Nissan Murano Z50 (2003 year). Manual - part 131

 

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Nissan Murano Z50 (2003 year). Manual - part 131

 

 

CYLINDER BLOCK

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2.

Install each plug to the cylinder block.

Apply liquid gasket. 
Use Genuine Thread Sealant or equivalent. Refer to 

GI-46,

"RECOMMENDED CHEMICAL PRODUCTS AND SEAL-
ANTS"

 .

3.

Install oil jet.

Insert oil jet dowel pin into the cylinder block dowel pin hole,
and tighten the mounting bolts.

4.

Install the main bearings and the thrust bearings.

a.

Remove dust, dirt, and oil on the bearing mating surfaces of the
cylinder block and the main bearing cap.

b.

Install the thrust bearings to the both sides of the No. 3 journal
housing on the cylinder block and the main bearing cap.

Install the thrust bearings with the oil groove facing the crank-
shaft arm (outside). 

Install bearing with a projection on one end on cylinder block,
and bearing with a projection at center on cap. Align each pro-
jection with mating notch.

c.

Install the main bearings paying attention to the direction.

The main bearing with an oil hole and groove goes on the cyl-
inder block. The one without them goes on the main bearing
cap.

Before installing the bearings, apply engine oil to the bearing
surface (inside). Do not apply oil to the back surface, but thor-
oughly clean it.

When installing, align the bearing stopper to the notch.

Ensure the oil holes on cylinder block and those on the corre-
sponding bearing are aligned.

Part

Washer

Tightening torque

A

No

7.8 - 11.8 N·m (0.8 - 1.2 kg-m, 69 - 104 in-lb)

B

Yes

24.5 - 29.4 N·m (2.5 - 2.9 kg-m, 18 - 21 ft-lb)

C

Yes

59 - 65 N·m (6.1 - 6.7 kg-m, 44 - 48 ft-lb)

PBIC1269E

PBIC0898E

PBIC0807E

SEM175F

EM-106

CYLINDER BLOCK

Revision; 2004 April

2003 Murano

5.

Install the crankshaft to the cylinder block.

While turning the crankshaft by hand, check that it turns
smoothly. 

6.

Install main bearing cap.

Main bearing caps are identified by identification mark cast on
them. For installation, face front mark to front side.

NOTE:
Main bearing cap cannot be replaced as a single part,
because it is machined together with cylinder block.

7.

Install main bearing beam.

Install main bearing beam with front mark facing downward
(oil pan side).

Install main bearing beam with front mark facing front of
engine.

8.

Inspect outer diameter of main bearing cap bolt. Refer to 

EM-

123, "OUTER DIAMETER OF MAIN BEARING CAP BOLT"

 .

9.

Install main bearing cap bolt.

a.

Apply new engine oil to threads and seat surfaces of mounting
bolts.

b.

Tighten bolts in numerical order with tightening torque 32.3 to
38.3 N·m (3.3 to 3.9 kg-m, 24 to 28 ft-lb) in several different
steps.

c.

Turn all bolts another 90 to 95 degrees clockwise [Target: 90
degrees (Angle tightening)].

CAUTION:

Use an angle wrench [special service tool: KV10112100
(BT8653-A)] to check tightening angle. Do not make judg-
ment by visual inspection. 

After installing mounting bolts, make sure that crankshaft can
be rotated smoothly by hand.

Check crankshaft side clearance. Refer to 

EM-115, "CRANK-

SHAFT SIDE CLEARANCE"

 .

10. Inspect outer diameter of connecting rod bolt. Refer to 

EM-123,

"OUTER DIAMETER OF CONNECTING ROD BOLT"

 .

11. Install the piston to the connecting rod. 
a.

Using a snap ring pliers, install a new snap ring to the groove of the piston rear side. 

Insert it fully into groove to install.

b.

Install the piston to the connecting rod.

Using an industrial drier or similar tool, heat the piston until the piston pin can be pushed in by hand
without excess force [approx. 60 to 70 

°

C (140 to 158 

°

F)]. From the front to the rear, insert the piston

pin into the piston and the connecting rod.

SEM456G

PBIC0881E

SEM851E

PBIC0921E

CYLINDER BLOCK

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Assemble so that the front mark on the piston crown and the
cylinder number on the connecting rod are positioned as
shown in the figure.

c.

Install a new snap ring to the groove of the piston front side. 

Insert it fully into groove to install.

After installing, check that the connecting rod moves
smoothly.

12. Using a piston ring expander (commercial service tool), install the piston rings.

If there is stamped mark on ring, mount it with marked side
up.
NOTE:
If there is no stamp on ring, no specific orientation is required
for installation.

CAUTION:

Be careful not to damage the piston.

Position each ring with the gap as shown in the figure refer-
ring to the piston front mark.

13. Install the connecting rod bearings to the connecting rod and the

connecting rod cap.

When installing the connecting rod bearings, apply engine oil
to the bearing surface (inside). Do not apply oil to the back
surface, but thoroughly clean it. 

When installing, align the connecting rod bearing stopper pro-
trusion with the cutout of the connecting rod to install. 

Check the oil hole on the connecting rod and that on the cor-
responding bearing are aligned. 

SEM838F

Stamped mark:

Top ring

: —

Second ring

: R

SEM757G

PBIC0808E

PBIC0266E

EM-108

CYLINDER BLOCK

Revision; 2004 April

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14. Install the piston and connecting rod assembly to the crankshaft. 

Position the crankshaft pin corresponding to the connecting
rod to be installed onto the bottom dead center. 

Apply engine oil sufficiently to the cylinder bore, piston and
crankshaft pin. 

Match the cylinder position with the cylinder number on the
connecting rod to install. 

Be sure that front mark on piston crown is facing front of
engine.

Using a piston ring compressor (special service tool) or suit-
able tool, install the piston with the front mark on the piston
crown facing the front of the engine.

CAUTION:

Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of
the connecting rod big end.

15. Install the connecting rod cap.

Match the stamped cylinder number marks on the connecting
rod with those on the cap to install.   

Be sure that front mark on connecting rod cap is facing front
of engine.

16. Tighten the connecting rod bolt as follows.

a.

Apply engine oil to the threads and seats of the connecting rod
bolts. 

b.

Tighten bolts to 18.6 to 20.6 N·m (1.9 to 2.1 kg-m, 14 to 15 ft-lb).

c.

Then tighten all bolts 90 to 95 degrees clockwise [target: 90
degrees (Angle tightening)].

CAUTION:

Always use an angle wrench [special service tool:
KV10112100 (BT8653-A)]. Avoid tightening based on visual
check alone.

After tightening the bolt, make sure that the crankshaft rotates
smoothly.

Check the connecting rod side clearance. Refer to 

EM-115, "CONNECTING ROD SIDE CLEARANCE"

.

17. Apply liquid gasket and install rear oil seal retainer.

Use Genuine RTV Silicone Sealant or equivalent. Refer to 

GI-

46, "RECOMMENDED CHEMICAL PRODUCTS AND SEAL-
ANTS"

 .

CAUTION:

Replace with the new parts.

NOTE:
Rear oil seal with rear oil seal retainer.

SEM620

PBIC0809E

SEM953E

PBIC0922E

CYLINDER BLOCK

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18. Install pilot converter using suitable tool.

Outer diameter of drift

Press-fit pilot converter with its chamfer facing crankshaft.

Install pilot converter as shown.

19. Install drive plate.

Install drive plate and reinforcement plate as shown in figure.

Secure the crankshaft using a suitable ring gear stopper or an
alternative manner.

Tighten the installation bolts crosswise over several times.

20. Install knock sensor.

Make sure that there is no foreign material on the cylinder
block mating surface and the back surface of the knock sen-
sor. 

Install knock sensor so that connector faces front of engine.

Do not tighten the mounting bolts while holding the connector.   

Make sure that the knock sensor does not interfere with other-
parts.

CAUTION:

If any impact by dropping is applied to the knock sensor,
replace it with new one.

After installing knock sensor, connect sub-harness, and lay it out to rear of engine.

21. Install followings in reverse order of removal.

Pilot converter

: Approx. 33 mm (1.30 in)

PBIC0899E

SEM537E

PBIC0910E

PBIC0810E

EM-110

CYLINDER BLOCK

Revision; 2004 April

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How to Select Piston and Bearing 

ABS0033L

DESCRIPTION

 *For the service parts, the grade for fitting cannot be selected between a piston pin and a connecting rod.
(Only 0 grade is available.) The information at the shipment from the plant is described as a reference.

The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.

For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.

For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.

HOW TO SELECT PISTON
When New Cylinder Block is Used

Check the cylinder bore grade (1, 2, or 3) on rear side of cylinder
block, and select a piston of the same grade.

The piston is available with piston pin as a set for the service
part. (Only 0 grade piston pin is available.)

When Cylinder Block is Reused

1.

Measure the cylinder block bore inner diameter. Refer to 

EM-

119, "Inner Diameter of Cylinder Bore"

 .

2.

Determine the bore grade by comparing the measurement with
the values under the cylinder bore inner diameter of the “Piston
Selection Table”.

3.

Select the piston of the same grade.

Selection points

Selection parts

Selection items

Selection methods

Between cylinder block and 
crankshaft

Main bearing

Main bearing grade
(bearing thickness)

Determined by match of cylin-
der block bearing housing 
grade (inner diameter of hous-
ing) and crankshaft journal 
grade (outer diameter of jour-
nal)

Between crankshaft and con-
necting rod

Connecting rod bearing

Connecting rod bearing grade 
(bearing thickness)

Combining service grades for 
connecting rod big end inner 
diameter and crankshaft pin 
outer diameter determine con-
necting rod bearing selection.

Between cylinder block and pis-
ton

Piston and piston pin assembly
(The piston is available 
together with piston pin as an 
assembly.)

Piston grade
(piston outer diameter)

Piston grade = cylinder bore 
grade (inner diameter of bore)

*Between piston and connect-
ing rod

SEM756G

PBIC0812E

CYLINDER BLOCK

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Piston Selection Table

Unit: mm (in)

NOTE:

The piston is available together with piston pin as an assembly.

The piston pin (piston pin bore) grade is provided only for the parts installed at the plant. For service parts,
no piston pin grades can be selected. (Only 0 grade is available.)

No second grade mark is available on piston.

HOW TO SELECT CONNECTING ROD BEARING
When New Connecting Rod and Crankshaft are Used

Check pin diameter grade number (0, 1, or 2) stamped in front of
crankshaft, and select connecting rod bearing of same grade
number.

NOTE:
There is no grading for connecting rod big end inner diameter.

When Crankshaft and Connecting Rod are Reused

1.

Measure dimensions of the big end inner diameter of connecting rod and outer diameter of crankshaft pin
individually. Refer to 

EM-117, "CONNECTING ROD BEARING HOUSING DIAMETER (BIG END)"

  and

EM-120, "OUTER DIAMETER OF CRANKSHAFT PIN"

 .

2.

Confirm the big end inner diameter of connecting rod is within the standard value.

3.

Apply the measured dimension to the “Connecting Rod Bearing Selection Table”.

4.

Determine the grade of crankshaft pin diameter grade by comparing the measurement with the values
under the crankshaft pin outer diameter of the “Connecting Rod Bearing Selection Table”.

5.

Select the connecting rod bearing of the same grade.

Connecting Rod Bearing Selection Table

Unit: mm (in)

Undersize Bearings Usage Guide

When the specified oil clearance is not obtained with standard size connecting rod bearings, use under-
size (US) bearings.

When using undersize bearing, measure the bearing inner diameter with bearing installed, and grind the
crankshaft pin so that the oil clearance satisfies the standard. 

Grade

1

2 (or no mark)

3

Inner diameter of cylinder bore

95.500 / 95.510

(3.7598 / 3.7602)

95.510 / 95.520

 (3.7602 / 3.7606)

95.520 / 95.530

(3.7606 / 3.7610)

Outer diameter of piston

95.480 / 95.490

(3.7590 / 3.7594)

95.490 / 95.500

(3.7594 / 3.7598)

95.500 / 95.510

(3.7598 / 3.7602)

SEM452G

Connecting rod big end inner diameter (Standard value)

55.000 - 55.013 (2.1654 - 2.1659)

          Crankshaft pin outer diameter

Grade (Mark)

— (No grade)

51.968 - 51.974

(2.0460 - 2.0462)

0

Bearing grade No. STD 0                              
Bearing thickness range: 1.500 - 1.503 (0.00591 - 0.0592)
Color: Black

51.962 - 51.968             

(2.0457 - 2.0460)

1

Bearing grade No. STD 1
Bearing thickness range: 1.503 - 1.506 (0.0592 - 0.0593)
Color: Brown

51.956 - 51.962

(2.0455 - 2.0457)

2

Bearing grade No. STD 2
Bearing thickness range: 1.506 - 1.509 (0.0593 - 0.0594)
Color: Green

EM-112

CYLINDER BLOCK

Revision; 2004 April

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   Bearing undersize table

Unit: mm (in)

CAUTION:

In grinding the crankshaft pin to use undersize bearings,
keep the fillet R (All crankshaft pins).

HOW TO SELECT MAIN BEARING
When New Cylinder Block and Crankshaft are Used

1.

“Main Bearing Selection Table” rows correspond to bearing
housing grade on rear left side of cylinder block.

2.

Apply journal diameter grade stamped on crankshaft front side
to columns in “Main Bearing Selection Table”.

3.

Find sign (main bearing grade) at crossing of row and column in
“Main Bearing Selection Table”.

When Cylinder Block and Crankshaft are Reused

1.

Measure inner diameter of cylinder block main bearing housing and outer diameter of crankshaft journal.
Refer to 

EM-118, "INNER DIAMETER OF MAIN BEARING HOUSING"

  an

EM-120, "OUTER DIAME-

TER OF CRANKSHAFT JOURNAL"

 .

2.

Find measured dimension in “Cylinder block bearing housing inner diameter” row of “Main Bearing Selec-
tion Table”.

3.

Find the measured dimension in “Crankshaft main journal diameter” column in the following selection
table.

4.

Select main bearing grade at the point where selected row and column meet in following selection table.

Size

Thickness

US  0.25 (0.0098)

1.626 - 1.634 (0.0640 - 0.0643)

PBIC0813E

SEM756G

SEM452G

CYLINDER BLOCK

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Main Bearing Selection Table

PBIC0814E

EM-114

CYLINDER BLOCK

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Main Bearing Grade Table (All Journals)

Undersize Bearing Usage Guide

Use undersize (US) bearing when oil clearance with standard
size main bearing is not within specification.

When using undersize (US) bearing, measure the bearing inner
diameter with bearing installed, and grind journal until oil clear-
ance falls within specification.
Bearing undersize table

Unit: mm (in)

CAUTION:

Keep fillet R when grinding crankshaft journal in order to
use undersize bearing (All journals). 

Grade number

Thickness “T” 

mm (in)

Width “W” 

mm (in)

Identification color

(UPR/LWR)

Remarks

0

2.000 - 2.003 (0.0787 - 0.0789)

19.9 - 20.1

 (0.783 - 0.791)

Black

Grade is the same for 
upper and lower bear-
ings.

1

2.003 - 2.006 (0.0789 - 0.0790)

Brown

2

2.006 - 2.009 (0.0790 - 0.0791)

Green

3

2.009 - 2.012 (0.0791 - 0.0792)

Yellow

4

2.012 - 2.015 (0.0792 - 0.0793)

Blue

5

2.015 - 2.018 (0.0793 - 0.0794)

Pink

6

2.018 - 2.021 (0.0794 - 0.0796)

Purple

7

2.021 - 2.024 (0.0796 - 0.0797)

White

01

UPP

2.003 - 2.006 (0.0789 - 0.0790)

Brown/Black

Grade is different for 
upper and lower bear-
ings.

LWR

2.000 - 2.003 (0.0787 - 0.0789)

12

UPR

2.006 - 2.009 (0.0790 - 0.0791)

Green/Brown

LWR

2.003 - 2.006 (0.0789 - 0.0790)

23

UPR

2.009 - 2.012 (0.0791 - 0.0792)

Yellow/Green

LWR

2.006 - 2.009 (0.0790 - 0.0791)

34

UPR

2.012 - 2.015 (0.0792 - 0.0793)

Blue/Yellow

LWR

2.009 - 2.012 (0.0791 - 0.0792)

45

UPR

2.015 - 2.018 (0.0793 - 0.0794)

Pink/Blue

LWR

2.012 - 2.015 (0.0792 - 0.0793)

56

UPR

2.018 - 2.021 (0.0794 - 0.0796)

Purple/Pink

LWR

2.015 - 2.018 (0.0793 - 0.0794)

67

UPR

2.021 - 2.024 (0.0796 - 0.0797)

White/Purple

LWR

2.018 - 2.021 (0.0794 - 0.0796)

Size

Thickness

US 0.25 (0.0098)

2.132 - 2.140 (0.0839 - 0.0843)

PBIC0813E

CYLINDER BLOCK

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Inspection After Disassembly

ABS0033M

CRANKSHAFT SIDE CLEARANCE

Using a dial gauge, measure the clearance between the thrust
bearings and the crankshaft arm when the crankshaft is moved
fully forward or backward.

If the measured value exceeds the limit, replace the thrust bear-
ings, and measure again. If it still exceeds the limit, replace the
crankshaft also.

CONNECTING ROD SIDE CLEARANCE

Measure side clearance between connecting rod and crankshaft
arm with feeler gauge.

If the measured value exceeds the limit, replace the connecting
rod, and measure again. If it still exceeds the limit, replace the
crankshaft also.

PISTON AND PISTON PIN CLEARANCE
Inner Diameter of Piston Pin

Measure the inner diameter of piston pin bore with an inside
micrometer.

Outer Diameter of Piston Pin

Measure outer diameter of piston pin with a micrometer.

Piston and Piston Pin Clearance

(Piston pin clearance) = (Piston pin bore diameter) – (Outer diameter of piston pin)

If clearance exceeds specification, replace piston/piston pin assembly with reference to specification of
each parts.

Standard

: 0.10 - 0.25 mm (0.0039 - 0.0098 in)

Limit

: 0.30 mm (0.0118 in)

EMQ0196D

Standard

: 0.20 - 0.35 mm (0.0079 - 0.0138 in)

Limit

: 0.40 mm (0.0157 in)

PBIC0815E

Standard

: 21.993 - 22.005 mm (0.8659 - 0.8663 in)

PBIC0116E

Standard

: 21.989 - 22.001 mm (0.8657 - 0.8662 in)

PBIC0117E

Standard

: 0.002 - 0.006 mm (0.0001 - 0.0002 in)

EM-116

CYLINDER BLOCK

Revision; 2004 April

2003 Murano

When replacing piston/piston pin assembly, refer to 

EM-119, "PISTON TO CYLINDER BORE CLEAR-

ANCE"

 .

PISTON RING SIDE CLEARANCE

Measure side clearance of piston ring and piston ring groove
with feeler gauge.

If out of specification, replace piston and/or piston ring assembly.

PISTON RING END GAP

Check if inner diameter of cylinder bore is within specification.
Refer to 

EM-119, "PISTON TO CYLINDER BORE CLEAR-

ANCE"

 .

Insert piston ring until middle of cylinder with piston, and mea-
sure gap.

If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylin-
der and use oversized piston and piston ring.

CONNECTING ROD BEND AND TORSION

Check with connecting rod aligner.

Standard:

Top ring

: 0.045 - 0.080 mm (0.0016 - 0.0031 in)

2nd ring

: 0.030 - 0.070 mm (0.0012 - 0.0028 in)

Oil ring

: 0.065 - 0.135 mm (0.0026 - 0.0053 in)

Limit:

     Top ring

: 0.11 mm (0.0043 in)

     2nd ring

: 0.1 mm (0.004 in)

SEM024AA

Standard:

Top ring

: 0.23 - 0.33 mm (0.0091 - 0.0130 in)

2nd ring

: 0.33 - 0.48 mm (0.0130 - 0.0189 in)

Oil ring

: 0.20 - 0.50 mm (0.0079 - 0.0197 in)

Limit:

     Top ring

: 0.54 mm (0.0213 in)

     2nd ring

: 0.80 mm (0.0315 in)

Oil ring

: 0.95 mm (0.0374 in)

PBIC0118E

Bend:

Limit : 0.15 mm (0.0059 in) per 100 mm (3.94 in) length

Torsion:

Limit : 0.30 mm (0.0118 in) per 100 mm (3.94 in) length

SEM038F

CYLINDER BLOCK

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If it exceeds the limit, replace connecting rod assembly.

CONNECTING ROD BEARING HOUSING DIAMETER (BIG END)

Install the connecting rod cap without the connecting rod bearing
installed. After tightening the connecting rod bolt to the specified
torque, measure the connecting rod big end inner diameter
using an inside micrometer. Refer to 

EM-104, "ASSEMBLY"

  for

the tightening procedure.

If it exceeds the standard, replace the connecting rod.

CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)
Inner Diameter of Connecting Rod (Small End)

Measure inner diameter of bushing.

Outer Diameter of Piston Pin

Measure outer diameter of piston pin.

SEM003F

Standard

: 55.000 - 55.013 mm (2.1654 - 2.1659 in)

PBIC1641E

Standard

: 22.000 - 22.012 mm (0.8661 - 0.8666 in)

PBIC0120E

Standard

: 21.989 - 22.001 mm (0.8657 - 0.8662 in)

PBIC0117E

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Connecting Rod Bushing Oil Clearance (Small End)

(Connecting rod small end oil clearance) = (Inner diameter of con-
necting rod small end) – (Outer diameter of piston pin)

If the measured value exceeds the standard, replace the con-
necting rod assembly and/or piston and piston pin assembly.

If replacing the piston and piston pin assembly, refer to 

EM-119,

"PISTON TO CYLINDER BORE CLEARANCE"

 .

If replacing the connecting rod assembly, refer to 

EM-121, "OIL

CLEARANCE OF CONNECTING ROD BEARING"

 .

Factory installed parts grading:

Service parts apply only to grade 0.

Unit: mm (in)

CYLINDER BLOCK DISTORTION

Using a scraper, remove gasket on the cylinder block surface,
and also remove oil, scale, carbon, or other contamination. 

CAUTION:

Be careful not to allow gasket flakes to enter the oil or
engine coolant passages.

Measure the distortion on the block upper face at some different
points in 6 directions.

If out of the distortion limit, replace the cylinder block.

INNER DIAMETER OF MAIN BEARING HOUSING

Install the main bearing caps and main bearing beam with the
main bearings removed, and tighten the mounting bolts to the
specified torque. Refer to 

EM-104, "ASSEMBLY"

  for the tighten-

ing procedure.

Using a bore gauge, measure the inner diameter of the main
bearing housing.

If out of specification, replace cylinder block and main bearing
caps as an assembly.

NOTE:
Cylinder block cannot be replaced as a single part because it is
machined together with main bearing cap.

Standard

: 0.005 - 0.017 mm (0.0002 - 0.0007 in)

Limit

: 0.030 mm (0.0012 in)

PBIC0809E

               Grade

                    0

                    1

Connecting rod small end 
inner diameter

         22.000 - 22.006          
       (0.8661 - 0.8664)

         22.006 - 22.012
        (0.8664 - 0.8666)

Piston pin bore diameter

        21.993 - 21.999
       (0.8659 - 0.8661)

         21.999 - 22. 005
        (0.8661 - 0.8663)

Piston pin outer diameter

        21.989 - 21.995
       (0.8657- 0.8659)

         21.995 - 22.001
        (0.8659 - 0.8662)

PBIC0812E

Limit

: 0.1 mm (0.004 in)

SEM123C

Standard

: 63.993 - 64.017 mm (2.5194 - 2.5203 in)

PBIC1643E

CYLINDER BLOCK

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PISTON TO CYLINDER BORE CLEARANCE
Inner Diameter of Cylinder Bore

Using a bore gauge, measure cylinder bore for wear, out-of-
round and taper at 6 different points on each cylinder. (X and Y
directions at A, B and C) (Y is in longitudinal direction of engine)

If the measured value exceeds the limit, or if there are scratches
and/or seizure on the cylinder inner wall, hone or rebore the
inner wall. 

An oversize piston is provided. When using an oversize piston,
rebore the cylinder so that the clearance of the piston-to-cylinder
bore satisfies the standard.

Outer Diameter of Piston

Measure piston skirt outer diameter using micrometer.

Piston-to-Cylinder Bore Clearance

Calculate by outer diameter of piston skirt and inner diameter of cylinder (direction X, position B).
(Clearance) = (Inner diameter of cylinder) – (Outer diameter of piston skirt).

If it exceeds the limit, replace piston/piston pin assembly. Refer to 

EM-110, "HOW TO SELECT PISTON"

 .

Reboring Cylinder Bore

1.

Cylinder bore size is determined by adding piston-to-cylinder bore clearance to piston diameter “A”.

Standard inner diameter:

95.500 - 95.530 mm (3.7598 - 3.7610 in)

Wear limit:

0.2 mm (0.008 in)

Out-of-round (Difference between X and Y):

0.015 mm (0.0006 in)

Taper limit (Difference between A and C):

 

0.01 mm (0.0004 in)

Oversize (OS)

: 0.2 mm (0.008 in)

PBIC0923E

SEM843E

Measure point

: Distance from the top 41.0 mm (1.614 in)

Standard

: 95.480 - 95.510 mm (3.7590 - 3.7602 in)

PBIC0125E

Standard

: 0.010 - 0.030 mm (0.0004 - 0.0012 in)

Limit

: 0.08 mm (0.0031 in)

Rebored size calculation: D = A + B - C

where,

D: Bored diameter

A: Piston diameter as measured

B: Piston - to - cylinder bore clearance (standard value)

C: Honing allowance 0.02 mm (0.0008 in)

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2.

Install main bearing caps and main bearing beam, and tighten to the specified torque. Otherwise, cylinder
bores may be distorted in final assembly.

3.

Cut cylinder bores.

When any cylinder needs boring, all other cylinders must also be bored.

Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a
time.

4.

Hone cylinders to obtain specified piston-to-cylinder bore clearance.

5.

Measure finished cylinder bore for out-of-round and taper.

Measurement should be done after cylinder bore cools down.

OUTER DIAMETER OF CRANKSHAFT JOURNAL

Measure outer diameter of crankshaft journals.

If it out of the standard, measure the main bearing oil clearance.
Then use the undersize bearing. Refer to 

EM-122, "OIL CLEAR-

ANCE OF MAIN BEARING"

 .

OUTER DIAMETER OF CRANKSHAFT PIN

Measure outer diameter of crankshaft pin.

If it out of the standard, measure the connecting rod bearing oil clearance. Then use the undersize bear-
ing. Refer to 

EM-121, "OIL CLEARANCE OF CONNECTING ROD BEARING"

 .

OUT-OF-ROUND AND TAPER OF CRANKSHAFT

Using a micrometer, measure the dimensions at 4 different
points shown in the figure on each journal and pin. 

Out-of-round is indicated by the difference in dimensions
between X and Y at A and B.

Taper is indicated by the difference in dimension between A and
B at X and Y.

If the measured value exceeds the limit, correct or replace the crankshaft.

If corrected, measure the bearing oil clearance of the corrected journal or pin. Then select the main bear-
ing or connecting rod bearing. Refer to 

EM-122, "OIL CLEARANCE OF MAIN BEARING"

    or 

EM-121,

"OIL CLEARANCE OF CONNECTING ROD BEARING"

 .

Standard

: 59.951 - 59.975 mm (2.3603 - 2.3612 in) dia.

PBIC0127E

Standard

: 51.956 - 51.974 mm (2.0455 - 2.0462 in) dia.

Limit:

Out-of-round
(Difference between X and Y)

: 0.002 mm (0.0001 in)

Taper
(Difference between A and B)

: 0.002 mm (0.0001 in)

SEM316A

 

 

 

 

 

 

 

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