"service manual"
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1. 0 eee 22 CPANKSN AM e eer deed ege ee ee 22 Available Connecting Rod DBearmg 23 Miscellaneous Component ccceeseeeeeeteeeeeees 23 EM 1 SI MA LG TF PD Ki ie a gt OUTER COMPONENT PARTS TB45E SEC 140 210 220 221 Hardtop for the Middle East Distributor BS e H 9 3 11 0 0 95 1 1 83 97 E Spark plug A Ke 3 82 4 51 DI 20 0 29 0 0 39 0 46 2 1 2 9 34 o 15 Radiator upper SQ hose bracket Engine ornament cover bracket as saei 3 20 3 80 0 33 0 38 29 33 Gasket CO Tighten in numerical order Exhaust manifold Ky 6 38 7 64 0 65 0 76 57 66 0 58 8 78 4 6 0 7 9 44 57 Z oy FQ Ee SE Heat d 2 NS X insulator Washer S e pe X SS K Bracket CO DI 27 0 31 0 Oxygen sensor lt K 2 8 3 1 20 22 lt o 40 0 50 0 4 1 5 1 30 36 Gasket f 7 K 6 38 7 46 Lon RE 0 65 0 76 j DEE er a8 57 66 Diffuser a 4 2 4 8 31 35 Gasket cap OZ a ae Gasket By E 29 4 34 3 8 DI 44 1 52 0 3 0 3 4 4 5 5 3 33 38 Three way catalyst 22 25 Insulator as Sea fe 5 1 6 5 1 EN To front tube 0 52 0 66 Bracket aa Nr ee Zeen me Insulator CO Always replace after D a d 5 1 6 5 l every disassembly 0 52 0 66 46 57 Wl Nem kg m in 1b DI 44 1 52 0 4 5 5 3 33 38 O Nem kg m ft lb SEM190H EM 2 CATALYST AND TURBOCHARGER Removal2. Go to SUP 6 Rev 1 MODIFICATION NOTICE ENGINE MECHANICAL soron EM e TB45E engine models with three way catalyst have been provided for the Middle East and General areas e Turbocharger for ZD30DDTi engine has been changed For information not included here refer to information for ZD30DDTi engine in NISSAN model Y61 series SERVICE MANUAL SUPPLEMENT III 2nd Revision Publication No SM9E Y61CG2 CONTENTS Cs OTB45E OUTER COMPONENT PARTS 2 CT ZzD30DDTi EH CATALYST AND TURBOCHARGER a00naa00a0aa0a0aanne 3 Removal and Installation csseseeeeeeeeeeeee 3 JAS POCHON eteg e etsaia e e ea E EE i 4 OIL PAN amp OIL GTRAINER cc ceeeeeesseeeeees 5 Removal and Installation csseseeeeeseeeeeeee 5 CAMSHAFT onakan a a 6 Removal and Installation cccsseeeseeeeeeeeeee 6 EE 6 VALVE CLEARANCE INSPECTIONS AND ADUSTMENTSG ee 8 e EE 8 TIMING GEAR oinik 9 Removal and Installation c csseeeeeeeeeeeeeeee 9 INS POCTION su cesicotcodicevecs dedigevetesageseveusier Eege 10 CYLINDER HEAD 11 Enn E 11 Disassembly and Aesemblv 11 INSPOCHOM BEE 11 CYLINDER BLOCK eec ere stat Eegeregie 15 INSPOCHON iii ice ee ee a E 15 Cl TBE oo SERVICE DATA AND SPECIFICATIONS SDS 17 VE AET 17 Camshaft and Camshaft Busbmg eee 17 Cl D nn SERVICE DATA AND SPECIFICATIONS SDS 18 KU 18 KETTEN 21 Camshaft and Camshaft Bearing
3. 22 64 72 0 20 0 008 23 27 73 81 i Intake and Exhaust 0 33 0 37 0 21 0 008 28 32 82 90 0 013 0 015 0 23 0 009 33 37 91 99 0 24 0 009 38 42 100 108 0 25 0 010 43 47 109 117 0 26 0 010 48 52 118 126 Whenever valve clearances are adjusted to cold specifications e Based on the engine coolant temperature the value indicated by CONSULT II during valve clearance adjustment select the setting value from above table e Determine setting value based on radiator coolant temperature if CONSULT II could not be used 1 Reference data at engine coolant temperature 82 C 180 F Camshaft and Camshaft Bushing Unit mm in Valve timing ZE QO A Z EM671 TB45E Cam height A BN Unit degree DES 42 314 42 564 Exhaust 1 6659 1 6757 EM 17 MA LG E a gt SERVICE DATA AND SPECIFICATIONS SDS Valve VALVE Unit mm in a d D c b a sch PBIC0413E Intake Valve length a 113 5 4 468 Exhaust Intake b 3 8 4 2 0 150 0 165 Exhaust Intake Valve margin c 1 5 0 059 Exhaust Intake 6 962 6 977 0 2741 0 2747 Valve stem diameter d Exhaust 6 945 6 960 0 2734 0 2740 Intake 31 9 32 1 1 256 1 264 Valve head diameter D Exhaust 29 9 30 1 1 177 1 185 Intake Valve seat angle a 45
4. 29 Crank gear EI Ss 4 s Idler gear A FY D 21 23 241 2 4 16 17 gt O A Thrust plate J Balancer shaft Left 8 3 6 4 1 ale 29 33 NA i de 2 9 3 4 Idler shaft FY FA 0 10 11 1 0 1 1 7 4 8 1 O ring 3 26 29 2 9 3 4 Y 21 24 Idler gear B A Thrust plate HI RA 3 HIE 29 33 2 9 3 4 21 24 Gear case TDC sensor o 25 28 2 5 2 9 18 20 T A Sa Je Deeg l Plug an SABI Bin BANOSA a 0 8 1 0 D 18 20 C 86 Tensioner pulley RS For setting inner area of idler gear A Po d E 25 28 Front oil seal CO a 2 5 2 9 18 20 BT Crank pulley N lt Bracket HIE 373 402 38 41 HA 275 296 da OO Always replace after O 25 28 EL every disassembly 2 5 2 9 g A Lubricate with new 18 20 3 engine oil X lt S SE Apply Genuine Liquid Bushi V e Di 25 28 2 5 2 9 18 20 Gasket or equivalent using P l DI 26 29 A O Nem kg m ft Ib Oro aa Spacer JI 68 77 6 9 7 9 50 57 IDX Wl Nem kg m in Ib 20 21 Washer 77 6 9 7 9 50 57 SEM185H EM 9 Micrometer Bore gauge Balancer shaft bearing FEM040A TIMING GEAR Inspection BALANCER SHAFT OIL CLEARANCE Outer diameter of balancer shaft journal Measure the outer diameter of the balancer shaft journal with a micrometer Standard Front side 50 875 50 895 mm 2 0029 2 0037 in dia Rear
5. 2 journal No 2 camshaft bracket pf Lo Goen e KBIA2318E Camshaft No 2 journal A dimension 19 455 19 507 0 7659 0 7680 No 2 camshaft bracket B dimension 19 338 19 390 0 7613 0 7634 Valve timing PBICO517E Unit degree a b c d e 232 220 6 34 50 Total indicator reading Runout TIR Total indicator reading Crankshaft Unit mm in Standard Less than 0 01 0 0004 0 03 0 0012 EM 22 SERVICE DATA AND SPECIFICATIONS SDS Available Connecting Rod Bearing BALANCER SHAFT BEARING Unit mm in Front 50 875 50 895 2 0029 2 0037 Balancer shaft journal outer diameter Rear 50 675 50 695 1 9951 1 9959 Front 50 955 50 980 2 0061 2 0071 Balancer shaft bearing inner diameter Rear 50 755 50 780 1 9982 1 9992 Standard 0 060 0 105 0 0024 0 0041 Balancer shaft journal oil clearance Limit 0 180 0 0071 Miscellaneous Components Unit mm in Standard 0 3 0 012 or less 0 7 0 028 5 9 0 232 or less Flywheel deflection TIR i imit Flywheel movement in rotation direction Total indicator reading EM 23 SI MA TF PD Ki ST RS E a gt
6. 00 45 30 Exhaust VALVE CLEARANCE Unit mm in Cold Intake and exhaust 0 30 0 40 0 012 0 016 Approximately 20 C 68 F EM 18 SERVICE DATA AND SPECIFICATIONS SDS Valve Cont d AVAILABLE VALVE LIFTER EI Identification mark Thickness 535 5 35 0 2106 MA 540 5 40 0 2126 550 5 50 0 2165 555 5 55 0 2185 LG 560 5 60 0 2205 565 5 65 0 2224 EC 570 5 70 0 2244 575 5 75 0 2264 580 5 80 0 2283 5 585 5 85 0 2303 590 5 90 0 2323 GL 595 5 95 0 2343 600 6 00 0 2362 MT 605 6 05 0 2382 PD Thickness of valve lifter FA KBIA2292E BA VALVE LIFTER BR Unit mm in S Valve lifter outer diameter 34 455 34 465 1 3565 1 3569 Lifter guide inner diameter 34 495 34 515 1 3581 1 3589 ST Clearance between lifter and lifter guide 0 030 0 060 0 0012 0 0024 RS BY HA EM 19 SERVICE DATA AND SPECIFICATIONS SDS Valve Cont d VALVE GUIDE Unit mm in FEM071 Standard Limit Outer diameter 11 023 11 034 0 4340 0 4344 Valve guide Inner diameter Finished size 7 000 7 018 0 2756 0 2763 _ Cylinder head valve guide hole diameter 10 996 10 975 0 4329 0 4321 Interference fit of valve guide 0 027 0 059 0 0011 0 0023 Intake 0 023 0 056 0 0009 0 0022 0 18 0 0071 Stem to guide clearance Exhaust 0 040 0 073 0 0016 0 0029 0 10 0 0039 Projection
7. mm 0 014 in Thickness of a new valve lifter can be identified by stamp marks on the reverse side inside the cylinder Stamp mark 535 indicates 5 35 mm 0 2106 in in thickness Available thickness of valve lifter 15 sizes with range 5 35 to 6 05 mm 0 2106 to 0 2382 in in steps of 0 05 mm 0 0020 in when manufactured at factory Refer to EM 19 AVAILABLE VALVE LIFTER 5 6 Install the selected valve lifter Install camshaft Refer to EM 44 Installation in NISSAN model Y61 series SERVICE MANUAL SUPPLEMENT III 2nd Revision Publication No SM9E Y61CG2 EM 44 Manually turn crankshaft pulley a few turns Make sure that valve clearances for cold engine are within specifications by referring to the specified values Valve clearance When engine is cool Approximately 20 C 68 F Intake and exhaust 0 30 0 40 mm 0 012 0 016 in EM 8 TIMING GEAR Removal and Installation GI 2 idler gears are shown in this chapter Idler gear A has scissors gear and idler gear B does not SEC 110 117 120 130 135 186 223 Vacuum pipe eh Fuel injection pump 0 25 28 2 5 2 9 dg 18 20 IO 25 28 A 2 5 2 9 lt L 18 20 Se Engraved line Front plate Seal washer RVD 45 53 4 5 5 5 33 39 Fuel injection pump gear A Fuel injection pump sprocket y Balancer shaft Right EI 0 21 23 2 1 2 4 16 17 ZA G DI 36 40 3 6 4 1 26
8. to 110 to 130 C 230 to 266 F in oil bath 2 Using valve guide drift multi purpose tool for 7 0 mm dia tap valve guides out from the combustion chamber side CAUTION Cylinder head contains heat Wear protective equipment to avoid getting burned when working 3 Heat cylinder head to 110 to 130 C 230 to 266 F in oil bath 4 Using valve guide drift multi purpose tool for 7 0 mm dia press fit valve guides from camshaft side referring to the dimension shown in the figure CAUTION Cylinder head contains heat Wear protective equipment to avoid getting burned when working EM 12 Valve guid reamer FEM072A OK G FEM073 CYLINDER HEAD ZD30DDTi Inspection Contd 5 Using suitable valve guide reamer perform reaming to the press fitted valve guides Reaming specifications Intake Exhaust 7 000 7 018 mm 0 2756 0 2763 in VALVE SEAT CONTACT Check valve for any evidence of pitting at valve contact surface and reseat or replace if worn out excessively e When repairing valve seats check valve and valve guide for wear beforehand If worn replace them Then check valve seat VALVE SEAT REPLACEMENT 1 Cut valve seat to make it thin and pull it out CAUTION Cutting valve seat too much may cause damage of cylinder head NOTE e After removing valve seat check cylinder head inner area for cracks If any cracks or deformation replace cylinder head with new one e C
9. D TURBOCHARGER Removal and Installation Cont d 2 Remove catalyst CAUTION Do not disassemble catalyst Inspection TURBOCHARGER Variable nozzle turbocharger VNTC control actuator Checking charge air pressure leaks Checking negative Turbine housing air pressure leaks Actuator rod SE wheel H Turbine ee Checking engine oil leaks Compressor housing Checking exhaust gas leaks SEM184H CAUTION When the compressor wheel turbine wheel or rotor shaft is damaged remove all the fragments and foreign matter left in the following passages in order to prevent a secondary failure Suction side Between turbocharger and intercooler Exhaust side Between turbocharger and catalytic converter Rotor shaft e Check that the rotor shaft rotates smoothly without any resis tance when it is rotated by your fingertips e Check that the rotor shaft is not loose when it is moved verti cally or horizontally Standard value for rotor shaft oil clearance 0 056 0 127 mm 0 0022 0 0050 in Rotor shaft SEM298G EM 4 OIL PAN amp OIL STRAINER 3 5 4 5 mm 0 138 0 177 in dia CO Always replace after every disassembly SEM347GA Removal and Installation INSTALLATION OIL PAN LOWER e Install oil pan Lower e Apply liquid gasket to inner sealing surface as shown in figure e Be sure liquid gasket is 3 5 to 4 5 mm 0 138 to 0 177 in e Attachin
10. and Installation SEC 144208 4 UP Face the protruding area in this direction _ Y side Turbocharger side Q ORS JS E 15 7 21 6 Vacuum hose G a 1 6 2 2 12 15 Gear case YS 1 CO Di 29 32 To variable nozzle 2 9 3 3 turbocharger VNTC 21 23 control solenoid valve a OP 29 32 Ore ne Lf E2 D LT P 25 28 Insulator 2 5 2 9 18 20 Air inlet pipe y L el Turbocharger assembly DI 25 28 2 5 2 9 18 20 To oil cooler housing ei 0 25 28 2 5 2 9 18 20 Qo fy 10 11 1 0 1 2 87 104 Copper washer oy o 16 21 1 6 2 2 12 15 Oil feed return tube To lower cylinder block 7 Pe CO Always replace after Ke Gasket CO every disassembly e 10 11 1 0 1 2 87 104 O Nem kg m ft lb kel Nem kg m in Ib SEM182H Mass air LZ SS REMOVAL flow sensor e HE Resonator 1 Remove the following parts G Sc LA e Undercover G ei GN Variable nozzle e Under guard f z LS turbocharger e Battery on left side for cold areas vanicie hom ATF VW VNTC contro e Exhaust front tube LN solenoid valve Refer to FE 7 EXHAUST SYSTEM in NISSAN model Y61 Ser fg 2 3 2 6 Nem series SERVICE MANUAL SUPPLEMENT III 2nd Revision rocker cover 20 23in lb e Remove wires harnesses tubes and pipes To turbocharger SEM296G EM 3 MA T J CATALYST AN
11. eter PD PA RA LIFTER GUIDE INNER DIAMETER Measure the lifter guide inner diameter of the cylinder head with an pp inside micrometer Standard 34 495 34 515 mm 1 3581 1 3589 in dia ST RS Inside micrometer e PBICO367E BT VALVE LIFTER CLEARANCE CALCULATIONS Clearance Lifter guide inner diameter Valve lifter outer diameter HA Standard 0 030 0 060 mm 0 0012 0 0024 in If it exceeds the standard value refer to the outer diameter and bore diameter standard values and replace valve lifter and or cyl EL inder head EM 7 VALVE CLEARANCE INSPECTIONS AND ADJUSTMENTS Micrometer KBIA0057E Thickness of valve lifter KBIA2292E Adjustments L Perform adjustment depending on selected head thickness of valve lifter Remove camshaft Refer to EM 41 Removal in NISSAN model Y61 series SERVICE MANUAL SUPPLEMENT III 2nd Revision Publication No SM9E Y61CG2 Remove valve lifters at the locations that are outside the stan dard Measure the center thickness of the removed valve lifters with a micrometer Use the equation below to calculate valve lifter thickness for replacement Valve lifter thickness calculation Thickness of replacement valve lifter t1 C1 C2 t1 Thickness of removed valve lifter C1 Measured valve clearance C2 Standard valve clearance When engine is cool Approximately 20 C 68 F Intake and exhaust 0 35
12. ft PBICO365E CAMSHAFT END PLAY e Set the dial gauge to the front end of the camshaft Measure the end play by moving the camshaft in the direction of the axle Standard 0 065 0 169 mm 0 0026 0 0067 in Limit 0 2 mm 0 0079 in K g De j AN SC ST VW Y oy PBICO366E EM 6 CAMSHAFT Inspection Cont d e Replace the following parts if outside the limit EI a Dimension A for camshaft No 2 journal ene Standard 19 455 19 507 mm 0 7659 0 7680 in b Dimension B for No 2 camshaft bracket MA No 2 journal Standard 19 338 19 390 mm 0 7613 0 7634 in e Replace camshaft and or cylinder head referring to the stan dards above NOTE No 2 camshaft bracket At Qo cOjo rO B It is impossible to replace only the camshaft bracket as the cam shaft bracket is manufactured with the cylinder head 5 KBIA2318E VISUAL INSPECTION OF VALVE LIFTER EC e Check if surface of valve lifter has any wear or cracks A e Replace valve lifter if necessary E e Select the thickness of the head so that valve clearance is the standard when replacing Refer to EM 46 Inspection in 4 NISSAN model Y61 series SERV MANUA PPLE CG MENT III 2nd Revision Publication No SM9E Y61CG2 KBIA2285E VALVE LIFTER OUTER DIAMETER Measure the outer diameter of the valve lifter with a micrometer Standard 34 455 34 465 mm 1 3565 1 3569 in dia UF Microm
13. g should be done within 5 minutes after coating Use Genuine Liquid Gasket or equivalent INSTALLATION OIL PAN UPPER AND OIL STRAINER e Install oil pan Upper e Apply liquid gasket to inner sealing surface as shown in figure e Be sure liquid gasket is 3 5 to 4 5 mm 0 138 to 0 177 in e Attaching should be done within 5 minutes after coating Use Genuine Liquid Gasket or equivalent EM 5 SI MA LG ma Q TF PD Ki ie a gt CAMSHAFT Removal and Installation SEC 130 o For tightening torque refer to the text Baffle plate Camshaft bracket A Camshaft Right side A Cam gear Refer to Timing Chain Right side A Cam sprocket i A D n Camshaft Left side EI TM SE PID e ep Conger Valve lifter JF 6 2 6 7 45 48 Lett side J Sg Washer KV 61 65 6 2 6 7 45 48 Idler gear Idler shaft EI LON A f Ch Selective parts Lubricate with new engine oil Thrust plate EI Nem kg m ft lb HI 49 57 5 0 5 9 37 42 i Cylinder head ele SEM189H Inspection CAMSHAFT RUNOUT e Prepare V block on a flat surface and secure camshaft journals No 1 and No 5 e Set the dial gauge vertically on journal No 3 e Rotate camshaft in one direction by hand then read needle movement on dial indicator Total indicator reading Limit 0 02 mm 0 0008 in elf it exceeds the limit replace camsha
14. heck inner diameter of valve seat mounting area Refer to Valve Seat 2 Heat cylinder head to approximately 110 to 130 C 230 to 266 F in oil bath 3 After cooling valve seats sufficiently with dry ice press fit it to cylinder head CAUTION e Cylinder head contains heat Wear protective equipment to avoid getting burned when working e Do not touch the cooled valve seats directly by bare hand EM 13 SI MA LG T J Intake side 27 9 28 1 mm dia 1 098 1 106 in 6 5 mm 0 256 in 2 3 2 7 mm dia 90 30 9 31 1 mm dia 1 217 1 224 in Exhaust side 25 9 26 1 mm dia 1 020 1 028 in 0 091 0 106 in 7 mm 0 28 in 2 3 2 7 mm dia A 0 091 0 106 in 90 28 9 29 1 mm dia 1 138 1 146 in SEM191H CYLINDER HEAD Inspection Cont d 4 Make sure that contacting status is satisfactory EM 14 ZD30DDTi CYLINDER BLOCK Inspection I SELECTIVE PISTON COMBINATION Selective combination chart MA e New pistons are classified into 4 weight classes at factory The same class pistons are used on a engine Weight grade symbol Weight class g 02 E 615 620 21 7 21 9 F 620 625 21 9 22 0 LG G 625 630 22 0 22 2 H 630 635 22 2 22 4 EC E GL MT AT CRANKSHAFT RUNOUT e Place V block onto surface plate to support No 2 and No 4 journals TEF e Position d
15. ial indicator vertically onto No 1 No 3 and No 5 journals 2 e Rotate crankshaft to read needle movement on dial indicator PD Total indicator reading Standard Less than 0 01 mm 0 0004 in FA Limit 0 03 mm 0 0012 in e Replace crankshaft if it exceeds the limit PBIC1756E RA CONNECTING ROD BEARING CRUSH HEIGHT Crush height e Tighten connecting rod caps to the specified torque with con BR necting rod bearings installed 0J 79 83 N m 8 0 8 5 kg m 58 61 ft lb e Remove connecting rod caps The connecting rod bearing end e must then be higher than the flat surface Standard Crush height must exist e f out of specification replace connecting rod bearings RS PBIC1646E BT MOVEMENT AMOUNT OF FLYWHEEL M T MODELS NOTE HA e Inspect for double mass flywheel only e Do not disassembly double mass flywheel 2 SIE IDX EM 15 PBIC1045E Torque wrench 9 8 1 0 87 29 9 8 1 0 87 AE Clutch cover mounting bolt Flywheel transmission side Unit Nem kg m ft lb PBIC2070E OV Nozzle NG PBICO392E m EMT0186D CYLINDER BLOCK Inspection Cont d Flywheel Deflection e Measure deflection of flywheel contact surface to the clutch with a dial gauge e Measure deflection at 250 mm 9 84 in dia Standard 0 3 mm 0 012 in or less Limit 0 7 mm 0 028 in or less e When measured value exceeds the limit replace it with a new one Move
16. length 12 8 13 2 0 5309 0 5197 EM 20 SERVICE DATA AND SPECIFICATIONS SDS Valve Seat Gl Unit mm in MA Intake D 6 5 0 256 2 3 2 7 LG 0 091 0 106 dia 27 9 28 1 1 098 1 106 dia EG 30 9 31 1 1 217 1 224 dia 89 90 Exhaust B 7 0 28 2 3 2 7 0 091 0 106 dia MT 25 9 26 1 1 020 1 028 dia 28 9 29 1 1 138 1 146 dia A 89 90 Unit mm in TE PBIC1726E PD Inner diameter of mounting area FA sEM373G T D Waif RS J KEAL L Kei ia BT i HA ci INT EXH PBIC0421E EL Standard Cylinder head seat recess diameter Intake 33 000 33 015 1 2992 1 2998 SE D Exhaust 31 495 31 510 1 2400 1 2405 Intake 0 050 0 078 0 0020 0 0031 IDX Valve seat interference fit Exhaust 0 040 0 066 0 0016 0 0026 EM 21 SERVICE DATA AND SPECIFICATIONS SDS Valve Seat Cont d 33 065 33 078 1 3018 1 3023 31 550 31 561 1 2421 1 2426 6 75 6 85 0 2657 0 2697 7 35 7 45 0 2894 0 2933 43 65 44 35 1 7185 1 7461 Intake Valve seat outer diameter d Exhaust Intake Height h Exhaust Intake Depth L Exhaust 43 65 44 35 1 7185 1 7461 Camshaft and Camshaft Bearing Standard Limit Camshaft runout TIR 0 02 0 0008 Camshaft end play 0 065 0 169 0 0026 0 0067 0 2 0 008 Camshaft No
17. ment Amount in Rotation Direction e Check the movement amount in the following procedure 1 Install a bolt to clutch cover mounting hole and place a torque wrench on the extended line of the flywheel center line e Tighten bolt at a force of 9 8 N m 1 kg m 87 in lb to keep it from loosening 2 Put a mating mark on circumferences of the two flywheel masses without applying any load Measurement standard points 3 Apply a force of 9 8 N m 1 kg m 87 in Ib in each direction and mark the movement amount on the mass on the transmission side 4 Measure dimensions of movement amounts A and B on circum ference of the flywheel on the transmission side Standard 5 9 mm 0 232 in or less e When measured value is outside the standard replace fly wheel OIL JET e Check nozzle for deformation and damage e Blow compressed air from nozzle and check for clogs Standard No deformation and no damage e Replace oil jet if it is out of the standard OIL JET RELIEF VALVE e Using a clean plastic stick press check valve in oil jet relief valve Make sure that valve moves smoothly with proper reac tion force Standard Valve moves smoothly with proper reaction force e If it is not satisfied replace oil jet relief valve EM 16 SERVICE DATA AND SPECIFICATIONS SDS Valve VALVE CLEARANCE Unit mm in C F Cold Hot 1 0 16 0 006 8 12 46 54 0 17 0 007 13 17 55 5 0 19 0 007 18
18. ng EE 8 EE Valve spring seat j Valve guide wl Valve guide CO f A o Valve seat Valve seat ke f d bk eg l Intake OO wl i ee Exhaust wl Valve eo Selective parts Intake A Always replace after Valve Exhaust DA every disassembly Lubricate with new engine oil A amp PBIC1749E Inspection a VALVE DIMENSION d Using micrometer measure the dimensions of each part p Standard Unit mm in c Intake valve Exhaust valve b a 113 5 4 468 113 5 4 468 a b 3 8 4 2 3 8 4 2 0 150 0 165 0 150 0 165 PBIC0413E G 1 5 0 059 1 5 0 059 d 6 962 6 977 6 945 6 960 0 2741 0 2747 0 2734 0 2740 D 31 9 32 1 29 9 30 1 1 256 1 264 1 177 1 185 a 45 00 45 30 45 00 45 30 EM 11 Micrometer SEM938C Valve guide drift FEM070A FEMO71 CYLINDER HEAD Inspection Cont d VALVE GUIDE CLEARANCE e Calculate the clearance by measuring valve stem outer diam eter and valve guide inner diameter Unit mm in Standard Limit 0 023 0 056 18 0 0071 intake 0 0009 0 0022 DAS 0 001 0 040 0 073 10 0 Exhaust 0 0016 0 0029 0 10 0 0039 e lf the measured value exceeds the limit replace valve guide and or valve VALVE GUIDE REPLACEMENT e There is no setup for oversized valve guide 1 Heat cylinder head
19. side 50 675 50 695 mm 1 9951 1 9959 in dia Inner diameter of balancer shaft bearing Measure the inner diameter of the balancer shaft bearing using a bore gauge Standard Front side 50 955 50 980 mm 2 0061 2 0071 in dia Rear side 50 755 50 780 mm 1 9982 1 9992 in dia Oil clearance calculations Oil clearance Bearing inner diameter Journal outer diameter Standard 0 060 0 105 mm 0 0024 0 0041 in Limit 0 180 mm 0 0071 in Replace the balancer shaft and or cylinder block if it exceeds the limit NOTE It is impossible to replace only balancer shaft bearing because balancer shaft bearing is manufactured with cylinder block EM 10 CYLINDER HEAD Inspection IDLER GEAR OIL CLEARANCE e Measure the inner diameter d of idler gear shaft hole Standard 26 000 26 020 mm 1 0236 1 0244 in e Measure the outer diameter d gt of idler shaft Standard 25 967 25 980 mm 1 0223 1 0228 in e Calculate gear clearance Clearance d d gt Standard 0 020 0 053 mm 0 0008 0 0021 in e Replace idler gear and or idler shaft if it is outside of the stan FEM057 dard Disassembly and Assembly SEC 111 130 Sa lifter A Valve collet valve spring retainer S vaive spring Kc Valve lifter E Valve collet Valve spring retainer Valve spring BS 00 M0r CT Valve oil seal wl p e SS SE oil seal CO A Valve spri
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