dimensions NISSAN ALMERA N16 2003 Electronic Repair Manual
[x] Cancel search | Manufacturer: NISSAN, Model Year: 2003, Model line: ALMERA N16, Model: NISSAN ALMERA N16 2003Pages: 3189, PDF Size: 54.76 MB
Page 3 of 3189
GENERAL INFORMATION
SECTION
GI
CONTENTS
PRECAUTIONS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[3
Precautions <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[..............3
PRECAUTIONS FOR SUPPLEMENTAL
RESTRAINT SYSTEM (SRS)″AIR BAG″AND
″SEAT BELT PRE-TENSIONER″
.................................3
PRECAUTIONS FOR NATS (NISSAN ANTI-THEFT
SYSTEM)
<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[...3
GENERAL PRECAUTIONS.........................................4
PRECAUTIONS FOR MULTIPORT FUEL
INJECTION SYSTEM OR ENGINE CONTROL
SYSTEM
<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....6
PRECAUTIONS FOR THREE WAY CATALYST...........6
PRECAUTIONS FOR HOSES.....................................6
PRECAUTIONS FOR ENGINE OILS...........................7
PRECAUTIONS FOR FUEL........................................8
PRECAUTIONS FOR AIR CONDITIONING..................9
HOW TO USE THIS MANUAL......................................10
HOW TO READ WIRING DIAGRAMS..........................12
Sample/Wiring Diagram - EXAMPL - ........................12
OPTIONAL SPLICE..................................................13
Description <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[.............14
CONNECTOR SYMBOLS.........................................16
HARNESS INDICATION...........................................17
COMPONENT INDICATION......................................17
SWITCH POSITIONS...............................................17
DETECTABLE LINES AND NON-DETECTABLE
LINES
<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[......18
MULTIPLE SWITCH.................................................19
REFERENCE AREA.................................................20
HOW TO PERFORM EFFICIENT DIAGNOSES
FOR AN ELECTRICAL INCIDENT...............................22
Work Flow <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[...........22
Incident Simulation Tests ...........................................23
INTRODUCTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011> 3
VEHICLE VIBRATION..............................................23
HEAT SENSITIVE<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011> 4
FREEZING<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011001100110011> 24
WATER INTRUSION................................................25
ELECTRICAL LOAD.................................................25
COLD OR HOT START UP.......................................25
Circuit Inspection .......................................................25
INTRODUCTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011> 5
TESTING FOR″OPENS″IN THE CIRCUIT................26
TESTING FOR″SHORTS″IN THE CIRCUIT..............27
GROUND INSPECTION...........................................28
VOLTAGE DROP TESTS..........................................28
CONTROL UNIT CIRCUIT TEST...............................30
HOW TO FOLLOW TROUBLE DIAGNOSES...............32
How to Follow Test Groups in Trouble Diagnoses ....33
Key to Symbols Signifying Measurements or
Procedures<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[............34
CONSULT-II CHECKING SYSTEM...............................36
Function and System Application ..............................36
Nickel Metal Hydride Battery Replacement...............37
Checking Equipment..................................................37
CONSULT-II Data Link Connector (DLC) Circuit ......38
INSPECTION PROCEDURE.....................................38
IDENTIFICATION INFORMATION................................39
Model Variation ..........................................................39
FOR EUROPE<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011> 9
FOR AUSTRALIA, NEW ZEALAND AND SOUTH
AFRICA
<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....39
PREFIX AND SUFFIX DESIGNATIONS.....................40
Identification Number .................................................40
VEHICLE IDENTIFICATION NUMBER
ARRANGEMENT
<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011> 1
IDENTIFICATION PLATE..........................................41
ENGINE SERIAL NUMBER.......................................42
AUTOMATIC TRANSAXLE NUMBER........................42
MANUAL TRANSAXLE NUMBER..............................43
Dimensions <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[...........44
Wheels and Tires .......................................................44
LIFTING POINTS AND TOW TRUCK TOWING...........45
Preparation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[............45
SPECIAL SERVICE TOOLS......................................45
Board-on Lift <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...........45
Garage Jack and Safety Stand .................................46
2-pole Lift <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............47
Tow Truck Towing ......................................................48
TOWING AN AUTOMATIC TRANSAXLE MODEL
WITH FOUR WHEELS ON GROUND
........................48
MA
EM
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
Page 46 of 3189
Dimensions=NJGI0008S03Unit: mm (in)
Item Sedan HB
Overall length 4,470 (176.0) 4,184 (164.7)
Overall width 1,695 (66.7) 1,710 (67.3)
Overall height 1,440 (56.7) 1,440 (56.7)
Front tread 1,470 (57.9) 1,470 (57.9)
Rear tread 1,450 (57.1) 1,455 (57.3)
Wheelbase 2,535 (99.8) 2,535 (99.8)
Wheels and TiresNJGI0008S04Sedan
Item Except for Europe Europe
Road wheelSteel/offset mm (in)14 x 5J/35 (1.38)
14 x 5-1/2JJ/45 (1.77)
15 x 6JJ/45 (1.77)14 x 5J/35 (1.38)
15 x 6JJ/45 (1.77)
Aluminum/offset mm (in) 14 x 6J (J)*/45 (1.77) 15 x 6J*/45 (1.77)
Tire sizeConventional175/65R14
175/70R14
185/65R14
185/65R15175/70R14
185/65R15
195/60R15
Spare Conventional T135/80D15
*: Option
Hatchback
Item
Road wheelSteel/offset mm (in)
15 x 6JJ/45 (1.77)
16 x 6JJ/45 (1.77)
Aluminum/offset mm (in)
Tire sizeConventional185/65R15
195/55R16
SpareConventional
T135/80/D15*
*: If so equipped (for some of A/T models)
IDENTIFICATION INFORMATION
Dimensions
GI-44
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![NISSAN ALMERA N16 2003 Electronic Repair Manual PREPARATION
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Commercial Service ToolsEBS00LPV
ST16610001
Pilot bushing pullerRemoving pilot bushing
KV101056S0*
Rear gear stopper
1. KV10105620
Adapter
2. KV10105610](/img/5/57350/w960_57350-84.png "NISSAN ALMERA N16 2003 Electronic Repair Manual PREPARATION
EM-7
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Commercial Service ToolsEBS00LPV
ST16610001
Pilot bushing pullerRemoving pilot bushing
KV101056S0*
Rear gear stopper
1. KV10105620
Adapter
2. KV10105610")
PREPARATION
EM-7
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Commercial Service ToolsEBS00LPV
ST16610001
Pilot bushing pullerRemoving pilot bushing
KV101056S0*
Rear gear stopper
1. KV10105620
Adapter
2. KV10105610
Plate assemblyPreventing crankshaft from rotating Tool number
To o l n a m eDescription
NT045
NT773
To o l n a m eDescription
Spark plug wrench Removing and installing spark plug
Crankshaft pulley puller Removing crankshaft pulley
Manual lift table caddy Removing and installing engine
Valve seat cutter set Finishing valve seat dimensions
Piston ring expander Removing and installing piston ring
NT047
PBIC0887E
ZZA1210D
NT048
NT030
Page 140 of 3189
![NISSAN ALMERA N16 2003 Electronic Repair Manual EM-62
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CYLINDER HEAD
8. Install valve collet.
●Compress valve spring with valve spring compressor (special
service tool). Install valve collet with magnet hand.
●Tap stem edge lightly with pla](/img/5/57350/w960_57350-139.png "NISSAN ALMERA N16 2003 Electronic Repair Manual EM-62
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CYLINDER HEAD
8. Install valve collet.
●Compress valve spring with valve spring compressor (special
service tool). Install valve collet with magnet hand.
●Tap stem edge lightly with pla")
EM-62
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CYLINDER HEAD
8. Install valve collet.
●Compress valve spring with valve spring compressor (special
service tool). Install valve collet with magnet hand.
●Tap stem edge lightly with plastic hammer after installation to
check its installed condition.
9. Install adjusting shim (if so equipped) and valve lifter.
10. Install engine coolant temperature sensor.
●Apply Genuine Liquid Gasket or equivalent to the thread.
11. Install spark plug tube.
●Press-fit spark plug tube following procedure below.
a. Remove old liquid gasket adhering to cylinder-head mounting
hole.
b. Apply liquid gasket to area within approximately 15 mm (0.59 in)
from edge of spark plug tube press-fit side.
●Use Genuine Liquid Gasket or equivalent.
c. Using a drift, press-fit spark plug tube so that its height “H” is as
specified in the figure.
CAUTION:
●When press-fitting, take care not to deform spark plug tube.
●After press-fitting, wipe off liquid gasket protruding onto cylinder-head upper face.
12. Install spark plug with spark plug wrench (commercial service tool).
Inspection After DisassemblyEBS00LQK
CYLINDER HEAD DISTORTION
1. Wipe off oil and remove water scale (like deposit), gasket,
sealer, carbon, etc with scraper.
CAUTION:
Use utmost care not to allow gasket debris to enter pas-
sages for oil or water.
2. At each of several locations on bottom surface of cylinder head,
measure distortion in six directions.
VALVE DIMENSIONS
Check dimensions of each valve. For dimensions, refer to EM-94,
"VA LV E" .
PBIC1016E
Standard press-fit height “H” :
: 41.0 - 42.0 mm (1.61 - 1.65 in)KBIA1248E
Limit : 0.1 mm (0.004 in)
PBIC0075E
SEM188A
Page 142 of 3189
![NISSAN ALMERA N16 2003 Electronic Repair Manual EM-64
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CYLINDER HEAD
4. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil.
5. Press valve guide from camshaft side to dimensions as in illus-
tration.
CAUTION:
Cylinder](/img/5/57350/w960_57350-141.png "NISSAN ALMERA N16 2003 Electronic Repair Manual EM-64
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CYLINDER HEAD
4. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil.
5. Press valve guide from camshaft side to dimensions as in illus-
tration.
CAUTION:
Cylinder")
EM-64
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CYLINDER HEAD
4. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil.
5. Press valve guide from camshaft side to dimensions as in illus-
tration.
CAUTION:
Cylinder head contains heat. When working, wear protec-
tive equipment to avoid getting burned.
6. Using valve guide reamer, apply reamer finish to valve guide.
VALVE SEAT CONTACT
●After confirming that the dimensions of valve guides and valves
are within specifications, perform this procedure.
●Apply prussian blue (or white lead) onto contacting surface of
valve seat to check the condition of the valve contact on the sur-
face.
●Check if the contact area band is continuous all around the cir-
cumference.
●If not, grind to adjust valve fitting and check again. If the contact-
ing surface still has N.G conditions even after the re-check,
replace valve seat.
VALVE SEAT REPLACEMENT
When valve seat is removed, replace with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
in cylinder head. Set the machine depth stop to ensure this.
SEM008A
PBIC0577E
Standard
Intake and exhaust
: 5.500 - 5.515 mm (0.2165 - 0.2171 in) dia.
SEM932C
EMA0487D
Page 143 of 3189
![NISSAN ALMERA N16 2003 Electronic Repair Manual CYLINDER HEAD
EM-65
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2. Ream cylinder head recess diameter for service valve seat.
●Be sure to ream in circles concentric to the valve guide center.
●This will enable](/img/5/57350/w960_57350-142.png "NISSAN ALMERA N16 2003 Electronic Repair Manual CYLINDER HEAD
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2. Ream cylinder head recess diameter for service valve seat.
●Be sure to ream in circles concentric to the valve guide center.
●This will enable")
CYLINDER HEAD
EM-65
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2. Ream cylinder head recess diameter for service valve seat.
●Be sure to ream in circles concentric to the valve guide center.
●This will enable valve seat to fit correctly.
3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil.
4. Provide valve seats cooled well with dry ice. Force fit valve seat
into cylinder head.
CAUTION:
●Avoid directly to touching cold valve seats.
●Cylinder head contains heat. When working, wear protec-
tive equipment to avoid getting burned.
5. Using valve seat cutter set (commercial service tool) or valve
seat grinder, finish the seat to the specified dimensions.
CAUTION:
When using valve seat cutter, firmly grip the cutter handle
with both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper
pressure on with the cutter or cutting many different times
may result in stage valve seat.Oversize [0.5 mm (0.020 in)]:
Intake : 31.5 mm (1.240 in)
Exhaust : 26.5 mm (1.043 in)
SEM795A
SEM008A
PBIC0579E
SEM934C
Page 144 of 3189
![NISSAN ALMERA N16 2003 Electronic Repair Manual EM-66
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CYLINDER HEAD
Grind to obtain the dimensions indicated in figure.
6. Using compound, grind to adjust valve fitting.
7. Check again for normal contact.
VALVE SPRING SQUARENESS
Set try squa](/img/5/57350/w960_57350-143.png "NISSAN ALMERA N16 2003 Electronic Repair Manual EM-66
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CYLINDER HEAD
Grind to obtain the dimensions indicated in figure.
6. Using compound, grind to adjust valve fitting.
7. Check again for normal contact.
VALVE SPRING SQUARENESS
Set try squa")
EM-66
[QG]
CYLINDER HEAD
Grind to obtain the dimensions indicated in figure.
6. Using compound, grind to adjust valve fitting.
7. Check again for normal contact.
VALVE SPRING SQUARENESS
Set try square along the side of valve spring and rotate the spring.
Measure the maximum clearance between the top face of spring and
try square.
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD
Check valve spring pressure with valve spring seat installed at spec-
ified spring height.
CAUTION:
Do not remove valve spring seat.Standard:
D1 dia. : 27.8 - 28.0 mm (1.094 - 1.102 in)
D2 dia. : 29.5 - 29.7 mm (1.161 - 1.169 in)
D3 dia. : 31.9 - 32.1 mm (1.256 - 1.264 in)
D4 dia. : 24.5 - 24.7 mm (0.965 - 0.972 in)
D5 dia. : 26.2 - 26.4 mm (1.031- 1.039 in)
PBIC0974E
Limit : 1.8 mm (0.071 in)
PBIC0080E
Standard:
Free height 40.0 mm (1.575 in)
Installation
height32.82 mm (1.2921 in)
Installation load 147.5 - 166.3 N (15.04 - 16.96 kg,
33.2 - 37.4 lb)
Height during
valve open23.64 mm (0.9307 in)
Load with valve
open347.8 - 392.2 N (35.5 - 40.0 kg,
78.2 - 88.2 lb)
SEM113
Page 168 of 3189
![NISSAN ALMERA N16 2003 Electronic Repair Manual EM-90
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CYLINDER BLOCK
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 (0.0](/img/5/57350/w960_57350-167.png "NISSAN ALMERA N16 2003 Electronic Repair Manual EM-90
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CYLINDER BLOCK
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 (0.0")
EM-90
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CYLINDER BLOCK
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-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.
OUTER DIAMETER OF CRANKSHAFT PIN
●Measure outer diameter of crankshaft pin.
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 A and B at 1 and 2.
●Taper is indicated by the difference in dimension between 1 and
2 at A and B.
CRANKSHAFT RUNOUT
●Place a V-block on a precise flat table to support the journals on
the both end of the crankshaft.
●Place a dial gauge straight up on the No. 3 journal.
●While rotating the crankshaft, read the movement of the pointer
on the dial gauge. (Total indicator reading)Standard : 49.940 - 49.964 mm (1.9661 - 1.9671 in) dia.
Standard : 39.956 - 39.974 mm (1.5731 - 1.5738 in) dia.
PBIC0270E
Limit:
Out-of-round (A – B) : 0.005 mm (0.0002 in)
Taper (1 – 2) : 0.005 mm (0.0002 in)
PBIC0614E
Limit: : 0.10 mm (0.004 in)
PBIC0271E
Page 172 of 3189
![NISSAN ALMERA N16 2003 Electronic Repair Manual EM-94
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SERVICE DATA AND SPECIFICATIONS (SDS)
SPARK PLUG
CYLINDER HEAD
Unit: mm (in)
VA LV E
Valve Dimensions
Unit: mm (in)
Valve Clearance
Shim Type
Unit: mm (in) Power steering oil pump 7.1 (0.28](/img/5/57350/w960_57350-171.png "NISSAN ALMERA N16 2003 Electronic Repair Manual EM-94
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SERVICE DATA AND SPECIFICATIONS (SDS)
SPARK PLUG
CYLINDER HEAD
Unit: mm (in)
VA LV E
Valve Dimensions
Unit: mm (in)
Valve Clearance
Shim Type
Unit: mm (in) Power steering oil pump 7.1 (0.28")
EM-94
[QG]
SERVICE DATA AND SPECIFICATIONS (SDS)
SPARK PLUG
CYLINDER HEAD
Unit: mm (in)
VA LV E
Valve Dimensions
Unit: mm (in)
Valve Clearance
Shim Type
Unit: mm (in) Power steering oil pump 7.1 (0.280)4.4 - 4.9
(0.173 - 0.193)3.9 - 4.4
(0.154 - 0.173)
Applied pushing force 98 N (10 kg, 22 lb)Deflection adjustment
Used belt
New belt
Limit After adjustment
Make NGK Champion
Ty p eStandard LFR5A-11 REC10YC4
Hot LFR4A-11 —
Cold LFR6A-11 —
Plug gap 1.0 - 1.1 mm (0.039 - 0.043 in)
Standard Limit
Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)
Height 117.9 (4.642) —
QG15DE QG18DE
Valve head diameter “D”Intake 28.9 - 29.2 (1.138 - 1.150) 29.9 - 30.2 (1.177 - 1.189)
Exhaust 23.9 - 24.2 (0.941 - 0.953) 24.9 - 25.2 (0.980 - 0.992)
Valve length “L”Intake 92.00 - 92.50 (3.6220 - 3.6417)
Exhaust 92.37 - 92.87 (3.6366 - 3.6563)
Valve stem diameter “d”Intake 5.465 - 5.480 (0.2152 - 0.2157)
Exhaust 5.445 - 5.460 (0.2144 - 0.2150)
Valve seat angle “α”44°15′ - 44°45′
Valve margin “T” 0.8 - 0.14 (0.031 - 0.055)
Valve margin “T” limit More than 0.5 (0.020)
Valve stem end surface grinding limit 0.2 (0.008)
SEM188
For adjusting For checking
Hot Cold* (reference data) Hot
Page 186 of 3189
REPLACING VALVE SEAT FOR SERVICE PARTS....52
VALVE DIMENSIONS...............................................54
VALVE SPRING<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011> 4
VALVE LIFTER<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011> 4
Assembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[............55
Installation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[...............56
CYLINDER HEAD GASKET SELECTION...................56
CYLINDER HEAD BOLT DEFORMATION CHECK.....57
CYLINDER HEAD-TO-BLOCK DIFFERENCE
CHECK
<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[....57
LIQUID GASKET APPLICATION ON REAR CHAIN
CASE
<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[.......57
CYLINDER HEAD INSTALLATION............................58
GLOW PLUG INSTALLATION...................................58
CAMSHAFT INSTALLATION.....................................58
Valve Clearance.........................................................59
CHECKING<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011001100110011> 9
ADJUSTING<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011> 0
ENGINE ASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011> 3
Removal and Installation ...........................................63
REMOVAL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[64
INSTALLATION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011> 5
CYLINDER BLOCK<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011> 6
Components<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..........66
Removal and Installation ...........................................67
Disassembly<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[...........67
PISTON AND CRANKSHAFT....................................67
Inspection<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..............70
CRANKSHAFT END PLAY.......................................70
CONNECTING ROD SIDE CLEARANCE...................70
PISTON AND PISTON PIN CLEARANCE..................71
PISTON RING SIDE CLEARANCE............................71
PISTON RING END GAP..........................................72
CONNECTING ROD BEND AND TORSION...............72
CYLINDER BLOCK DISTORTION AND WEAR...........72
PISTON-TO-BORE CLEARANCE..............................73
CRANKSHAFT<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011> 5
MAIN BEARING HOUSING INNER DIAMETER..........75
BEARING CLEARANCE...........................................75
MAIN BEARING CRUSH HEIGHT.............................79
MAIN BEARING CAP BOLT DEFORMATION.............79
CONNECTING ROD BUSHING CLEARANCE
(SMALL END)
<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011> 9
CONNECTING ROD BOLT DEFORMATION..............80
FLYWHEEL RUNOUT..............................................80
OIL JET<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[...80
OIL JET RELIEF VALVE...........................................80
Assembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[............81
PISTON<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[...81
CRANKSHAFT<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011> 1
REPLACEMENT OF PILOT BUSHING.......................84
SERVICE DATA AND SPECIFICATIONS (SDS).........86
General Specifications ...............................................86
Compression Pressure ..............................................86
Belt Deflection............................................................86
Cylinder Head <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11[.........86
Valve <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011[................87
VA L V E<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[.....87
VALVE CLEARANCE................................................87
AVAILABLE SHIMS..................................................87
VALVE SPRING<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011> 8
VALVE LIFTER<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011> 9
VALVE GUIDE<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011> 9
Valve Seat<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011[............90
Camshaft and Camshaft Bearing ..............................92
Cylinder Block ............................................................93
Piston, Piston Ring and Piston Pin ...........................94
AVAILABLE PISTON................................................94
PISTON RING<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011> 4
PISTON PIN<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011> 4
Connecting Rod .........................................................95
Crankshaft<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[.............95
Available Main Bearing ..............................................96
UNDERSIZE<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011> 6
Available Connecting Rod Bearing............................96
CONNECTING ROD BEARING.................................96
UNDERSIZE<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011> 6
Miscellaneous Components.......................................96
BEARING CLEARANCE...........................................97
CONTENTS(Cont’d)
EM-2