Qashqai J11. Engine mechanical (HRA2DDT, K9K, MR20DD) - part 15

CYLINDER BLOCK

EM-225

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

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• Loosen and remove main bearing cap bolts in the order from

10 to 1 as shown in the figure.

• Use TORX socket.

11. Remove main bearing caps.

• Tap main bearing caps lightly with a plastic hammer for removal. 

CAUTION:

Be careful not to damage the mounting surface.

12. Remove crankshaft.

CAUTION:

• Be careful not to damage or deform signal plate 

mounted on rear end of crankshaft 

.

• When setting crankshaft on a flat floor surface, use a

block of wood to avoid interference between signal plate
and the floor surface.

• Never remove signal plate unless it is necessary to do so.
NOTE:
When removing or installing signal plate, use TORX socket.

13. Pull rear oil seal out from rear end of crankshaft.
14. Remove main bearings and thrust bearings from cylinder block and main bearing caps.

CAUTION:

Identify installation positions, and store them without mixing them up.

ASSEMBLY

CAUTION:

Do not reuse O-rings or washers.
1.

Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material.

CAUTION:

Use a goggles to protect your eye.

2.

Install each plug to cylinder block as shown in the figure.

CAUTION:

Do not reuse washer.
• Apply liquid gasket to the thread of water drain plug 

.

Use Genuine Liquid Gasket (Three Bond 1215) or equiva-
lent.

• Apply sealant to the thread of plug 

.

Use genuine high strength thread locking sealant (Three
Bond 1386B) or equivalent.
NOTE:
Do not apply liquid gasket or high strength thread locking sealant to the plug 

.

• Tighten each plug as specified below.

: Engine front

JSBIA4604ZZ

PBIC3234J

: Washer

: Engine front

PBIC3999E

EM-226

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

CYLINDER BLOCK

3.

Install main bearings and thrust bearings with the following procedure:

a.

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

b.

Install thrust bearings to the both sides of the No. 3 journal hous-
ing 

 on cylinder block.

• Install thrust bearings with the oil groove 

 facing crankshaft

arm (outside). 

c.

Install the main bearings paying attention to the direction.
• Before installing main bearings, apply new engine oil to the bearing surface (inside). Do not apply new

engine oil to the back surface, but thoroughly clean it.

• When installing, align main bearing to the center position of cylinder block and main bearing cap.
• The difference 

 between main bearing (upper) 

 and main

bearing (lower) 

 should be 0.85 mm (0.0335 in) or less when

installing.

• Ensure the oil holes on cylinder block and oil holes 

 on the

main bearings 

 are aligned.

4.

Install signal plate to crankshaft if removed.

a.

Set the signal plate with the flange facing toward the counter weight side (engine front side) to the crank-
shaft rear surface.

b.

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

Part

Washer

Tightening torque

Yes

54.0 N·m (5.5 kg-m, 40 ft-lb)

No

19.6 N·m (2.0 kg-m, 14 ft-lb)

No

9.8 N·m (1.0 kg-m, 87 in-lb)

: Engine front

PBIC3258J

: Cylinder block

: Main bearing cap

PBIC3237J

PBIC3236J

CYLINDER BLOCK

EM-227

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

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c.

Position crankshaft 

 and signal plate 

 using a dowel pin (ser-

vice part), and tighten mounting bolts in the order from 1 to 4 as
shown in the figure using TORX socket.

NOTE:
Dowel pin of crankshaft and signal plate is provided as a set for
each.

d.

Tighten mounting bolts in numerical order as shown in the figure
again.

e.

Remove dowel pin. (service parts)

CAUTION:

Be sure to remove dowel pin.

5.

Install crankshaft to cylinder block.
• While turning crankshaft by hand, check that it turns smoothly. 

6.

Install main bearing caps with the following procedure:

a.

Install main bearing caps referring to the journal No. stamp 
and front mark 

 as shown in the figure. 

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

b.

Tighten main bearing cap bolts in the order from 1 to 10 as
shown in the figure with the following procedure:

i.

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

ii.

Tighten main bearing cap bolts.

iii.

Turn main bearing cap bolts 60 degrees clockwise (angle tightening) in order from No. 1 to 10 in the fig-
ure.

CAUTION:

Confirm the tightening angle by using an angle wrench
[SST: KV10112100] 

 or protractor. Never judge by visual

inspection without the tool. 

• After installing mounting bolts, check that crankshaft can be rotated smoothly by hand.
• Check crankshaft end play. Refer to 

EM-231, "Inspection"

.

7.

Install piston to connecting rod with the following procedure: 

: Dowel pin hole

: Engine front

PBIC3238J

PBIC3239J

: Engine front

: 34.3 N·m (3.5 kg-m, 25 ft-lb)

JSBIA4604ZZ

PBIC3240J

EM-228

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

CYLINDER BLOCK

a.

Using snap ring pliers, install new snap ring to the groove of the piston rear side. 
• Insert it fully into groove to install. 

b.

Assemble piston to connecting rod.
• Using an industrial use drier or similar tool, heat the piston until the piston pin can be pushed in by hand

without excess force [approximately 60 to 70

°

C (140 to 158

°

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

pin into piston and connecting rod.

• Assemble so that the front mark 

 on the piston head and the

oil hole 

 and the cylinder number 

 on connecting rod are

positioned as shown in the figure.

c.

Install new snap ring to the groove of the piston front side. 
• Insert it fully into groove to install. 
• After installing, check that connecting rod moves smoothly.

8.

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

CAUTION:

• Be careful not to damage piston.
• Be careful not to damage piston rings by expanding them excessively.
• Position each ring with the gap as shown in the figure referring

to the piston front mark.

CAUTION:

Never contact the rail end gap under the oil ring with the
oil drain cast groove of piston.

• Install second ring with the stamped surface facing upward.

9.

Install connecting rod bearing upper 

 and lower 

 to connect-

ing rod 

 and connecting rod cap 

.

• Install the connecting rod in the dimension shown in the figure. 
• Check that connecting rod bearing oil hole 

 is completely in

the inside of connecting rod oil hole chamfered area 

.

• When installing connecting rod bearings, apply new engine oil

to the bearing surface (inside). Do not apply new engine oil to
the back surface, but thoroughly clean it. 
NOTE:
• There is no positioning tab.

: Management code

: Big end diameter grade

: Front mark (connecting rod cap)

: Oil ring upper or lower rail gap

: Front mark

: Second ring and oil ring spacer gap

: Top ring gap

: Stamped mark

JPBIA4434ZZ

PBIC3242J

: Oil hole (connecting rod)

: View D

: OK

: NG

: 2.55 - 2.95 mm (0.1004 - 0.1161 in)

: Engine front

JPBIA2155ZZ

CYLINDER BLOCK

EM-229

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

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• Install the connecting rod bearings in the center of connecting rod and connecting rod cap as shown in

the figure. For service operation, the center position can be checked, visually.

10. Install piston and connecting rod assembly to crankshaft. 

• Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center. 
• Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin. 
• Match the cylinder position with the cylinder number 

 on

connecting rod to install. 

• Install so that front mark 

 on the piston head faces the front

of engine.

• Using a piston ring compressor [SST: EM03470000] 

 or suit-

able tool, install piston with the front mark on the piston head
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.

11. Install connecting rod cap. 

• Match the stamped cylinder number marks 

 on connecting

rod with those on connecting rod cap to install.   

12. Tighten connecting rod cap bolt with the following procedure:

CAUTION:

• Check that there is no gap in the thrust surface 

 of the

joint between connecting rod 

 and connecting rod cap

 and that these parts are in the correct position. And

then, tighten the connecting rod cap bolts.

• If the connecting rod cap bolts are reused, measure the

outer diameter. Refer to 

EM-231, "Inspection"

.

a.

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

b.

Tighten connecting rod cap bolts.

c.

Completely loosen connecting rod cap bolts.

: Oil hole

: Management code

: Big end diameter grade

: Front mark (connecting rod cap)

JPBIA4434ZZ

PBIC3244J

: Front mark (piston)

: Oil hole

: Management code

: Big end diameter grade

: Front mark (connecting rod cap)

JPBIA4434ZZ

: 27.5 N·m (2.8 kg-m, 20 ft-lb)

PBIC3510J

EM-230

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

CYLINDER BLOCK

d.

Tighten connecting rod cap bolts.

e.

Then turn all connecting rod cap bolts 60 degrees clockwise (angle tightening).

CAUTION:

Check and confirm the tightening angle by using an angle
wrench [SST: KV10112100] 

 or protractor. Never judge by

visual inspection without the tool.

• After tightening connecting rod cap bolt, check that crankshaft rotates smoothly. 
• Check the connecting rod side clearance. Refer to 

EM-231, "Inspection"

.

13. Install oil pan (upper). Refer to 

EM-218, "Exploded View"

.

NOTE:
Install the rear oil seal after installing the oil pan (upper).

14. Install rear oil seal. Refer to 

EM-206, "REAR OIL SEAL : Removal and Installation"

.

15. Install drive plate. Refer to 

EM-181, "Removal and Installation"

16. Install knock sensor.

• Install knock sensor 

 with harness connector facing toward

the rear of engine. 

CAUTION:

• Never tighten mounting bolts while holding the harness

connector.   

• If any impact by dropping is applied to knock sensor,

replace it with a new one.

NOTE:
• Check that there is no foreign material on the cylinder block mating surface and the back surface of

knock sensor. 

• Check that knock sensor does not interfere with other parts.

17. Install crankshaft position sensor (POS) and crankshaft position sensor (POS) cover.

CAUTION:

• Handle crankshaft position sensor (POS) carefully and avoid impacts.
• Never disassemble.
• Never place crankshaft position sensor (POS) in a location where it is exposed to magnetism.

: 0 N·m (0 kg-m, 0 ft-lb)

: 19.6 N·m (2.0 kg-m, 14 ft-lb)

PBIC3245J

: Cylinder block left side

: Engine front

JPBIA5163ZZ

CYLINDER BLOCK

EM-231

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

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18. Install oil filter (for intake valve timing control) 

 in the direction

shown in the figure.
• Check that the oil filter (for intake valve timing control) does

not protrude from the upper surface of cylinder block 

 after

installation.

19. Assemble in the reverse order of disassembly.

Inspection

INFOID:0000000010715517

CRANKSHAFT END PLAY

• Measure the clearance between thrust bearings and crankshaft

arm when crankshaft is moved fully forward or backward with a dial
indicator (A).

• If the measured value exceeds the limit, replace thrust bearings,

and measure again. If it still exceeds the limit, replace crankshaft
also.

CONNECTING ROD SIDE CLEARANCE

• Measure the side clearance between connecting rod and crank-

shaft arm with a feeler gauge (A).

• If the measured value exceeds the limit, replace connecting rod,

and measure again. If it still exceeds the limit, replace crankshaft
also.

PISTON TO PISTON PIN OIL CLEARANCE

Piston Pin Hole Diameter 

Measure the inner diameter of piston pin hole with an inside
micrometer (A).

Piston Pin Outer Diameter 

PBIC3260J

Standard and Limit

: Refer to 

EM-253, "Cylinder 

Block"

.

JSBIA2509ZZ

Standard and Limit

: Refer to 

EM-253, "Cylinder 

Block"

.

JPBIA0689ZZ

Standard

: Refer to 

EM-253, "Cylinder Block"

.

JSBIA2510ZZ

EM-232

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

CYLINDER BLOCK

Measure the outer diameter of piston pin with a micrometer (A).

Piston to Piston Pin Oil Clearance

(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)

• If oil clearance is out of the standard, replace piston and piston pin assembly. 
• When replacing piston and piston pin assembly. Refer to 

EM-240, "Description"

.

NOTE:
• Piston is available together with piston pin as assembly.
• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no

grades can be selected. (Only grade “0” is available.) 

PISTON RING SIDE CLEARANCE

• Measure the side clearance of piston ring and piston ring groove

with a feeler gauge (A).

• If the measured value exceeds the limit, replace piston ring, and

measure again. If it still exceeds the limit, replace piston also.

PISTON RING END GAP

• Check that cylinder bore inner diameter is within specification. Refer to “PISTON TO CYLINDER BORE

CLEARANCE”.

• Lubricate with new engine oil to piston 

 and piston ring 

, and

then insert 

 piston ring until middle of cylinder 

 with piston, and

measure piston ring end gap with a feeler gauge (C).

• If the measured value exceeds the limit, replace piston ring, and

measure again. If it still exceeds the limit, rebore cylinder and use
oversized piston and piston rings.

CONNECTING ROD BEND AND TORSION

Standard : 

Refer 

to 

EM-253, "Cylinder Block"

.

JSBIA2511ZZ

Standard : 

Refer 

to 

EM-253, "Cylinder Block"

.

Standard and Limit

: Refer to 

EM-253, "Cylinder 

Block"

.

JSBIA2512ZZ

Standard and Limit

: Refer to 

EM-253, "Cylinder 

Block"

.

JSBIA2513ZZ

CYLINDER BLOCK

EM-233

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

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• Check with a connecting rod aligner.

• If it exceeds the limit, replace connecting rod assembly.

CONNECTING ROD BIG END DIAMETER

• Install connecting rod cap 

 without connecting rod bearing

installed, and tightening connecting rod cap bolts to the specified
torque. Refer to 

EM-223, "Disassembly and Assembly"

.

• Measure the inner diameter of connecting rod big end with an

inside micrometer.

• If out of the standard, replace connecting rod assembly.

CONNECTING ROD BUSHING OIL CLEARANCE

Connecting Rod Bushing Inner Diameter

Measure the inner diameter of connecting rod bushing with an inside
micrometer (A).

Piston Pin Outer Diameter

: Bend

: Torsion

C

: Feeler gauge

Limit

: Refer to 

EM-253, "Cylinder Block"

.

JSBIA2514ZZ

: Connecting rod

: Example

: Measuring direction of inner diameter

Standard : 

Refer 

to 

EM-253, "Cylinder Block"

.

PBIC3269J

Standard : 

Refer 

to 

EM-253, "Cylinder Block"

.

JPBIA0223ZZ

EM-234

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

CYLINDER BLOCK

Measure the outer diameter of piston pin with a micrometer (A).

Connecting Rod Bushing Oil Clearance

(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)

• If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin

assembly.

• If replacing piston and piston pin assembly. Refer to 

EM-240, "Piston"

.

• If replacing connecting rod assembly. Refer to 

EM-241, "Connecting Rod Bearing"

.

CYLINDER BLOCK TOP SURFACE DISTORTION

• Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or

other contamination. 

CAUTION:

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

• Measure the distortion on the cylinder block upper face at some

different points in six directions with a straight edge (A) and feeler
gauge (B).

• If it exceeds the limit, replace cylinder block.

MAIN BEARING HOUSING INNER DIAMETER

• Install main bearing cap without main bearings installed, and tighten main bearing cap mounting bolts to the

specified torque. Refer to 

EM-223, "Disassembly and Assembly"

.

• Measure the inner diameter of main bearing housing with a cylinder gauge. 
• Measure the position shown in the figure [5 mm (0.20 in)] back-

ward from main bearing housing front side in the 2 directions as
shown in the figure. The smaller one is the measured value.

• If out of the standard, replace cylinder block and main bearing

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

PISTON TO CYLINDER BORE CLEARANCE

Standard : 

Refer 

to 

EM-253, "Cylinder Block"

.

JSBIA2511ZZ

Standard and Limit 

: Refer to 

EM-253, "Cylinder Block"

.

Limit : 

Refer 

to 

EM-253, "Cylinder Block"

.

JSBIA2526ZZ

: Cylinder block

: Main bearing cap

: Engine front

Standard : 

Refer 

to 

EM-253, "Cylinder Block"

.

PBIC4005E

CYLINDER BLOCK

EM-235

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

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Cylinder Bore Inner Diameter

• Using a cylinder gauge, measure the cylinder bore for wear, out-of-

round and taper at six different points on each cylinder. [

 and 

directions at 

, 

, and 

] [

 is in longitudinal direction of engine]

NOTE:
When determining cylinder bore grade, measure the cylinder bore

 direction at 

 position.

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

replace cylinder block. 
NOTE:
Oversize piston is not provided.

Piston Skirt Diameter

Measure the outer diameter of piston skirt with a micrometer (A).

Piston to Cylinder Bore Clearance

Calculate by piston skirt diameter and cylinder bore inner diameter
[direction , 

position ].

(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diame-
ter)

: 10 mm (0.39 in)

: 60 mm (2.36 in)

: 130 mm (5.12 in)

Standard:

Cylinder bore inner diameter 

: Refer to 

EM-253, "Cylinder Block"

.

Limit:

Out-of-round [Difference between 

 and 

]

Taper [Difference between 

 and 

]

: Refer to 

EM-253, "Cylinder Block"

.

JPBIA2059ZZ

Standard : 

Refer 

to 

EM-253, "Cylinder Block"

.

JPBIA0227ZZ

: Direction A

: Position C

: Position E

: 10 mm (0.39 in)

: 60 mm (2.36 in)

: 130 mm (5.12 in)

Standard and Limit 

: Refer to 

EM-253, "Cylinder Block"

.

JPBIA2059ZZ

EM-236

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

CYLINDER BLOCK

• If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block. Refer to 

EM-240, "Pis-

ton"

.

CRANKSHAFT MAIN JOURNAL DIAMETER

• Measure the outer diameter of crankshaft main journals with a

micrometer (A).

• If out of the standard, measure the main bearing oil clearance.

Then use undersize bearing. Refer to 

EM-243, "Main Bearing"

.

CRANKSHAFT PIN JOURNAL DIAMETER 

• Measure the outer diameter of crankshaft pin journal with a micrometer.

• If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer

to 

EM-241, "Connecting Rod Bearing"

.

OUT-OF-ROUND AND TAPER OF CRANKSHAFT

• Measure the dimensions at four different points as shown in the

figure on each main journal and pin journal with a micrometer. 

• Out-of-round is indicated by the difference in dimensions between

 and 

 at 

 and 

.

• Taper is indicated by the difference in dimension between 

 and

 at 

 and 

.

• If the measured value exceeds the limit, correct or replace crankshaft.
• If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select

main bearing and/or connecting rod bearing. Refer to 

EM-241, "Connecting Rod Bearing"

 and/or 

EM-243,

"Main Bearing"

.

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 indicator (A) straight up on the No. 3 journal. 
• While rotating crankshaft, read the movement of the pointer on the

dial indicator. (Total indicator reading)

• If it exceeds the limit, replace crankshaft.

CONNECTING ROD BEARING OIL CLEARANCE

Method by Calculation

Standard : 

Refer 

to 

EM-253, "Cylinder Block"

.

JPBIA6344ZZ

Standard : 

Refer 

to 

EM-253, "Cylinder Block"

.

Limit:

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

Taper [Difference between (A) and (B)]

: Refer to 

EM-253, "Cylinder Block"

.

JPBIA0229ZZ

Standard and Limit

: Refer to 

EM-253, "Cylinder 

Block"

.

JPBIA6345ZZ

CYLINDER BLOCK

EM-237

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

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P

O

• Install connecting rod bearings 

 to connecting rod 

 and con-

necting rod bearing cap 

, and tighten connecting rod cap bolts to

the specified torque. Refer to 

EM-223, "Disassembly and Assem-

bly"

. 

• Measure the inner diameter of connecting rod bearing with an

inside micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter)
– (Crankshaft pin journal diameter)

• If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end

diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to 

EM-241,

"Connecting Rod Bearing"

.

Method of Using Plastigage

• Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely. 
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil

holes.

• Install connecting rod bearings to connecting rod and cap, and tighten connecting rod cap bolts to the speci-

fied torque. Refer to 

EM-241, "Connecting Rod Bearing"

.

CAUTION:

Never rotate crankshaft.

• Remove connecting rod cap and bearing, and using the scale (A)

on the plastigage bag, measure the plastigage width. 
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.

MAIN BEARING OIL CLEARANCE

Method by Calculation

• Install main bearings 

 to cylinder block 

 and main bearing cap

, and tighten main bearing cap mounting bolts to the specified

torque. Refer to 

EM-223, "Disassembly and Assembly"

. 

• Measure the inner diameter of main bearing with a cylinder gauge.
(Bearing oil clearance) = (Main bearing inner diameter) – (Crank-
shaft main journal diameter)

• If clearance exceeds the limit, select proper main bearing according to main bearing inner diameter and

crankshaft main journal diameter to obtain specified bearing oil clearance. Refer to 

EM-243, "Main Bearing"

.

Method of Using Plastigage

• Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely. 
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil

holes.

: Example

: Inner diameter measuring direction

Standard and Limit 

:  Refer  to 

EM-256, "Connecting Rod Bearing"

.

PBIC3275J

JPBIA6346ZZ

: Example

: Inner diameter measuring direction

Standard and Limit

: Refer to 

EM-257, "Main Bearing"

.

PBIC3277J

EM-238

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

CYLINDER BLOCK

• Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap mounting bolts to

the specified torque. Refer to 

EM-223, "Disassembly and Assembly"

. 

CAUTION:

Never rotate crankshaft.

• Remove main bearing cap and bearings, and using the scale (A)

on the plastigage bag, measure the plastigage width. 
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.

MAIN BEARING CRUSH HEIGHT 

• When main bearing cap is removed after being tightened to the

specified torque with main bearings 

 installed, the tip end of

bearing must protrude 

. Refer to 

EM-223, "Disassembly and

Assembly"

.

• If the standard is not met, replace main bearings.

CONNECTING ROD BEARING CRUSH HEIGHT

• When connecting rod cap is removed after being tightened to the

specified torque with connecting rod bearings 

 installed, the tip

end of bearing must protrude 

. Refer to 

EM-223, "Disassembly

and Assembly"

.

• If the standard is not met, replace connecting rod bearings.

MAIN BEARING CAP BOLT OUTER DIAMETER 

• Measure the outer diameters (d

1

) and (d

2

) at two positions as

shown in the figure.

• If reduction appears in places other than 

 range, regard it as (d

2

).

• If it exceeds the limit (a large difference in dimensions), replace

main bearing cap mounting bolt with a new one.

CONNECTING ROD CAP BOLT OUTER DIAMETER 

JPBIA6347ZZ

: Example

Standard

: There must be crush height.

PBIC3279J

: Example

Standard

: There must be crush height.

PBIC3279J

: (d1) measuring position

: (d2) measuring position

Limit [(d

1

) – (d

2

)]: 0.15 mm (0.0059 in) 

PBIC4015E

CYLINDER BLOCK

EM-239

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

C

D

E

F

G

H

I

J

K

L

M

A

EM

N

P

O

• Measure the outer diameter (d) at position as shown in the figure.
• If reduction appears in a position other than (d), regard it as (d).

• When (d) exceeds the limit (when it becomes thinner), replace

connecting rod cap bolt with a new one.

CLOGGED OR DAMAGED OIL FILTER (FOR VALVE TIMING CONTROL)

• Check that there is no foreign material on the oil filter and check it

for clogging.

- Clean it if necessary.
• Check the oil filter for damage.
- Replace it if necessary.

Limit: 7.75 mm (0.3051 in) 

PBIC4016E

PBIC3273J

EM-240

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

HOW TO SELECT PISTON AND BEARING

HOW TO SELECT PISTON AND BEARING

Description

INFOID:0000000010715518

• 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.

Piston

INFOID:0000000010715519

WHEN NEW CYLINDER BLOCK IS USED

• Check the cylinder bore grade on rear left side of cylinder block 

,

and select piston of the same grade.

• If there is a correction stamp mark on the cylinder block, use it as a

correct reference.

WHEN CYLINDER BLOCK IS REUSED

1.

Measure the cylinder bore inner diameter. Refer to 

EM-253, "Cylinder Block"

.

2.

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

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 diame-
ter and crankshaft pin outer di-
ameter determine connecting 
rod bearing selection.

Between cylinder block and pis-
ton

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

Piston grade (piston outer diam-
eter)

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

: Correction stamp

: Standard stamp

: Cylinder No. 1 bore grade

: Cylinder No. 2 bore grade

: Cylinder No. 3 bore grade

: Cylinder No. 4 bore grade

: No. 1 main bearing housing grade

: No. 2 main bearing housing grade

: No. 3 main bearing housing grade

: No. 4 main bearing housing grade

: No. 5 main bearing housing grade

: Engine front

PBIC3264J