 213.
BLOCK MOUNTING BOLT ............................... 189 . CHANGING AIR CLEANER ELEMENT ............ 213 .
OUTER DIAMETER OF CONNECTING ROD CHARGE AIR COOLER ......................................... 215 .
BOLT ................................................................ 189
. Removal and Installation ...................................... 215 .
MOVEMENT AMOUNT OF FLYWHEEL (M/T REMOVAL ......................................................... 215
.
MODELS) ......................................................... 190
. INSPECTION AFTER REMOVAL ..................... 215 .
SERVICE DATA AND SPECIFICATIONS (SDS) ... 191 . INSTALLATION ................................................. 215.
Standard and Limit ............................................... 191. INTAKE MANIFOLD ............................................... 216 .
GENERAL SPECIFICATIONS .......................... 191 . Removal and Installation ...................................... 216 .
INTAKE MANIFOLD AND EXHAUST MANI- REMOVAL ......................................................... 216
.
FOLD ................................................................ 191
. INSPECTION AFTER REMOVAL ..................... 217 .
DRIVE BELTS .................................................. 191 . INSTALLATION ................................................. 217.
SPARK PLUG ................................................... 191 . INSPECTION AFTER INSTALLATION ............. 218 .
CYLINDER HEAD ............................................ 192 . CATALYST .............................................................. 219
.
VALVE ............................................................... 192
. Removal and Installation ...................................... 219 .
CAMSHAFT AND CAMSHAFT BEARING ....... 195 . REMOVAL ......................................................... 219
.
CYLINDER BLOCK .......................................... 195 . INSTALLATION ................................................. 219.
PISTON, PISTON RING AND PISTON PIN ..... 196 . EXHAUST MANIFOLD AND TURBOCHARGER .. 220 .
CONNECTING ROD ........................................ 197 . Removal and Installation ...................................... 220 .
CRANKSHAFT ................................................. 198 . REMOVAL ......................................................... 220
.
MAIN BEARING ............................................... 199 . INSTALLATION ................................................. 221.
CONNECTING ROD BEARING ....................... 200 . INSPECTION AFTER INSTALLATION ............. 221 .
Tightening Torque ................................................ 201. Disassembly and Assembly ................................. 222 .
REMOVAL ......................................................... 222
.
YD INSPECTION AFTER REMOVAL ..................... 222 .
Turbocharger ........................................................ 223
.
PRECAUTIONS ...................................................... 203 . ROTOR SHAFT CLEARANCE ......................... 223 .
Precautions for Drain Coolant ............................. 203 . ROTOR SHAFT END PLAY .............................. 223 .
Precautions for Disconnecting Fuel Piping .......... 203 . TURBINE WHEEL ............................................ 224 .
Precautions for Removal and Disassembly ......... 203 . COMPRESSOR WHEEL .................................. 224 .
Precautions for Inspection, Repair and Replace- VARIABLE NOZZLE TURBOCHARGER CON-
ment ..................................................................... 203
. TROL ACTUATOR ............................................ 224 .
Precautions for Assembly and Installation ........... 203 . TROUBLE DIAGNOSIS OF TURBOCHARGER.224
Parts Requiring Angular Tightening ..................... 203 . OIL PAN AND OIL STRAINER ............................... 226 .
Precautions for Liquid Gasket ............................. 204 . Removal and Installation ...................................... 226 .
REMOVAL OF LIQUID GASKET SEALING ..... 204 . REMOVAL ......................................................... 226
.
LIQUID GASKET APPLICATION PROCEDURE 204 . INSPECTION AFTER REMOVAL ..................... 228 .
PREPARATION ...................................................... 205 . INSTALLATION ................................................. 228.
Special Service Tools .......................................... 205 . INSPECTION AFTER INSTALLATION ............. 230 .
Commercial Service Tools ................................... 207 . GLOW PLUG .......................................................... 231
.
NOISE, VIBRATION, AND HARSHNESS (NVH) Removal and Installation ...................................... 231 .
TROUBLESHOOTING ........................................... 209 . REMOVAL ......................................................... 231
.
NVH Troubleshooting --Engine Noise ................ 209 . INSTALLATION ................................................. 231.
Use the Chart Below to Help You Find the Cause VACUUM PUMP ..................................................... 232 .
of the Symptom. .................................................. 210 . Removal and Installation ...................................... 232 .
DRIVE BELTS ........................................................ 211 . INSPECTION BEFORE REMOVAL .................. 232 .
Checking Drive Belts ........................................... 211 . REMOVAL ......................................................... 232
.
Tension Adjustment ............................................. 211 . INSTALLATION ................................................. 233.
AIR CONDITIONER COMPRESSOR BELT ..... 212 . INSPECTION AFTER INSTALLATION ............. 233 .
ALTERNATOR AND WATER PUMP BELT ....... 212 . Disassembly and Assembly ................................. 234 .
Removal and Installation ..................................... 212 . DISASSEMBLY ................................................. 234 .
REMOVAL ........................................................ 212 . ASSEMBLY ....................................................... 234
.
INSTALLATION ................................................. 212 .
EM-4
INJECTION TUBE AND FUEL INJECTOR ........... 236 . ASSEMBLY ...................................................... 293 .
Removal and Installation ..................................... 236
. How to Select Piston and Bearing ....................... 297 . A
REMOVAL ........................................................ 236
. DESCRIPTION ................................................. 297 .
INSTALLATION ................................................ 237
. HOW TO SELECT PISTON ............................. 297 .
INSPECTION AFTER INSTALLATION ............ 238 . HOW TO SELECT CONNECTING ROD BEAR- EM
FUEL SUPPLY PUMP ........................................... 239 . ING ................................................................... 298
.
Removal and Installation ..................................... 239
. HOW TO SELECT MAIN BEARING ................. 299 .
REMOVAL ........................................................ 239
. Inspection After Disassembly .............................. 300 .
INSPECTION AFTER REMOVAL .................... 244 . CRANKSHAFT SIDE CLEARANCE ................. 300 . C
INSTALLATION ................................................ 244
. CONNECTING ROD SIDE CLEARANCE ........ 300 .
ROCKER COVER .................................................. 248. PISTON TO PISTON PIN CLEARANCE .......... 301 .
Removal and Installation ..................................... 248
. PISTON RING SIDE CLEARANCE .................. 301 . D
REMOVAL ........................................................ 248
. PISTON RING END GAP ................................. 302 .
INSTALLATION ................................................ 249
. CONNECTING ROD BEND AND TORSION ... 302 .
INSPECTION AFTER INSTALLATION ............ 249 . CONNECTING ROD BIG END INNER DIAME- E
CAMSHAFT ........................................................... 250
. TER .................................................................. 302
.
Removal and Installation ..................................... 250
. CONNECTING ROD BUSHING OIL CLEAR-
REMOVAL ........................................................ 250
. ANCE (SMALL END) ........................................ 303 .
INSPECTION AFTER REMOVAL .................... 251 . CYLINDER BLOCK TOP SURFACE DISTOR- F
INSTALLATION ................................................ 254
. TION ................................................................. 303
.
Valve Clearance .................................................. 255
. MAIN BEARING HOUSING INNER DIAMETER 304 .
INSPECTION ................................................... 255
. PISTON TO CYLINDER BORE CLEARANCE . 304 G
ADJUSTMENTS ............................................... 256. CRANKSHAFT JOURNAL OUTER DIAMETER 305 .
SECONDARY TIMING CHAIN .............................. 259 . CRANKSHAFT PIN OUTER DIAMETER ......... 305 .
Removal and Installation ..................................... 259
. CRANKSHAFT OUT-OF-ROUND AND TAPER. 305 H
REMOVAL ........................................................ 259
. CRANKSHAFT RUNOUT ................................. 306 .
INSPECTION AFTER REMOVAL .................... 261 . CONNECTING ROD BEARING OIL CLEAR-
INSTALLATION ................................................ 262
. ANCE ............................................................... 306
.
I
PRIMARY TIMING CHAIN ..................................... 264 . MAIN BEARING OIL CLEARANCE ................. 306 .
Removal and Installation ..................................... 264
. MAIN BEARING CRUSH HEIGHT ................... 307 .
REMOVAL ........................................................ 266
. MAIN BEARING CAP BOLT DEFORMATION . 307
INSPECTION AFTER REMOVAL .................... 268 . CONNECTING ROD BOLT DEFORMATION ... 307 . J
INSTALLATION ................................................ 269
. OIL JET ............................................................ 308
.
CYLINDER HEAD .................................................. 274
. OIL JET RELIEF VALVE ................................... 308 .
On-Vehicle Service .............................................. 274
. MOVEMENT AMOUNT OF FLYWHEEL .......... 308 . K
CHECKING COMPRESSION PRESSURE ..... 274 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 310 .
Removal and Installation ..................................... 275
. Standard and Limit ............................................... 310 .
REMOVAL ........................................................ 275
. GENERAL SPECIFICATIONS .......................... 310 .
L
INSPECTION AFTER REMOVAL .................... 276 . INTAKE MANIFOLD AND EXHAUST MANI-
INSTALLATION ................................................ 276
. FOLD ................................................................ 310
.
Disassembly and Assembly ................................ 279 . DRIVE BELTS .................................................. 310 .
DISASSEMBLY ................................................ 279
. CYLINDER HEAD ............................................ 311 . M
ASSEMBLY ...................................................... 280
. VALVE .............................................................. 311
.
INSPECTION AFTER DISASSEMBLY ............ 280 . CAMSHAFT AND CAMSHAFT BEARING ....... 315 .
ENGINE ASSEMBLY ............................................. 285 . CYLINDER BLOCK .......................................... 315 .
Removal and Installation ..................................... 285
. PISTON, PISTON RING AND PISTON PIN ..... 316 .
REMOVAL ........................................................ 285
. CONNECTNG ROD ......................................... 317 .
INSTALLATION ................................................ 287
. CRANKSHAFT ................................................. 317 .
INSPECTION AFTER INSTALLATION ............ 287 . AVAILABLE MAIN BEARING ........................... 318 .
CYLINDER BLOCK ............................................... 288 . AVAILABLE CONNECTING ROD BEARING ... 318 .
Disassembly and Assembly ................................ 288 . MISCELLANEOUS COMPONENTS ................ 318 .
DISASSEMBLY ................................................ 289
. Tightening Torque ................................................ 319 .
EM-5
PRECAUTIONS
[QG]
PRECAUTIONS
[QG] PFP:00001
Precautions for Drain Coolant EBS00GUD
q Drain coolant when engine is cooled.
Precautions for Disconnecting Fuel Piping EBS00GUE
q Before starting work, make sure no fire or spark producing items are in the work area.
q Release fuel pressure before disassembly.
q After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly EBS00GUF
q When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
q Exercise maximum care to avoid damage to mating or sliding surfaces.
q Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
q Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
q When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precautions for Inspection, Repair and Replacement EBS00GUG
q Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way,
and replace if necessary.
Precautions for Assembly and Installation EBS00GUH
q Use torque wrench to tighten bolts or nuts.
q When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.
q Replace with new gasket, packing, oil seal or O-ring.
q Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
q Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
q Release air within route after draining coolant.
q After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems
for leakage.
Parts Requiring Angular Tightening EBS00GUI
q Use an angle wrench for the final tightening of the following engine parts.
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