Nissan Frontier D22. Manual - part 686

CYLINDER BLOCK

EM-51

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PISTON RING SIDE CLEARANCE

Measure the piston ring side clearance as shown. If the clearance
exceeds the specification, replace piston ring.
If the clearance exceeds the maximum side clearance limit with the
new piston ring, replace piston.

PISTON RING END GAP

1.

Measure the piston ring end gap as shown. If out of specifica-
tion, replace piston ring. If gap exceeds maximum limit with a
new ring, rebore cylinder and use oversized piston and piston
rings. Refer to 

EM-69, "Piston, Piston Ring and Piston pin"

 .

2.

When replacing the piston, check cylinder block surface for scratches or seizure. If scratches or seizure
are found, hone or replace the cylinder block.

CONNECTING ROD BEND AND TORSION

Measure the connecting rod bend and torsion as shown.
If either of the measurements exceed the limits, replace the connect-
ing rod assembly.

Side Clearance

Top ring

: 0.04 - 0.08 mm (0.0016 - 0.0031 in)

2nd ring

: 0.03 - 0.07 mm (0.0012 - 0.0028 in)

Oil ring

: 0.065 - 0.135 mm (0.0026 - 0.0053 in)

Limit (Top, 2nd)

: 0.1 mm (0.004 in)

SEM249CA

SEM250C

Piston Ring End Gap

Top ring

: 0.28 - 0.52 mm (0.0110 - 0.0205 in)

2nd ring

: 0.45 - 0.69 mm (0.0177 - 0.0272 in)

Oil ring (rail ring)

: 0.20 - 0.69 mm (0.0079 - 0.0272 in)

Limit

: 1.0 mm (0.039 in)

SEM038F

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CYLINDER BLOCK

CYLINDER BLOCK DISTORTION AND WEAR

1.

Clean upper face of cylinder block.

2.

Use a reliable straightedge and feeler gauge to check the flat-
ness of the cylinder block upper face surface. Check along the
six positions as shown.

3.

If the block distortion exceeds specification, resurface the block. Replace the block if necessary.
The limit for cylinder block resurfacing is determined by cylinder head resurfacing.
Amount of cylinder head resurfacing is “A”
Amount of cylinder block resurfacing is “B”

4.

If necessary, replace cylinder block.

PISTON-TO-CYLINDER BORE CLEARANCE 

1.

Using a bore gauge, measure cylinder bore for wear, out-of-
round and taper.
If it exceeds the limit, rebore all cylinders. Replace cylinder block
if necessary.

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

SEM003F

Cylinder block distortion

Standard

: —

Limit

: 0.1 mm (0.004 in)

SEM255CB

The maximum limit is as follows

: A + B = 0.2 mm (0.008 in)

Nominal block height at crankshaft center

: 246.95 - 247.05 mm (9.7224 - 9.7264 in)

Max. block distortion limit = A + B

: 0.2 mm (0.008 in)

Standard inner diameter

: Refer to 

EM-67, 

"Cylinder Block"

 .

Out-of-round (X 

− Y) standard : 0.015 mm (0.0006 in)

Taper (A 

− B) standard

: 0.010 mm (0.0004 in)

Wear limit

: 0.2 mm (0.008 in)

SEM040

CYLINDER BLOCK

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2.

Check for scratches and seizure. If seizure is found, hone it.

CAUTION:

If the cylinder block and pistons are replaced, match the
piston grade with the grade number on the cylinder block
upper surface as shown. Refer to 

EM-69, "PISTON"

 .

3.

Measure piston skirt diameter.

4.

Check that piston-to-cylinder bore clearance is within specification.

5.

Determine the piston oversize according to the amount of cylinder bore wear for the specified piston-to-
bore clearance.

NOTE:
Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for ser-
vice. Refer to 

EM-69, "PISTON"

 .

6.

Cylinder rebore diameter "D" is determined by adding piston-to-cylinder bore clearance "B" to the piston
diameter “A” and subtracting the honing allowance "C".

7.

Install the main bearing caps and tighten the cap bolts to specification. This will prevent distortion of the
cylinder bores during the honing process.

8.

Hone the cylinder bores to obtain the specified piston-to-cylinder bore clearance.

CAUTION:

●

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

●

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

9.

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

CAUTION:

●

Measurement should be done after cylinder bore cools down.

CRANKSHAFT

1.

Check the crankshaft main and pin journals for scratches, wear, or cracks.

SEM257C

Piston diameter “A”

: refer to 

EM-69, "PISTON"

 

.

Measuring point "A" at 
height “a” from the top

: approximately 48 mm 
(1.89 in)

SEM258C

Piston-to-cylinder bore clearance “B”

: 0.020 - 0.040 mm (0.0008 - 0.0016 in)

Rebore size calculation: D = A + B - C

Where,

D

: rebore diameter

A

: piston diameter as measured

B

: piston-to-cylinder bore clearance

C

: honing allowance of 0.02 mm (0.0008 in)

Main bearing cap bolts

: 46 - 56 N·m (4.7 - 5.7 kg-m, 34 - 41 ft-lb)

EM-54

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CYLINDER BLOCK

2.

With a micrometer, measure the journals for taper and out-of-
round.

3.

Measure the crankshaft runout.

4.

If the crankshaft is out of specification, replace the crankshaft.

BEARING CLEARANCE
Method A (using a bore gauge and micrometer)

Use Method A or Method B. Method A is preferred because it is more accurate.

NOTE:
Use the following procedures to inspect the bearing clearance using Method A (bore gauge and micrometer).

Main bearing

1.

Set main bearings in their proper positions on the cylinder block
and main bearing caps. Follow the position numbering as
shown.

2.

Install the main bearing caps on the cylinder block.

●

Tighten the main bearing cap bolts in two or three steps to specification.

Out-of-round (X 

− Y)

Main journal

:

less than 0.01 mm (0.0004 in)

Crankshaft pin

:

less than 0.005 mm (0.0002 in)

Taper (A 

− B)

Main journal

:

less than 0.01 mm (0.0004 in)

Crankshaft pin

:

less than 0.005 mm (0.0002 in)

SEM316A

Runout (total indicator reading)

: less than 0.10 mm 
(0.0039 in)

SEM254C

SEM448C

Main bearing cap bolts

: 46 - 56 N·m (4.7 - 5.7 kg-m, 34 - 41 ft-lb)