1984 Nissan 300ZX

ENGINE MECHANICAL
I
SECTION
EM E
CONTENTS
ENGINE COMPONENTS -Outer PartsCOMPRESSION PRESSURE
.
EM- 2
..
..
EM- 5
TIMING BELT
CYLINDER HEAD
EM- 4
.
EM-11
OIL PAN
EM-23
OIL SEAL REPLACEMENT
EM-24
ENGINE REMOVAL
ENGINE OVERHAUL
SERVICE DATA AND SPECIFICATIONS
EM-25
SPECIAL SERVICE TOOLS
EM-26
(S D S )
...
EM-35
EM43
ENGINE COMPONENTS -Outer Parts-
SEM234A
EM-2
- D C on
YL
I
istributar gear position
..
...
Turbocharger assembly/
Use new gaskets, O-rings and bronze washers
0 Tighten collector and collector cover as shown to the right
Loosen them in reverse order of removal As for tightening
order of exhaust manifolds and collector, refer to Cylinder
Head
0
w
VI
P
0 N rn Ikgrn,ft-lbl
After twhtentng nu;, bend lock washers
Use new lack washers
Collector cover
I
I
COMPRESSION PRESSURE
Measurement of C
1
2
npression Pressure
Warm up engine
Remove all spark plugs
Use a suitable plug wrench shown below.
Wrench with a magnet
to hold spark plug
16 mm
( 0 63 in)
/
-
SEM294A
3
Attach a compression tester
SEM237A
4
Depress accelerator pedal t o fully open
throttle.
5
Crank engine and read gauge indication
Compression pressure:
kPa (kg/cm*, psi) a t rpm
Standard
Non-turbo 1,196 (12.2, 173)/300
Turbo
1,138 (11.6, 16511300
Minimum
Non-turbo 883 (9.0,128)/300
Turbo
834 (8.5,121)/300
Differential limit between cylinders:
98 (1.0. 14)/300
EM-4
I f cylinder compression in one or more cylinders is low, pour a small amount of engine
oil into cylinders through the spark plug holes
and retest cornpression
If adding oil helps the compression pressure,
chances are that piston rings are worn or damaged.
If pressure stays low, valve may be sticking or
seating improperly
If cylinder compression in any two adjacent
cylinders is low, and if adding 011 does not help
the compression, there i s leakage past the
gasketed surface
TIMING BELT
Timing belt
a Ensure timing belt IS clean and free from 011 or water
b Before installing timing belt, confirm that No 1 cylinder 86 set at T 0 C on compression stroke
c Align arrow on timing belt forward
d Adlust belt tenrian with all plugs removed and both rocker shafts loosened completely
e Align white lines on timing belt with punch mark on camshaft pulleys and crankshaft Pulley
Rear belt cover
Cylinder block
\
%, ,
m 7 8 - 8 8 1 8 0 - 9 0 . 5 8 65)
Conical washer
Belt tensloner nut
4 3 - 5 8 ( 4 4 - 5 9 . 3 2 - 431
Front upper belt cover
3 - 5 10 3 0 5 . 2 2 361
to threads of c o m a
Belt tensioner
Front lower belt cover
-4
Timing belt plate
Crank pulley plate
123.132
1125.135.90.98)
\Crank
m
pulley
N m (kg-m, ft-lbl
SEM238A
Ren
Non-turbo model
Air conditioner
cammessor
7
Turbo model
Air conditioner
comoressor
7
After removing cylinder head, do not rotate crankshaft and camshaft separately, because valves will
hit piston heads
1 Remove radiator shroud, fan and pulleys
Refer t o Cooling System-Radiator (Section
LC).
2 Drain coolant from radiator and remove water
pump hose
Be careful not t o attach coolant t o drive belts
3. Remove the following belts
Power steering drive belt
Compressor drive belt
Alternator drive belt
f- Alternator
EM-5
SEMZ39A
9-w3
ilaq 6 u i u i i aAouai uaqi
Guilds u i n i a i pue lauoisuai ilaq 6uiluii uasool '9
'siaho3 ilaq lam01 pue laddn 1uoi4 anouau 5
1138 9NIWIl
TIMING BELT
Inspection
Visually check t h e condition of the timing belt
Replace if any abnormality IS found
Item to check
Belt
is
Cause
Problem
Improper handling
broken
Poor belt cover sealing
Coolant leakage a t water pump
SEM393A
Camshaft jamming
Tooth is broken1
tooth root i s
cracked
Distributor jamming
Damaged camshaftlcrankshaft oil seal
SEM394A
Tensioner jamming
Back surface i s
crackedlworn
Overheated engine
Interference with belt covei
SEM395A
EM-7
TIMING BELT
inspection (Cont'd1
Cause
Problem
Item to check
Improper installation of belt
Side surface is worn
Malfunctioning crank pulley plateltiming
belt plate
0
Side surface of belt i s worn to such an
extent that there is no trace of cutoff
performed during manufacturing process
0
Belt corners are worn and round
0
Wicks are frayed and coming out
*
~
~
~
~
~
*
Poor belt cover sealing
Teeth are worn
0
Coolant leakage a t water pump
0
Camshaft not functioning properly
0
Distributor not functioning properly
0
Excessive belt tension
0
Poor oil sealing of each oil seal
0
Coolant leakage at water pump
0
Poor belt cover sealing
Canvas o n tooth face is worn down
0
Canvas o n tooth is fluffy, rubber layer is
worn down and faded white, or weft IS
worn down and invisible
SEM397A
~~~
OiVCoolant or water is
stuck t o belt
EM-8
TIMING BELT
1
Confirm that No. 1 cylinder
i t s compression stroke.
IS
set a t T D C on
Rear
.
.
belt cover
Aligning
marks
I
I
7
/
\
4
Set timing belt
a.
Ensure timing belt is clean and free from oil
or water Do not bend it
Align white lines on timing belt with punch
mark on camshaft pulleys and crankshaft
pulley.
Have arrow on timing belt pointing toward
front belt covers
b
Al~gntngmarks
C
Aligning
marks 7
= + = = i i ~ $ A l t g n ! n g
o,ipump
Crank pulley
(Inner)
A
-
Aligning
marks
marks
No 1 cylinder
at IOP dead center
in compression stroke
SEM241A
2
Remove both rocker covers and loosen all
rocker shaft securing bolts
Loosen all rocker shaft securing bolts thoroughly
so t h a t timing belt tension can be adjusted correctly.
3
~ncompression stroke
SEM242A
5
Install tensloner and return spring
Slowly turn tensioner with hexagon wrench
clockwise and counterclockwise two or three
times
Arrow A
SEM243A
If coarse stud IS once removed, apply locking sealer
to threads of stud before installing
SEM244A
6
Tighten tensioner lock nut
ps1
.
EM-9
43-58N.m
(4 4 - 5.9 kgm, 32 - 43 ft-lb)
TIMING BELT
Installation (Cont'd)
7
Tighten rocker shaft securlng bolts in two or
three stages.
L H rocker shafts
n 18-22N.m
Intake manifold
ride
(1.8-2.2kg-m, 13-16ft-lb)
R H. rocker shafts
Exhaust manifold side
SEM245A
Before tightening, be sure to set camshaft lobe at
the position where lobe IS not lifted.
Intake
8
Install lower and umer belt covers
Belt cover front (upper)
I
9
Belt cover (rear)
,
BOli c 14 PSI I
I
0
Belt cover front (lower)
SEM: .EA
EM-I0
CYLINDER HEAD
m l . 3 I O 1 - 0 3,O 7 . 2 2)-
L H rocker cave!
(1 8 - 2 2.13 - 161
Valve hfter guide
Cylinder head bolt
Tbghten them in 5
Valve spring retainer
2nd Tighten them to 59 N m 16 0 kg-m. 43 ft-lbl
3rd Loosen them completely
Valve outer spnng
Valve inner spring
Valve oil seal
0
1
1 idler
cap
Outer spring seat
Exhaust valve
n
-
78 88 (8 0 . 9 0 . 5 8 . 6 5 )
~ s w i t h i nthe specification
0
When installing sliding parts such as
bearings, be sure to apply engine oil
on the sliding surfaces
Use new gaskets and oil seals
N rn l k g m , f t - l b )
SEM250A
EM-I1
CYLINDER HEAD
Rer
To facilitate removal of both cylinder heads, it is
advisable t o dismount the engine as a unit in
advance.
1
val
4 Remove power steering pump bracket
Remove timing belt.
Set No 1 cylinder a t T D C on its compression
stroke
After removing cylinder head, do not rotate
crankshaft and camshaft separately, because valves
will h i t piston heads.
2
Remove collector cover and collector
Before removing collector, be sure to drain coolant
removing drain cocks in cylinder block
SEM253A
5
Loosen in numerical order and tighten
m reverse order of removal
3
Remove intake manifold with
assembly.
I II
SEM251A
fuel
tube
Remove exhaust manifold covers
SEM297A
6 Disconnect exhaust manifold connecting tube
Loosen m numerical order
SEM252A
EM-I2
SEM298A
CYLINDER HEAD
Removal (Cont’d)
7. Remove camshaft pulleys and rear timing cover
securing bolts.
8 Remove compressor and rocker covers
1. Remove exhaust manifold.
R.H exhaust manifold
L.H exhaust manifold
No 2
9. Remove cylinder head with exhaust manifold
NO 1
NO
3
No4
No6
~ a o s e nan numerical order
NO 5
2
SEM536A
Remove rocker shafts with rocker arms.
The bolts should be loosened in two or three
Stages.
SEM258A
EM-I3
CYLINDER HEAD
Inspection
Disassembly (Cont'd)
3
Remove hydraulic valve lifters and lifter guide
CAMSHAFT END PLAY
a.
Hold hydraulic valve lifters with wire so that
they will not drop from lifter guide.
Camshaft end play
0 03 - 0.06 mm (0.0012 - 0 0024 in)
b.
Do n o t put hydraulic valve lifters upside down,
otherwise air will enter valve lifter, causing it t o
make a noise.
c. Do not disassemble hydraulic valve lifter.
d. Put identification mark on valve lifters not to
avoid mixing them up.
4.
End ~ l a v
Remove camshaft
,
Camshaft
Locate p l a t e
SEM260A
If camshaft end play exceeds the specified
limit, select thickness of cam locate plate so
that end play is within the specification.
SEM259A
Identjfication
mark C
Unit mm im)
EM-I4
No
ldentification
mark
A
Punched
identif cation
mark
SEM26lA
CYLINDER HEAD
Inspection (Cont'd)
Example
When camshaft end play is 0 08 mm (00031 in)
with shim @ used, change shim @ t o shim @ so
that camshaft end play is 0 05 mm (00020 in)
VALVE GUIDE CLEARANCE
Valve guide clearance should be measured
parallel with rocker arm (Generally, a large
amount of wear occurs in this direction.)
Stem t o guide clearance:
Maximum limit
0 10 m m (0.0039in)
Maximum allowable deflection
(Dial indicator reading)
0.2 mm ( 0 008 in)
CYLINDER HEAD DISTORTION
Measuring points
SEMZ63A
Replacement
SEM262A
If beyond the specified limit, resurface it
Replace valve and/or valve guide
1 To remove valve guide heat cylinder head t o
150 t o 160°C (302 t o 320°F) and drive out
valve guide with a press [under a 20 kN (2t, 2 2
US ton, 2 0 Imp ton) pressure] or hammer,
and suitable tool
Resurfacing limit.
The resurfacing limit of cylinder head IS determined by the cylinder block resurfacing in an
engine
Amount of cylinder head resurfacing is " A '
Amount of cylinder block resurfacing is " B
The maximum limit is as follows:
A + B = 0.2 mm (0.008 in)
SEMOOBA
EM-I5
CYLINDER HEAD
4
Ream valve guide
Finished size:
Intake
7 000 - 7 018 mm (0.2756 - 0.2763 in)
Exhaust
8.000 - 8.018 rnrn (0.3150 - 0.3157 in)
SEM264A
2
Ream cylinder head valve guide hole
Valve gwda hole inride diameter
Intake11 175-11 196(04400-04408)
Exhaust
12175-12196(04793-04802~
,
,
SEM272A
VALVE INSERTS
Check valve inserts for any evidence of pitting a t
valve contact surface, and reseat or replace if worn
out excessively
When repairing valve inserts, check valve and
valve guide for wear beforehand. I f worn,
replace them. Then correct valve seat.
The cutting should be done with both hands
for uniform cutting.
3. Heat cylinder head t o 150 t o 160°C (302 t o
320°F) and press service valve guide onto
cylinder head
Replacement
If necessary, replace valve inserts as follows.
1
After removing valve insert, ream the cylinder
head recess
2. Heat cylinder head t o a temperature of 150 t o
160°C (302 t o 320°F)
3 Press fit insert until it seats on the bottom, and
caulk more than 4 points
4. Cut or grind valve inserts using suitable tool a t
the soecified dimensions as shown in S D.S
SEMt71A
E M - I6
CYLINDER HEAD
VALVE DIMENSIONS
Check dimensions in each valve. For dimensions,
refer to S D S
When valve head has been worn down t o 0 5 mm
(0.020 in) in margin thickness, replace the valve.
Grinding allowance for valve stem tip is 0.2 mm
(0.008 in) or less
T
(Margin thickness1
4iSEM265A
5 After cutting, lap valve inserts with a lapping
6
compound
Check contact condition of valve inserts
*
F-
SEM188A
CAMSHAFT JOURNAL CLEARANCE
Wear limit
0.15 mm (0.0059 in)
VALVE SPRING SQUARENESS
Out of square
Outer
Less than 2.2 mm (0.087 in)
Inner
Less than 1.9 mm (0.075 in)
Standard mxde diameter
47 00 47 025 rnrn
-
(1 8504. 1.8514 m)
SEM288A
VALVE SPRING PRESSURE LOAD
REfer to S.D
SEMZ67A
EM-I 7
S
CYLINDER HEAD
Inspection (Cont'd)
HYDRAULIC VALVE LIFTER
1
Check contact and sliding surfaces for wear or
scratches.
Install outer valve spring (uneven pitch type) with
i t s narrow pitch side toward cylinder head side
Install valve component parts.
#T
&+
SEMZBOA
SEM052
2
3
If valve lifters are noisy, check valve lifter
(1) Depress plunger forcibly with your finger
Wide pitch
4
Install camshaft
Apply engine oil t o camshaft oil seal and install
it in place
Adjust camshaft end play with locate plate installed
If it moves about 1 mm (0.04 in), it indicates air is
inside valve lifter
(2) Re-install rocker arm and rocker cover.
(3) Bleed air by running engine a t 1,000 rpm under
no-load for about 10 minutes.
(4) Next, remove rocker cover and rocker arm and
check to ensure all air IS bled. (Refer t o step
(1) above)
(5) If there is still air, replace valve lifter.
E M - I8
CYLINDER HEAD
1 Before installing cyllnder head, make sure that
No 1 cylinder is set a t T D C on i t s compression stroke as follows
(1) Crankshaft timing pulley mark should be
aligned with mark on oil pump housing
CgF
3. Tighten cylinder head bolts with washers using
ST10120000.
Tightening order
R H side
No 1
No 3
NO 5
L.H side
SEM278A
(2) Have knock pin in front end of camshaft facing
upward
Knock pin
No 2
No 4
No 6
SEMSSSA
Tightening procedures
1st
2nd
3rd
4th
Do not rotate crankshaft and camshaft separately,
because valves will hit piston heads.
2 Install cylinder head with new gasket
5th
Tighten all bolts t o 29 N.m
(3 0 kg-m, 22 ft-lb)
Tighten all bolts t o 59 N m
(6 0 kgm, 43 ft-lb)
Loosen all bolts completely.
Tighten all bolts t o 29 N m
(3.0 kg-m, 22 ft-lb)
Tighten all bolts to 54 to 64 N m
(5.5 t o 6.5 kg-m, 40 to 47 ft-lb)
or if you have an angle wench, turn all
bolts 60.65 degrees clockwise
After engine has been operated for several minutes,
retighten if necessary.
EM-19
CYLINDER HEAD
Installatic
4
Tighten rear timing cover.
5
Install camshaft pulleys
PJ)
.
(Cont'd)
6
7
8
Camshaftpulley.
78.88 N m
(8.0 - 9 0 k g m , 58 - 65 ft-lb)
Assemble valve lifters to their original position and
hold all valve lifters with wire
SEM305A
R H. camshaft pulley and L.H. camshaft pulley are
different parts. Be sure t o install them in the right
positions.
L
A
SEM303A
Identification mark
R H camshaft pulley
L H camshaft pulley
Install timing belt and adjust belt tension
Install front upper and lower belt covers
Install valve lifters and lifter guide
0'53'
-3'27'
EM-20
-.
SEM280A
CYLINDER HEAD
Installation (Cont'd)
9 Install rocker shafts with rocker arms a n d tighten rocker shaft securmg bolts
R
H
rocker shafts
in
two or three stages
Exhaust manbfald side
rn
m
iNo3
Rocker shaft direction
-@7lmHW7
@I
~ l l a
. ...
Intake manifold side
L H rocker shafts
intake manifold ride
Exhaust manifold ride
SEM281A
10 Install rocker cover
Confirm rocker cover bolts, washers and trays are
free from oil.
11 Install intake m a n i f o l d a n d fuel tube
Tighten in two or three stages.
.
Nut
1st
2nd
Bolt
1st
2nd
3-5N.m
(0.3 - 0.5 k g m , 2.2 - 3.6 ft-lb)
24-27N.m
(2.4 2.8 k g m , 17 - 20 ft-lb)
-
Tighten In numerical order
SEM529A
3-5N.m
(0.3 - 0.5 kgm, 2.2 3.6 ft-lb)
24-27N.m
(2.4 2.8 kgm, 17 - 20 ft-lb)
-
-
EM-21
CYLINDER MEAD
Installation (Cont'd)
12 Install exhaust manifolds and connecting tube
R H exhaust manlfold
No 5
No 3
No 1
L H exhaust manifold
No 2
NO 4
No 6
Tighren m numerical order
SEM535A
13 After assembling all disassembled parts, fill
radiator with coolant up to the specified level
Refer t o Changing Engine Coolant (Sections
MA and LC)
EM-22
OIL PAN
Ren
1
2
INSTALLATION
Drain engine oil
Raise vehicle and support it with safety stands
.
I
1
Apply sealant
” A\
011 Seal
Sealant
3
4
5
6
7
8
9
10
11
12
13
14
15
Remove front stabilizer bar securing bolts and
nuts from suspension crossmember
Remove steering column shaft from gear
housing
Remove tension rod securing nuts from transverse link
Lift engine
Remove rear plate cover from transmission
case
Remove oil pan securing bolts
Remove suspension crossmember securing
bolts
Remove strut mounting insulator securing nuts
Remove screws securing refrigerant lines and
power steering tubes t o suspension crossmember
Lower suspension crossmember
Remove oil pan from rear side
Remove oil strainer from oil pump assembly
and cylinder block.
Remove oil pump assembly
2
m
106-07.43 5 1
N rn Ikg-m, ft-lbl
I 1 2 . 1 6 . 9 - 121
SLC547
EM-23
reta,ner 7
SEM542A
Install oil pan
5-7Nm
(0 5 - 0 7 kg-m, 3 6 - 5 1 ft-lb)
Tighten !n numerical order
SEM543A
OIL SEAL REPLACEMENT
-Replacement
1
2
3
4
of Camshaft Oil Seal-
Remove timing belt
Remove camshaft pulleys
Remove camshaft oil seal
Apply engine oil to camshaft oil seal and install
it in place
4
Remove valve oil seals
SEM28SA
5 Apply engine oil to valve oil seal and install
in place.
it
SEM284A
5
Install timing belt
-Replacement of Valve Oil Seal 1
2
3
Remove collector and rocker cover ( L H only)
Remove rocker shaft assembly and valve lifters
w i t h valve guide
Remove valve springs, retainer and collets
SEM286A
When installing valve oil seal in exhaust manifold
side, tool is not necessary.
Valve
011 real-
Valve
rpr'ng =at
SEM257A
1
pi
b+
(0.0391
SEM287A
EM-24
ENGINE REMOVAL
CAUTION.
When installing engine gussets, tighten bolts in
a.
6 stages as shown below
b
Before disconnecting fuel hose, release f u e l
pressure from fuel line Refer to t h e "Releasing
A (Two bolts)
Rear plate cover
E (i
bolt)
w0
Fuel Pressure" in section MA
A f t e r separating engine and transmission, remove engine from t h e vehicle A t this t i m e use
a suitable safety stand such as hydraulic hoist
to support transmission
Remove R H exhaust manifold and exhaust
connecting tube, then separate engine and
transmission
1Gusset istarter ridel
,-Gasket
SEM54OA
Ttghtening order
IIt
A.1
'1
Exhaust connecting tube
L
'2
2nd
3rd
41h
5th
61h
D'2
A'2
F'Zand
G.2
E.2
8'2 and
C'2
Toghien temporarity
Tqhfen mrnplefely
R H exhaust manifold
SEM526A.
. 4 2 13 2 . 4 3,23- 311
45 - 60 ( 4 6 - 6 1,33.44)
25- 34 ( 2 5 - 3 5 . 1 8 - 25)
N rn (kg-m. ft-lbl
SEM307A
EM-25
ENGINE OVERHAUL
-
PISTON AND PISTON PIN CLEARANCE
PISTON AND CRANKSHAFT
1
Inspection
Confirm the fitting of piston pin into piston
pin hole to such an extent that it can be
pressed smoothly by finger a t room temperature
Place engine on work stand
KL. 10106500
Piston pin t o piston clearance:
0 008 - 0.012 mm (0.0003 - 0.0005 in)
SEM308A
2
3
4
5.
6
7
8
Remove timing belt
Drain coolant and remove water pump
Drain oil
Remove oil pan and oil pump
Remove cylinder heads
Remove pistons
Remove bearing cap and crankshaft
\
SEM312A
PISTON RING SIDE CLEARANCE
Side clearance:
Top ring
0 040 - 0.073 mm (0 0016.0.0029 in)
2nd ring
0.030 - 0.063 mm (0.0012.0.0025 in)
Oil ring
0.015 - 0.190 mm (0.0006.0.0075 in)
Max. limit of side clearance (Top and 2nd
rings)
0 1 mm (0.004 in)
Loosen
numerical order
y-
Thickness gauge
I
SEM3llA
SEM313A
EM-27
ENGINE OVERHAUL
Inspection (Cont'd)
PISTON RING GAP
Ring gap:
Top ring
0 21 - 0 44 mm (0 0083 - 0.0173 in)
2nd ring
0.18 - 0.44 mm (0.0071 - 0.0173 in)
Oil ring
0 20 - 0.76 mm ( 0 0079 0.0299 in)
-
'
I
yic--J
/
EM142
Method B
Main bearing
1
2
SEM314A
Install main bearings to cylinder block and
main bearing cap
Install main bearing cap to cylinder block
Tighten all bolts in correct order and in two or
three stages
:
BEARING CLEARANCE
Bearing clearance:
Main bearing
0.028 - 0.055 mm (0.0011 0.0022 in)
Limit 0.090 mm (0.0035 in)
Connecting rod bearing
0.010 .0.052 mm (0.0004 0.0020 in)
Limit 0.090 mm (0.0035 in)
3
~
~
Method A
CAUTl ON :
8
Do not turn crankshaft or connecting rod
while the plastigage is being inserted.
When bearing clearance exceeds the specified
limit, ensure that the proper bearing has been
installed. Then if excessive bearing clearance
exists, use thicker main bearing or undersized
bearing so that the specified bearing clearance
is obtained.
EM-28
90-l00Nm
(9.2 - 10 2 kg-m, 67. 74 ft-lb)
Measure inside diameter "A" of main journal
ENGINE OVERHAUL
Inspection (Cont'd)
4
Measure outside diameter
in crankshaft
"B" of main journal
CRANKSHAFT INSPECTION
1
2
Check crankshaft journals for score, bias, wear
or cracks If faults are minor, correct wlth
fine crocus cloth
Check journals with a micrometer for taper and
out-of-round.
Out-of-round (X-Y):
0 006 mm (0.0002 in)
Taper (A-B).
Less than 0.006 mm ((LO002 in)
SEM506A
5
Calculate main bearing clearance
Main bearing clearance
=A-B
U
Connecting rod bearing
1
2
p-l
3
Install connecting rod bearing t o connecting
rod and cap
Install connecting rod cap t o connecting rod
a
44-54N.m
(4.5 - 5.5 kg-m, 33 40 ft-lb)
-
Measure inside diameter "C" of bearing
When regrinding crank pin and crank journal,
measure "L" dimension in fillet roll. Make sure
the measurements exceed the specified limit. If
the measurements are within the specified
limit, do not regrind
L. More than 0.13 mm (0.0051 in)
I
SEM507A
W
4 Measure outside diameter "D" of connecting
rod bearing in crankshaft.
Calculate connecting rod bearing clearance
Connecting rod bearing clearance
=C-D
04
.@-@
SEM316A
A
5
Taper
Outuf-round
SEMl84A
b. Do not grind off fillet roll.
c Refer to S.D.S for regrinding crankshaft and
available service parts
EM-29
ENGINE OVERHAUL
Inspection (Cont'd)
Amount of cylinder head resurfacing is "A"
Amount of cylinder block resurfacing IS "B"
The maximum limit is as follows.
A + B = 0.2 mm ( 0 008 in)
CRANKSHAFT RUNOUT
Check crankshaft runout
Runout fT I R (Total indicator Reading11
Less than 0 10 rnrn IO 0039 in1
Using a bore gauge, measure cylinder bore for
wear, out-of-round or taper
Standard inside diameter.
87.00 87.05 mm
(3.4252 - 3 4272 in)
Wear limit:
0.20 mm (0.0079 in)
Out-of-round (X-Y) limit:
0.015 mm (0.0006 in)
Taper (A-B) limit:
0.015 mm (0.0006 in)
-
SEM318A
CYLINDER BLOCK DISTORTION AND
WEAR
Warpage of plrfam
Less than 0 1 rnm ( 0
SEM3tSA
If beyond the specified limit, resurface it.
Unit
Resurfacing limit.
The resurfacing limit of cylinder block is determined by the cylinder head resurfacing in an
engine.
mrn I
d
SEM321A
Check for scratches or seizure If seizure is found,
hone it.
Never bore it.
I f wear exceeds the specified limit, replace cylinder
block.
EM-30
ENGINE OVERHAUL
Inspection (Cont’d)
0
If either cylmder block or plston is replaced
with new one, select the same piston as plston
grade number punched on cylinder block upper
surfaces.
Piston orade number and ring set
SEM557A
PISTON TO CYLINDER WALL CLEARANCE
1 Measure piston diameter
2
Check that piston clearance
specification
IS
withln the
Piston clearance
0.025 - 0 045 mm (0.0010 - 0.0018 in)
EM-31
ENGINE OVERHAUL
Assernbly
Inspection (Cont'd)
PISTON
PISTON-TO-CYLINDER CLEARANCE
(Using feeler gauge)
a.
When pulling feeler gauge straight upward, measure
t h e extracting force It IS recommended that piston
and cylinder be heated t o 20°C (68°F)
Feeler gauge thickness:
0.04 mm (0.0016 in)
Extracting force.
2.0 - 14.7 N (0 2 - 1 5 kg, 0 4 - 3.3 Ib)
Numbers are stamped on the connecting rod
and cap corresponding t o each cylinder'. Care
should be taken t o avoid a wrong combination
including bearing.
b. When pressing piston pin in connecting rod,
apply engine oil t o pin and small end of connecting rod.
n
10300
SEM32SA
5EM324A
CRANKSHAFT
Set main bearings in the proper position on
cylinder block
1
FLYWHEEL RUNOUT
Runout (Total indicator reading).
Less than 0 15 mm (0.0059 in)
Upper main bearmg
Dial gauge
A
No 1.
* With
081
groove
Lower main bearing
No 4
SEM327A
Install ring on flywheel, heating ring gear t o about
180 to 220°C (356t o 428°F)
EM-32
ENGINE OVERHAUL
:Cont'd)
2
If either crankshaft, cylinder block or main
bearing is reused again, it IS necessary t o
measure main bearing clearance.
If all of crankshaft, cylinder block and main
bearing are replaced with new ones, it IS necessary t o select thickness of main bearings as follows
a Grade number of each cylinder block main
journal is punched on the respective cylinder
block
No 1 ioumal
No 4
No 2
NO 3
p/
c
Select suitable thickness of main bearing
according t o the following table
Main journal
grade number
Main bearing
grade number
Crankshaft journal
grade number
1
1
2
3
2
2
3
4
For example
Main journal grade number 1
Crankshaft journal grade number 2
Main bearing grade number = 1 + 2
=3
W
Main bearing:
Refer t o S.D.S.
SEM508A
b
Grade number of each crankshaft main journal
is punched on the respective crankshaft
3
Install main bearing cap and tighten bolts t o
the specified torque
.
9 0 - 100N.m
(92 - 10 2 kg-m, 67 - 74 ft-lb)
Tighten in two or three stages
SEM510A
After securing bearing cap bolts, ascertain that
crankshaft turns smoothly by hand.
EM-33
ENGINE OVERHAUL
Assernbll
4
6
install piston assembly
Measure connecting rod clearance
Connecting rod clearance:
Standard
0.20 - 0.35 m m (0.0079 - 0 0138 in)
Limit
0.40 mm (0.0157 in)
Set piston rings as shown below.
ton pin direcrion
Thrust direction
SEM180A
Mark should be faclng upward
5. Measure crankshaft free end play at No 4
bearing
Crankshaft free end play:
Standard
0.05 - 0.17 mm (0.0020 - 0.0067 in)
Limit
0.30 mm ( 0 0118 in)
SEMSllA
EM-34
SEMSlZA
SERVICE DATA AND SPECIFICATIONS (S. D.S.)
General Specifications
Inspection and Adjustment
I
HEAD
-
CYLINDER
VG30E
Unit mrn Id
V-6
Cylinder arrangement
Displacement
cm' lcu in)
8oreandStroke
mm (In1
Head surface flatnerr
2.960 1180 621
Standard
Limit
Less than
0 05 I O 00201
0 1 100041
87 x 83 I 3 4 3 x 3 271
VALVE
OHC
Valve arrangement
1-2 3 4 - 5 5
Firing order
Number of piston rings
Compresston
T IMargn thtcknerrl
2
I
f
1
011
Number of main bearings
4
Camprerrion ratlo
Non-turbo
90
Tiirho
78
Valve timing
e
TDC
2
1
.
Engine
VG30E
Item
Valve head diameter "D '
Intake
Ethaust
Valve length "L'
Intake
Echaurt
4 2 0 - 4 2 2 I 1 654-16611
35 0 - 3 5 2 I 1 378.1 386)
1 2 5 3 - 125 9 I 4 93 - 4 961
124 2 - 124 8 1 4 8 9 - 4 911
EM120
~~
BDC
Unit degree
a
b
c
d
e
f
252'
252'
20"
52'
16"
62"
Valve stem diameter '*d"
Intake
Exhaust
6 965 - 6 980 IO 2742 - 0 27481
7 945-7 960 103128-031341
Valve seat angle "a"
Intake
Exhaust
Unit kPa lkglcm2, prd/rpm
Non-turbo
'
'
Standard
Minimum
~~~
Differential limit
between cylinders
I
Valve margin "T"
Intake
Turbo
Exhaust
1,1961122,173~
1.138111 6,1651
883 I 9 0, 1281
/300
1300
98 I 1 0. 141
1300
834 I8 5,121)
~
T
O
98 ( 1 0.14)
1300
13100511
1 5 ( 0 0591
Valve margin '7" limit
0 5 10 0201
Valve stem end surface
grinding limit
0 2 I O 008)
Valve clearance
Intake
0 101
Exhaust
0 I01
EM-35
SERVICE DATA AND SPECIFICATIONS (S.D.S.)
Inspection and A
Valve guide
Valve spring
Free height
Outer
51 2 I 2 0161
l""W
44 9 ( 1 7681
m m (ml
Outer
Pressure height
m m / N lmmlkg, m/lb)
l""W
mm
30 01523 7
1300/534. 1 181111771
40 O D 5 0 1
( 4 0 0/255, 1 575/56 21
Inner
350/1206
135 0/12 3, 1 378/27 11
Outer
2 2 (00871
Inner
1 9 10 0751
Service
Intake
11023-11034
104340 043441
11223 11234
(04418-04423)
Exhaust
12 023 - 12 034
(04733.04738)
12 223.12 234
104812 04817)
Outer
diameter
Valve guide
Inner
diameter
[Finished
Intake
7 000-7 018
10 2756.0 27631
rml
Exhaust
8 000 - 8 018
(03150.031571
(in)
Cylinder head
Intake
valve gwde hole
diameter
Exhaust
Hydraulic valve lifter
Unit m m (in1
Lifter outride diameter
1 5 9 4 7 - 15 957
I O 6278 - 0 62821
Lifter guide inside diameter
16 000 - 16 013
(06299 - 0 63041
Clearance between lifter and
lifter guide
Standard
Valve guide
24 51250 1
(24 5/25 5, 0 965/56 21
Outer
Assembled heioht
mm/N lmm/kg, d l b l
Out of square
Jstment (Cont'd)
0 043.0066
10 001 7 . 0 00261
Interference
f t t of valve
guide
10975-10996
IO4321 -043291
11 175 11 196
104400 044081
11 975 11 996
104715-047231
12175 1 2 1 9 6
(04793-04802)
0 027 - 0 059
I O 0011 0 00231
Intake
0 027 - 0 059
(0001 1 - 0 00231
Exhaust
Standard
Stem t o gu&
clearance
Intake
limn
EM-36
0 020.0 053
(00 0 0 8 ~ 0
00211
0 1 (0004)
Exhaust
Valve deflection
Max tolerance
O M 0 -0073
(00016 - 0 0029)
-
0 2 10 0081
SERVICE DATA AND SPECIFICATIONS (S.D.S.)
Inspection and P
ustment (Cont'd)
CAMSHAFT AND CAMSHAFT BEARING
Valve seat
Unit
EXHAUST
mm (in1
I
3 4 4 - 34 6
I 1 354. 1 3621 dia
Standard
Max tolerance
Camshaft Journal to
bearing clearance
Ogo
I O 0018.0 00351
0 15 IO 00591
Inner diameter of
cam,,haft bearing
47 00.47 025
I1 8504 185141
-
Outer diameter of
camshaft ioumal
46 935.46 955
I1 8478.1 84861
Camshaft runout
LT 113.1
Less than
0 02 I O 00081
01 I O O M I
SEM533A
Camshaft
INTAKE
0 0 3 006
I O 0012.0 00241
I1 638. 1 6461 dia
-
EM671
45 I 1 77) dia
Cam height "A"
unit
Intake
mm Iinl
Exhaust
SEM534A
Wear limit of cam height
'Total mdtcator reading
EM-37
39 607 - 39 657 I 1 5593 1 56131
0 15 (000591
SERVICE DATA AND SPECIFICATiBNS (S. D.S.)
inspection and f
ustrnent (Cont'd)
PISTON, PISTON RING AND PISTON PIN
CYLINDER BLOCK
m m Iinl
Unit
Available piston
Unit m m ( i n )
%
SEM321A
Surface flatness
Standard
Less than 0 03 10 00121
Cvlmder bore
Inner diameter
Standard
Grade NO
Grade NO
Grade N o
GradeNo
GradeNo
Model
0 10 I O 00391
Limit
Non-turbo
1
2
3
4
5
0 02 10 WO81
overs1ze ISerwceI
GradeNo 3
GradeNo 4
GradeNo 5
GradeNo 6
GradeNo 7
Wear limit
870W-87010(34252.342561
87 010 - 87 020 (3 4256.3 42601
87 020 - 87 030 13 4260.3 42641
87 030 - 87 040 13 4264.3 4268)
87 040 - 8 7 050 13 4268 3 42721
87
87
87
87
87
020.87 030 13 4260.3
030 - 87 040 13 4264 .3
040.87 050 13 4268.3
050.87 060 13 4272.3
060 - 87 070 13 4276.3
PlLtO"
skirt
dimeter
',A"
42641
42681
42721
42761
4279)
Standard
GradeNo 1
GradeNo 2
Grade NO 3
Grade N o 4
Grade N o 5
86 965 - 86
86 9 7 5 . 8 6
86 985 85
86 995 - 87
87 005 - 87
975 13 4238 3 42421
985 13 4242.3 42461
995 13 4246.3 4250)
005 13 4250.3 42541
015 13 4254 - 3 42581
0 02 I O 00081
oversize ISewiceI
GradeNo 3
Grade N o 4
GradeNo 5
Grade NO 6
Grade NO 7
86 985 - 86
86 995 87
87 0 0 5 . 8 7
87 0 1 5 . 8 7
87 025 87
995 13 4246.3 4250)
005 13 4250.3 42541
015 13 4254.3 42581
025 13 4258 3 42621
035 13 4262 - 3 42661
"a" dimension
0 20 10 00791
Outuf-round IX-YI
Less than 0 015 10 00061
P i s t o n pin hole diameter
Taper IA-E-Cl
Less than 0 015 IO OOO6)
Ptston clearance to
cylinder block
Main journal mner
diameter
GradeNo 0
66 645 -66654 (26238.262421
GradeNo 1
66 654 - 66 663 I2 6242.2 62451
GradeNo 2
66 663.66 672 12 6245.2 62491
Ddfference in inner
dnameter between cylinders
Standard
Wear limit
Less than 0 05 10 0020)
0 20 (00079)
EM-38
Turbo
-
1
200f0787)
21 5108461
21 001 .21 008 IO 8268
.O 82711
0025-0045f00010-000181
SERVICE DATA AND SPEClfflCATlONS (S.D.S.)
Inspection and A
ustment (Cont'd)
CRANKSHAFT
Piston ring
Unit mm linl
Unit m m l i d
Main lournel dia "Dm'
Limit
Standard
Side clearance
0040 0073
I O 0016 - 0 0029)
TOP
2nd
0 030 - 0 063
I O 0012 0 0025)
081
0015 0190
100006 000751
Ring gap
TOP
I
021 - 0 4 4
I O 0083 - 0 01 731
62 967.62 975 12 4790 2 4793)
GiadeNo 1
62 959 62 967 ( 2 4787 - 2 47901
GiadeNo 2
6 2 951 .62 959 12 4784.2 47871
0 1 10 004)
P~niournal
dla "DP"
-
1
49 961 49 974 ( 1 9670 - 1 96751
Center distance "r"
38 0 I 1 4961
Out of round ( X - Y l
Standard
Less than 0 006 I O 0002)
Taper IA-Bl
Standard
2nd
041 Ira11 rlngl
GiadeNo 0
Runout IT I R
Standard
0 20-0 7 6
10 0079 0 0299)
0 006 I O 00021
1
Less than 0 1 0 10 00391
Free end play
0 05.0 17 (00020 - 0 00671
Standard
0 3 0 10 01 181
Llrnlt
Piston pin
Unit m m l i d
Piston pin outer diameter
20 993 - 20 998
10 8265.0 82671
Plrton pm t o prston clearance
0008.0012
100003 00005)
Interference f i t of piston pin
t o connecting rod
0022 0040
I O 009 - 0 00161
n
OP
Out-of-round
Taper
CONNECTING ROD
Unit
Center distance
Bend. tonion [per 100 13 941 1
Limit
Piston pin bore dia
SEM645
X Y
A.B
m m lid
15410-15420
16 0669 - 6 07091
0 10 I O 00391
20 958.20 971
(08251 - 0 82561
EM715
Big end play
Standard
0 20.0 35 I O 0079 - 0 01381
Ltmit
0 6 I O 0241
EM-39
(ZZLO 0. OZLO 01
&&8 1 - 628 L
FOdZO 6CZZ1
Mollah
l&ZLO 0. ZZLO 01
L E 8 1 - &E8 1
WdZO-6EZZL
an18
~LLLOO-91LO01
128 L - LL8 L
OOdZO-6CZZ L
3114M
(6LLOO-LLLO01
5 Z 8 L - 17.8 1
LOdZO GCZZL
uMoJ8
(OZLO 0 - 6LLO 01
628 1 .928 L
ZO~Z~SEZZL
uaaa
18bL 01
6L
(an0016 110 inoqiiM) 6ui~eaquiew & pue
&
(CZLO 0. ZZLO 01
L E 8 1 &&8 1
COdZO-SLZZL
Mollah
WdZoSLZZL
anin
OOdZOEZZZL
WrlM
LOdZOEZZZL
UMoJ8
ZOdZOEZZZL
u a w
(ZZLO 0. OZLO 0)
&E8 1 .628 I
COdZO-EZZZL
MollaA
-
wdzo-&zzzt
anis
uaar3 ZOdZOSLZZL
UMoJ8
allqM
z 'ON
&
(98801 l O Z L O O - 6 L L O O )
pz2
628
Sz8,
(6LLOO-LLLO01
528 1 . 128 L
(LLLOO 5LLOO)
1 2 8 1 L18L
(CZLOO Z Z L O 0 1
L E 8 L .CE8 1
(ZZLO 0 - OZLO 01
&E8 1 .628 L
(98801
z2
&
,
~OZLOO-6LLOOl
6z8 .8z8
(6LLOO'LLLOOl
5 2 8 1 . 128 L
LOdZO-51ZZ1
(LLLOO-91LOO~
128 L - L18 1
OOdZO-81ZZL
V'LZEW3S
b ON
Z
ON
1 ON
SERVICE DATA AND SPECIFICATIONS (S.D.S.)
Inspection and A
AVAILABLE CONNECTING ROD BEARING
No. 4 main bearing (With oil groove)
Grade
number
Thickness '7
mm I d
1
2
Identrf!catmn
Part number
Color
12247 02POO
White
821
IO0717 007191
12247-02POl
Brown
829
100719-00720
12247-02PO2
Green
12247-02PO3
Yellow
12247-02PM
Blue
100715 007171
833
100720 007221
833
837
100722 007231
istrnent (Cont'd)
Connecting rod bearing undersize
-
Unit mm Ion1
Crank pin journal diameter "Dp"
Standard
49 961 - 49 974 ( 1 9670 - 1 96751
Under size
0 08 I O 00311
0121000471
0 25 (000981
49 881 49 894 I 1 9638.1 96431
49 841 49 854 ( 1 9622 - 1 96281
49711 4 9 7 2 4 1 1 9 5 7 1 - 1 9 5 7 6 1
MISCELLANEOUS COMPONENTS
Unit mm
I d
Flywheel
Runout I T I R
No. 4 main bearing (Without oil groove)
Grade
number
Thickness "T"
mm 11nI
Part number
821
100715 007171
1225502POO
1
Less than 0 15 I O 00591
Identification
Color
White
Bearing clearance
-~~
Unit
mm 11nI
~
Main bearing clearance
'
825
100717-007191
12255 02P01
Brown
Standard
Limit
I O 0719 - 0 07201
833
10 0720 - 0 07221
833. 837
I O 0722.0 07231
12255-02P02
Green
12255-02PO3
Yellow
Connecting rod bearing
clearance
Standard
Limit
12255-02P04
Blue
EM-41
0 025 - 0 055 (00010 - 0 00221
0 090 I O 00351
0 010.0 052 I O 0004 0 00201
0 090 I O 00351
SERVICE DATA AND SPECIFICATIONS (S.D.S.)
Tig htenii
TIGHTENING TORQUE
Torque
Engine internal parts
Engine outer parts
Nm
kg-m
Nm
kq-m
ft-lb
ft-lb
Rocker cover
1-3
01-03
07-22
Tenrmner nut
43 - 58
44-59
32.43
Collector cover
6 8
06-08
43-58
Collector
18-22
18-22
13-16
Belt cover
3 5
03-05
22-36
18 22
18-22
13 - 16
Throttle chamber
18.22
18-22
13-16
Rocker shaft
E G R control valve
18-22
18-22
13 16
Camshaft pulley
78.88
80-90
58.65
22-29
Cyl~nderhead
54.64
55-65
40 - 47
12-14
Camshaft locate plate
78 - 88
80-90
58.65
17-20
Water pump
16 - 21
16-21
12-15
29.39
30-40
22.29
Intake relief valve
29.39
Intake manifold bolt
16 20
Intake manifold nut
24 - 27
30-40
16-20
24-28
Injector holder
3-5
03-05
22-36
Drain plug
Water temperature sensor
15 - 20
15-20
11 14
011 pan
5-7
05-07
36-51
Thermal transmltter
15-20
15-20
11-14
29.39
30-40
22.29
Exhaust manifold
18 22
18-22
13-16
011
strainer regulator valve
Plug
Exhaust manifold stay
22 - 27
22-28
16-20
Exhaust outlet
25 29
25-30
18 22
E G R tube
34 44
35-45
25-33
Exhaust connecting tube
22 - 27
22-28
16-20
Exhaust gas sensor
40-50
41-51
30-37
Crank pulley
123 132
125-135
90-98
Water mlet
16 - 21
16-21
12-15
Detowtion sensor
25-34
25-35
18-25
Pc
v
29-39
30-40
22 29
Dirtnbutor bolt
5-6
05-06
36-43
Alternator adjusting bar
14 - 17
14-17
10-12
5-6
05-06
36-43
WlYe
bolt
Air regulator
011
strainer bracket
16.21
16-21
12-15
Flywheel
98 - 108
10-11
72 - 80
Rear 011 seal retalner
6
06
43
Connecting rod
44 - 54
45-55
33 .40
Main bearing cap
90 100
92-102
67-74
35-45
25.33
20-30
14 - 22
kg-m
ft
Water drain plug
34 - 44
Spark plug
20.29
Turbocharger related parts
Nm
Ib
011
feed tube
15.20
15-20
11-14
011return tube
10-12
10-12
7-9
Turbocharger unlt
44.54
45
EM-42
55
33-40
SPECIAL SERVICE TOOLS
Tool number
(Kent-Moore No
ST0501S000
0ST05011000
(
-
-
@
-
Engine stand
Base
Engine attachment
1
KVlOllOOOO
(
Engine stand assembly
1
0 KV10106500
(
Tool name
)
@ ST05012000
(
I
-
P
Sub attachment
1
KV10110600
)
(
KV10107501
I
-
Valve oil seal drift
)
ST10120000
Cylinder head bolt wrench
(J25613l
EM-43
SPECIAL SERVICE TOOLS
Tool number
(Kent-Moore No 1
Tool name
KVlOllO300
Piston pin press stand assembly
(
@
-
1
KV10110310
I
@
-
KVV0110330
(
-
-
@
-
Drift
)
KV10110320
(
Spring
)
@ KV10110340
(
Press stand
1
@ ST13030030
(
Spacer
)
@ ST13030020
(
Cap
)
Center shaft
)
EM-44