Page 2681 of 5598

CYLINDER BLOCKEM-119
< UNIT DISASSEMBLY AND ASSEMBLY >
C
DE
F
G H
I
J
K L
M A
EM
NP
O
Measure the distortion on the cylinder block upper face at some
different points in six directions (C ), (D), (E), (F), (G) and (H) with a
straightedge (A) and a feeler gauge (B).
If it exceeds the limit, replace cylinder block.
MAIN BEARING HOUSING INNER DIAMETER
Install main bearing cap (2) without installing main bearings, and tighten main bearing cap bolts to the specified torque. Refer to EM-
107, "Disassembly and Assembly" for the tightening procedure.
Measure the inner diameter of main bearing housing with a bore
gauge.
If out of the standard, replace cylinder block (1) and main bearing cap as assembly.
NOTE:
Cylinder block cannot be replaced as a single part, because it is
machined together with main bearing cap.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore inner Diameter
Using a bore gauge, measure cylinder bore for wear, out-of-round
and taper at six different points on each cylinder. [(A) and (B) direc-
tions at (C), (D) and (E)] 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 re-bore the inner wall.
Oversize piston is provided. When using oversize piston, re-bore cylinder so that the clearance of the piston-
to-cylinder bore satisfies the standard.
CAUTION:
When using oversize pist on, use oversize pistons for all cyl inders with oversize piston rings.
Piston Skirt Diameter
Limit : Refer to EM-137, "CylinderBlock".
JPBIA0224ZZ
Standard : Refer to EM-137, "CylinderBlock".
JPBIA0225ZZ
f : 10 mm (0.39 in)
g : 60 mm (2.36 in)
h : 120 mm (4.72 in)
JPBIA2279ZZ
Wear limit:
Refer to EM-137, "
CylinderBlock".
Out-of-round (Difference between “A” and “B”):
Taper limit (Difference between “C” and “E”):
Oversize (O/S) : 0.2 mm (0.008 in)
Revision: 2010 May2011 QX56
Page 2682 of 5598

EM-120
< UNIT DISASSEMBLY AND ASSEMBLY >
CYLINDER BLOCK
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 (B), position (D)].
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter).
If the calculated value exceeds the limit, r eplace piston and piston pin assembly. Refer to EM-137,
"CylinderBlock".
Re-boring Cylinder Bore
1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.
2. Install main bearing cap, and tighten to the specifi ed torque. Otherwise, cylinder bores may be distorted in
final assembly.
3. Cut cylinder bores. NOTE:
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 the specified piston to cylinder bore clearance.
5. Measure finished cylinder bore for the out-of-round and taper. NOTE:
Perform measurement after cylinder bore cools down.
CRANKSHAFT MAIN JOURNAL DIAMETER
Measure the outer diameter of cranks haft main journals with a micrometer.
Measure point
: Refer to EM-137, "
CylinderBlock".
Standard
JPBIA0227ZZ
A : Longitudinal direction
C : Top position
E : Bottom position
f : 10 mm (0.39 in)
g : 60 mm (2.36 in)
h : 120 mm (4.72 in)
JPBIA2279ZZ
Standard and limit : Refer to EM-137, "CylinderBlock".
Re-bored size calculation: D = A + B – C
where, D: Bored diameter
A: Piston skirt diameter as measured
B: Piston to cylinder bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 in)
Standard : Refer to EM-137, "
CylinderBlock".
Revision: 2010 May2011 QX56
Page 2683 of 5598

CYLINDER BLOCKEM-121
< UNIT DISASSEMBLY AND ASSEMBLY >
C
DE
F
G H
I
J
K L
M A
EM
NP
O
If out of the standard, measure the main bearing
oil clearance. Then use undersize bearing. Refer to EM-
128, "MainBearing".
CRANKSHAFT PIN JOURNAL DIAMETER
Measure the outer diameter of crankshaft pin journal with a
micrometer (A).
If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer to EM-126,
"ConnectingRodBearing".
CRANKSHAFT OUT-OF-ROUND AND TAPER
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 t he difference in the dimensions
between (d) and (c) at (a) and (b).
Taper is indicated by the difference in the dimensions between.
If the measured value exceeds the li mit, correct or replace crankshaft.
If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select
the main bearing and/or connecting rod bearing. Refer to EM-128, "
MainBearing" and/or EM-126,
"ConnectingRodBearing".
CRANKSHAFT RUNOUT
Place V-block on precise flat table, and support the journals on
both ends of crankshaft.
Place a dial indicator straight up on the No. 3 journal.
While rotating crankshaft, read the movement of the pointer on a
dial indicator. (Total indicator reading)
If it exceeds the limit, replace crankshaft.
CONNECTING ROD BEARING OIL CLEARANCE
Method by Calculation
Standard : Refer to EM-137, "CylinderBlock".
JPBIA0228ZZ
JPBIA0229ZZ
Out-of-round (Difference between “c” and “d”)
: Refer to EM-137, "CylinderBlock".
Taper (Difference between “a”and “b”)
Standard and limit : Refer to EM-137, "
CylinderBlock".
SEM346D
Revision: 2010 May2011 QX56
Page 2684 of 5598

EM-122
< UNIT DISASSEMBLY AND ASSEMBLY >
CYLINDER BLOCK
Install connecting rod bearings (1) to connecting rod (2) and con-necting rod cap, and tighten connecting rod bolts to the specified
torque. Refer to EM-107, "
Disassembly and Assembly" for the
tightening procedure.
Measure the inner diameter of connecting rod bearing with an inside micrometer.
(Oil clearance) = (Connecting rod bearing inner di ameter) – (Crankshaft pin journal diameter)
If the calculated value exceeds the limit, select proper connecting rod bearing according to connecting rod
big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer to
EM-125, "
Description".
Method of Using Plastigage
Remove oil and dust on crankshaft pin 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.
Install connecting rod bearings to connecting rod and connecting rod bearing cap, and tighten connecting
rod bolts to the specified torque. Refer to EM-107, "
Disassembly and Assembly" for the tightening proce-
dure.
CAUTION:
Never rotate crankshaft.
Remove connecting rod bearing cap and bearings, and using the
scale on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured va lue exceeds the limit is the
same as that described in the “Method by Calculation”.
MAIN BEARING OIL CLEARANCE
Method by Calculation
Install main bearings (3) to cylinder block (1) and main bearing cap (2), and tighten main bearing cap bolts to the specified torque.
Refer to EM-107, "
Disassembly and Assembly" for the tightening
procedure.
Measure the inner diameter of main bearing with a bore gauge.
(Oil clearance) = (Main bearing inner diameter) – (Crankshaft main
journal diameter)
If the calculated value exceeds t he limit, select proper main bear-
ing according to main bearing inner diameter and crankshaft main
journal diameter to obtain the specified bearing oil clearance.
Refer to EM-125, "
Description".
Method of Using Plastigage
Remove engine oil and dust on crankshaft journal and the surfaces of each bearing completely.
JPBIA0230ZZ
Standard and limit : Refer to EM-142, "ConnectingRodBearing".
JPBIA0231ZZ
Standard and limit : Refer to EM-141, "MainBearing".
JPBIA0232ZZ
Revision: 2010 May2011 QX56
Page 2685 of 5598

CYLINDER BLOCKEM-123
< UNIT DISASSEMBLY AND ASSEMBLY >
C
DE
F
G H
I
J
K L
M A
EM
NP
O
Cut a plastigage slightly shorter than the bearing width,
and place it in crankshaft axial direction, avoiding oil
holes.
Install main bearing to cylinder block and main bearing cap, and tighten main bearing cap bolts with main
bearing cap to the specified torque. Refer to EM-107, "
Disassembly and Assembly" for the tightening proce-
dure.
CAUTION:
Never rotate crankshaft.
Remove main bearing cap and bearings, and using the scale on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is the
same as that described in the “Method by Calculation”.
MAIN BEARING CRUSH HEIGHT
When main bearing cap is removed after being tightened to thespecified torque with main bearings (1) installed, the tip end of
bearing must protrude. Refer to EM-107, "
Disassembly and
Assembly" for the tightening procedure.
If the standard is not met, replace main bearings.
CONNECTING ROD BEARING CRUSH HEIGHT
When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings (1) installed,
the tip end of bearing must protrude. Refer to EM-107, "
Disassem-
bly and Assembly" for the tightening procedure.
If the standard is not met, replace connecting rod bearings.
MAIN BEARING CAP BOLT OUTER DIAMETER
Measure the outer diameters (A), (B) at two positions as shown in
the figure.
If reduction appears in (A) range, regard it (B).
If it exceeds the limit (large difference in dimensions), replace main bearing cap bolts with new one.
MAIN BEARING CAP SUB BOLT OUTER DIAMETER
JPBIA0231ZZ
A : Crush height
Standard : There must be crush height.
JPBIA0233ZZ
A : Crush height
Standard : There must be crush height.
JPBIA0233ZZ
c : 20 mm (0.79 in)
d : 55 mm (2.17 in)
e : 12 mm (0.47 in)
Limit [(B) – (A)] : 0.15 mm (0.0059 in)
JPBIA2280ZZ
Revision: 2010 May2011 QX56
Page 2686 of 5598

EM-124
< UNIT DISASSEMBLY AND ASSEMBLY >
CYLINDER BLOCK
Measure the outer diameters (A), (B) at two positions as shown in
the figure.
If reduction appears in (A) range, regard it (B).
If it exceeds the limit (large difference in dimensions), replace main bearing cap sub bolts with new one.
CONNECTING ROD BOLT OUTER DIAMETER
1. Measure the outer diameters [(a), (b) and (c)] at the position shown in the figure.
2. Obtain a mean value (d) of (a) and (b).
3. Subtract (c) from (d).
4. If it exceeds the limit (large difference in dimensions), replace the bolt with new one.
DRIVE PLATE
Check drive plate and signal plate (A) for deformation or damage.
CAUTION:
Never disassemble drive plate.
Never place drive plate with signal plate facing down.
When handling signal plate, take care not to damage or scratch it.
Handle signal plate in a manner that prevents it from becom-
ing magnetized.
If damage is found, replace drive plate.
OIL JET
Check nozzle for deformation and damage.
Blow compressed air from nozzle, and check for clogs.
Using a clean plastic stick, press check valve in oil je t relief valve. Check that valve moves smoothly with
proper reaction force.
If it is not satisfied, clean or replace oil jet.
c : 20 mm (0.79 in)
d : 15 mm (0.59 in)
e : 9 mm (0.35 in)
Limit [(B) – (A)] : 0.10 mm (0.0039 in)
JPBIA2280ZZ
a : Value at the end of the smaller diameter of the bolt
b : Value at the end of the smaller diameter of the bolt [opposite side of (a)]
c : Value of the smallest diameter of the smaller of the bolt
Limit [(d) – (c)] : 0.08 mm (0.0032 in)JPBIA0262ZZ
B : Ring gear
: Engine front
JPBIA2282ZZ
Revision: 2010 May2011 QX56
Page 2687 of 5598

HOW TO SELECT PISTON AND BEARINGEM-125
< UNIT DISASSEMBLY AND ASSEMBLY >
C
DE
F
G H
I
J
K L
M A
EM
NP
O
HOW TO SELECT PISTON AND BEARING
DescriptionINFOID:0000000006289585
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 dimens ion 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.
PistonINFOID:0000000006289586
WHEN NEW CYLINDER BLOCK IS USED
Check the cylinder bore grade on the bottom face of the cylinder
block, and select the piston of the same grade.
NOTE:
Piston is available with piston pin as a set for the service part.
WHEN NEW CYLINDER BLOCK IS REUSED
1. Measure the cylinder bore inner diameter. Refer to EM-137, "CylinderBlock".
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)Determined by match of con-
necting rod big end diameter
grade (inner diameter of hous-
ing) and crankshaft pin outer di-
ameter.
Between cylinder block and pis-
ton Piston and piston pin assembly
(Piston is available together
with piston pin as assembly.) Piston grade
(piston skirt diameter)
Piston grade = cylinder bore
grade (inner diameter of bore)
KBIA2495E
Revision: 2010 May2011 QX56
Page 2688 of 5598

EM-126
< UNIT DISASSEMBLY AND ASSEMBLY >
HOW TO SELECT PISTON AND BEARING
2. Determine the bore grade by comparing the measurement withthe values under the cylinder bore inner diameter of the “PIS-
TON SELECTION TABLE”.
3. Select piston of the same grade.
PISTON SELECTION TABLE
Unit: mm (in)
NOTE:
Piston is available together with piston pin as assembly.
Connecting Rod BearingINFOID:0000000006289587
WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED
1. Apply connecting rod big end diameter grade stamped (D) on connecting rod side face to the row in the “CONNECTING ROD
BEARING SELECTION TABLE”.
A: Bank 2
B: Bank 1
C : Front mark
D : Piston grade number
E : Piston pin grade number
F : Identification code
JPBIA3744ZZ
Grade 1 2 3
Cylinder bore inner diameter 98.000 - 98.010
(3.8583 - 3.8587) 98.010 - 98.020
(3.8587 - 3.8590) 98.020 - 98.030
(3.8590 - 3.8594)
Piston skirt diameter 97.980 - 97.990
(3.8575 - 3.8579) 97.990 - 98.000
(3.8579 - 3.8583) 98.000 - 98.010
(3.8583 - 3.8587)
A : Sample codes
B : Bearing stopper groove
C : Small-end diameter grade
E : Weight grade
F : Cylinder No.
G : Management code
H: Front mark
JPBIA2273ZZ
Revision: 2010 May2011 QX56