Page 137 of 2493

AEM028
4. Measure outer diameter ªDpº of each crankshaft pin journal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance=CþDp
Standard: 0.014 - 0.039 mm (0.0006 - 0.0015 in)
Limit: 0.1 mm (0.004 in)
If it exceeds the limit, replace bearing.
If clearance cannot be adjusted using any standard bearing
grade, grind crankshaft journal and use undersized bearing.
Refer to step 5, EM-57.
SEM437CA
+If a new bearing, crankshaft or connecting rod is replaced,
select connecting rod bearing according to the following table.
Connecting rod bearing grade number:
These numbers are punched in either Arabic or Roman numerals.
Crankshaft pin journal grade number Connecting rod bearing grade color
0Ð
1 Brown
2 Green
EM142
Method B (Using Plastigage)
CAUTION:
+Do not turn crankshaft or connecting rod while Plastigage
is being inserted.
+If incorrect bearing clearance exists, use a thicker or
undersized main bearing to ensure specified clearance.
AEM029
CONNECTING ROD BUSHING CLEARANCE (SMALL
END)
NJEM0026S091. Measure inner diameter ªCº of bushing.
AEM030
2. Measure outer diameter ªDpº of piston pin.
3. Calculate connecting rod bushing clearance.
Connecting rod bushing clearance=CþDp
Standard:
0.005 - 0.017 mm (0.0002 - 0.0007 in)
Limit:
0.023 mm (0.0009 in)
If it exceeds the limit, replace connecting rod assembly or
connecting rod bushing and/or piston pin.
CYLINDER BLOCKQG
Inspection (Cont'd)
EM-59
Page 138 of 2493

SEM062A
REPLACEMENT OF CONNECTING ROD BUSHING
(SMALL END)
NJEM0026S101. Drive in small end bushing until it is flush with end surface of
rod.
Be sure to align the oil holes.
2. Ream the bushing so that clearance with piston pin is within
specification.
Clearance between connecting rod bushing and piston
pin:
0.005 - 0.017 mm (0.0002 - 0.0007 in)
SEM931F
FLYWHEEL/DRIVE PLATE RUNOUTNJEM0026S12Runout (Total indicator reading):
Flywheel (M/T models)
Less than 0.15 mm (0.0059 in)
Drive plate (A/T models)*
Less than 0.2 mm (0.008 in)
*Measuring points: Approximately 115 mm (4.53
in) from crankshaft center
CAUTION:
+Do not allow any magnetic materials to contact the ring
gear teeth and rear plate.
+Do not resurface flywheel. Replace as necessary.
SEM166B
AssemblyNJEM0027PISTONNJEM0027S011. Install new snap ring on one side of piston pin hole.
SEM932F
2. Heat piston to 60 to 70ÉC (140 to 158ÉF) and assemble piston,
piston pin, connecting rod and new snap ring.
+Align the direction of piston and connecting rod.
+Numbers stamped on connecting rod and cap correspond
to each cylinder.
+After assembly, make sure connecting rod swings
smoothly.
CYLINDER BLOCKQG
Inspection (Cont'd)
EM-60
Page 139 of 2493
SEM522G
3. Set piston rings as shown.
CAUTION:
+When piston rings are not replaced, make sure that piston
rings are mounted in their original position.
+Install new piston rings either side up if there is no punch
mark.
SEM160B
+Align piston rings so that end gaps are positioned as
shown.
SEM934F
SEM366E
SEM420C
CRANKSHAFTNJEM0027S021. Install signal plate to crankshaft.
2. Set main bearings in their proper positions on cylinder block
and main bearing cap.
+Confirm that correct main bearings are selected by using
Method A or Method B. Refer to EM-57.
+Apply new engine oil to bearing surfaces.
CYLINDER BLOCKQG
Assembly (Cont'd)
EM-61
Page 140 of 2493

SEM933F
3. Install crankshaft and main bearing caps and tighten bolts to
the specified torque.
+Apply new engine oil to the bolt thread and seat surface.
+Prior to tightening bearing cap bolts, shift crankshaft back
and forth to properly seat the bearing caps.
+Tighten bearing cap bolts gradually in two or three stages.
Start with center bearing and move outward as shown in
figure.
+After securing bearing cap bolts, make sure crankshaft
turns smoothly by hand.
SEM116F
4. Measure crankshaft end play.
Crankshaft end play:
Standard
0.060 - 0.260 mm (0.0024 - 0.0102 in)
Limit
0.3 mm (0.012 in)
If beyond the limit, replace thrust bearing with new ones.
SEM168D
5. Install connecting rod bearings in connecting rods and con-
necting rod caps.
+Confirm that correct bearings are used. Refer to EM-58.
+Install bearings so that oil hole in connecting rod aligns
with oil hole of bearing.
+Apply new engine oil to bolt threads and bearing surfaces.
SEM942F
6. Install pistons with connecting rods.
a. Install them into corresponding cylinders with Tool.
+Make sure connecting rod does not scratch cylinder wall.
+Make sure connecting rod bolts do not scratch crankshaft
pin journals.
+Arrange so that front mark on piston head faces engine.
+Apply new engine oil to piston rings and sliding surface
of piston.
SEM943F
b. Install connecting rod caps.
Apply new engine oil to bolt threads and nut seating surfaces.
Tighten connecting rod cap nuts in the following procedure:
+Tighten to 13.72 to 15.68 N´m (1.399 to 1.599 kg-m, 10.120
to 11.566 ft-lb).
+Turn nuts to 35É to 40É degrees clockwise with an angle
wrench. If an angle wrench is not available, tighten nuts to
23 to 28 N´m (2.3 to 2.9 kg-m, 17 to 21 ft-lb).
CYLINDER BLOCKQG
Assembly (Cont'd)
EM-62
Page 141 of 2493
SEM935F
7. Measure connecting rod side clearance.
Connecting rod side clearance:
Standard
0.200 - 0.470 mm (0.0079 - 0.0185 in)
Limit
0.5 mm (0.020 in)
If beyond the limit, replace connecting rod and/or crank-
shaft.
AEM248
8. Install rear oil seal retainer.
a. Before installing rear oil seal retainer, remove old liquid gasket
from cylinder block and retainer.
b. Apply a continuous bead of liquid gasket to rear oil seal
retainer.
+Use Genuine Liquid Gasket or equivalent.
+Apply around inner side of bolt holes.
9. Install crankshaft positon sensor (POS).
SEM936F
10. Install knock sensor.
CYLINDER BLOCKQG
Assembly (Cont'd)
EM-63
Page 142 of 2493

General SpecificationsNJEM0028
EngineQG15DE QG18DE
ClassificationGasoline
Cylinder arrangement4, in-line
Displacement
cm
3(cu in)1,497 (91.35) 1,769 (107.94)
Bore´stroke
mm (in)73.6´88.0 (2.898´3.465) 80.0´88.0 (3.150´3.465)
Valve arrangementDOHC
Firing order1-3-4-2
Number of piston ringsCompression 2
Oil 1
Number of main bearings5
Compression ratio9.5 (9.9*)
*: For QG15DE for Europe
EM120
abcde f
Valve timingQG18DE 222É 236É 0É (20É) 56É (36É) þ2É 44É
QG15DE 222É 222É 0É 42É þ2É 44É
( ): Valve timing control ON
Compression PressureNJEM0029Unit: kPa (bar, kg/cm2, psi)/350 rpm
Standard1,324 (13.24, 13.5, 192)
1,372 (13.720, 13.99, 198.9)*
Minimum1,128 (11.28, 11.5, 164)
1,176 (11.759, 11.99, 170.5)*
Difference limit between cylinders 98 (0.98, 1.0, 14)
*: For QG15DE
Belt DeflectionNJEM0045Unit: mm (in)
Applied engineUsed belt deflection
Deflection of new belt
LimitDeflection after adjust-
ment
AlternatorWith air conditioner
compressorQG15´18DE 8.1 (0.319)5.3 - 5.7
(0.209 - 0.224)4.5 - 5.0
(0.177 - 0.197)
Without air conditioner
compressorQG15´18DE 10.2 (0.402)6.5 - 7.0
(0.256 - 0.276)5.5 - 6.1
(0.217 - 0.240)
SERVICE DATA AND SPECIFICATIONS (SDS)QG
General Specifications
EM-64
Page 143 of 2493
Applied engineUsed belt deflection
Deflection of new belt
LimitDeflection after adjust-
ment
Power steering oil pumpQG15DE 8.5 (0.335)5.2 - 5.8
(0.205 - 0.228)4.6 - 5.2
(0.181 - 0.205)
QG18DE 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)
Spark PlugNJEM0046
NGK Champion
TypeStandard BKR5E-11 RC10YC4
Hot BKR4E-11 Ð
Cold BKR6E-11 Ð
Plug gap mm (in)1.0 - 1.1 (0.039 - 0.043)
Cylinder HeadNJEM0030Unit: mm (in)
Standard Limit
Head surface flatness Less than 0.03 (0.0012) 0.1 (0.004)
Height 117.8 - 118.0 (4.638 - 4.646) Ð
SERVICE DATA AND SPECIFICATIONS (SDS)QG
Belt Deflection (Cont'd)
EM-65
Page 144 of 2493

ValveNJEM0031VALVENJEM0031S01Unit: mm (in)
SEM188A
QG15DE QG18DE
Valve head diameter ªDºIntake28.9 - 29.2
(1.138 - 1.150)29.9 - 30.2
(1.177 - 1.189)
Exhaust23.9 - 24.2
(0.941 - 0.953)24.9 - 25.2
(0.980 - 0.992)
Valve length ªLºIntake 92.00 - 92.50 (3.6220 - 3.6417)
Exhaust 92.37 - 92.87 (3.6366 - 3.6563)
Valve stem diameter ªdºIntake 5.465 - 5.480 (0.2152 - 0.2157)
Exhaust 5.445 - 5.460 (0.2144 - 0.2150)
Valve face angle ªaº45É15¢- 45É45¢
Valve margin ªTº1 (0.04)
Valve margin ªTº limitMore than 0.5 (0.020 in)
Valve stem end surface grinding limit 0.2 (0.008)
VALVE SPRINGNJEM0031S02
Free height mm (in)40.0 (1.575)
Pressure N (kg, lb)
at height mm (in)Standard370.0 (37.73, 83.19)
at 23.64 (0.9307)
Limit347.8 (35.46, 78.19)
at 23.64 (0.9307)
Out-of-square mm (in)Less than 1.80 (0.0709)
VALVE LIFTERNJEM0031S10Unit: mm (in)
Valve lifter outside diameter 29.960 - 29.975 (1.1795 - 1.1801)
Lifter guide inside diameter 30.000 - 30.021 (1.1811 - 1.1819)
Clearance between valve lifter and valve lifter guide 0.025 - 0.065 (0.0010 - 0.0026)
SERVICE DATA AND SPECIFICATIONS (SDS)QG
Valve
EM-66