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ENGINE SECTION EX EXHAUST SYSTEM A EX C D E CONTENTS F HR12DE, HR15DE K9K PRECAUTION PRECAUTION PRECAUTIONS PRECAUTIONS Removal and Installation Removal and Installation PREPARATION PREPARATION PREPARATION PREPARATION Special Service Tools Commercial Service Tools Commercial Service Tools PERIODIC MAINTENANCE REMOVAL AND INSTALLATION H I PERIODIC MAINTENANCE 10 EXHAUST SYSTEM 10 EXHAUST SYSTEM Inspection G J Inspection 10 REMOVAL AND INSTALLATION 11 K EXHAUST SYSTEM 11 EXHAUST SYSTEM Exploded View Removal and Installation Inspection Exploded View 11 Removal and Installation 11 Inspection 12 L M N O P Revision: 2012 July EX-1 N17 PRECAUTIONS [HR12DE, HR15DE] < PRECAUTION > PRECAUTION PRECAUTIONS Removal and Installation INFOID:0000000006657876 CAUTION: • Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat resistance, corrosion resistance, and shape • Perform the operation with the exhaust system fully cooled down because the system will be hot just after engine stops • Be careful not to cut your hand on the heat insulator edge Revision: 2012 July EX-2 N17 PREPARATION [HR12DE, HR15DE] < PREPARATION > PREPARATION A PREPARATION Special Service Tools INFOID:0000000006657877 Tool number Tool name KV10114400 Heated oxygen sensor wrench EX Description C Loosening or tightening heated oxygen sensor a: For 22 mm (0.87 in) width hexagon nut D E S-NT636 Commercial Service Tools INFOID:0000000006657878 Tool name Description Power tool Loosening nuts and bolts F G H I PBIC0190E Heated oxygen sensor thread cleaner JPBIA0238ZZ Reconditioning the exhaust system threads before installing a new heated oxygen sensor (Use with anti-seize lubricant shown below.) A: For zirconia heated oxygen sensor [18 mm (0.71 in) dia.] B: For titania heated oxygen sensor [12 mm (0.47 in) dia.] C: Mating surface shave cylinder D: Flutes Lubricating heated oxygen sensor thread cleaner when reconditioning exhaust system threads Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907) J K L M N AEM489 O P Revision: 2012 July EX-3 N17 EXHAUST SYSTEM [HR12DE, HR15DE] < PERIODIC MAINTENANCE > PERIODIC MAINTENANCE EXHAUST SYSTEM Inspection INFOID:0000000006657879 Check exhaust pipes, muffler, and mounting for improper attachment, leakage, cracks, damage or deterioration • If anything is found, repair or replace damaged parts SMA211A Revision: 2012 July EX-4 N17 EXHAUST SYSTEM [HR12DE, HR15DE] < REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION A EXHAUST SYSTEM Exploded View INFOID:0000000006657880 EX HR12DE C D E F G H I J JPBIA5709GB Seal bearing Spring Heated oxygen sensor Exhaust front tube Seal bearing Mounting rubber Center muffler Ring gasket Main muffler K : Always replace after every disassembly L : N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) M N O P Revision: 2012 July EX-5 N17 EXHAUST SYSTEM [HR12DE, HR15DE] < REMOVAL AND INSTALLATION > HR15DE JSBIA2100GB Heated oxygen sensor 2 Catalyst cover (upper) Seal bearing Catalyst cover (lower) Spring Spring Mounting rubber Main muffler Ring gasket 10 Center muffler 11 Mounting rubber 12 Seal bearing 13 Exhaust front tube : Always replace after every disassembly : N·m (kg-m, in-lb) : N·m (kg-m, ft-lb) Removal and Installation INFOID:0000000006657881 REMOVAL • Disconnect each joint and mounting • Remove heated oxygen sensor with following procedure: - Using heated oxygen sensor wrench [SST: KV10114400] (A), removal heated oxygen sensor (1) CAUTION: • Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one • Before installing new heated oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner (commercial service tool) and approved Anti-seize lubricant (commercial servicetool) JPBIA3468ZZ INSTALLATION Note the following, and install in the reverse order of removal CAUTION: • Always replace seal bearings and gasket with new ones when reassembling Revision: 2012 July EX-6 N17 EXHAUST SYSTEM [HR12DE, HR15DE] < REMOVAL AND INSTALLATION > • Discard any heated oxygen sensor which has been dropped onto a hard surface such as a concrete floor Use a new one A • Before installing a new heated oxygen sensor 2, clean exhaust system threads using the heated oxygen sensor thread cleaner (commercial service tool) and apply anti-seize lubricant (commercial service tool) EX • Never over torque heated oxygen sensor Doing so may cause damage to the heated oxygen sensor 2, resulting in the “MIL” coming on • Prevent rust preventives from adhering to the sensor body • If heat insulator is badly deformed, repair or replace it If deposits such as mud pile up on the heat C insulator, remove them • When installing heat insulator avoid large gaps or interference between heat insulator and each exhaust pipe D • Remove deposits from the sealing surface of each connection Connect them securely to avoid gas leakage • Temporarily tighten mounting nuts and bolts Check each part for unusual interference and mountE ing rubber interference, and then tighten them to the specified torque • When installing each mounting rubber, avoid twisting or unusual extension in up/down, front/rear and right/left directions F Exhaust Manifold to Exhaust Front Tube Securely insert seal bearing (2) into exhaust manifold (1) side in the direction shown in the figure G 3 : Spring : Bolt : Exhaust front tube H CAUTION: Never damage seal bearing surface when installing With spring, tighten bolt CAUTION: • Ensure springs are seated correctly on the flange and not sitting on (A) • Be careful that bolt does not interfere with mounting hole of exhaust front tube After installing, check that bolt does not interfere with mounting hole of exhaust front tube I JPBIA3652ZZ J K Exhaust Front Tube to Center Muffler Securely insert seal bearing (2) into exhaust front tube (1) side in the direction shown in the figure L 3 : Spring : Bolt : Center muffler M CAUTION: Never damage seal bearing surface when installing With spring, tighten bolt CAUTION: • Ensure springs are seated correctly on the flange and not sitting on (A) • Be careful that bolt does not interfere with mounting hole of center muffler After installing, check that bolt does not interfere with mounting hole of center muffler Inspection N JPBIA3652ZZ O INFOID:0000000006657882 INSPECTION AFTER INSTALLATION • Check clearance between tail tube and rear bumper is even • With engine running, check exhaust tube joints for gas leakage and unusual noises • Check to ensure that mounting brackets and mounting rubbers are installed properly and free from undue stress Improper installation could result in excessive noise and vibration Revision: 2012 July EX-7 N17 P PRECAUTIONS [K9K] < PRECAUTION > PRECAUTION PRECAUTIONS Removal and Installation INFOID:0000000007838729 CAUTION: • Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat resistance, corrosion resistance, and shape • Perform the operation with the exhaust system fully cooled down because the system will be hot just after engine stops • Be careful not to cut your hand on the heat insulator edge Revision: 2012 July EX-8 N17 PREPARATION [K9K] < PREPARATION > PREPARATION A PREPARATION Commercial Service Tools INFOID:0000000007838730 Tool name Description Power tool Loosening nuts and bolts EX C D E PBIC0190E F G H I J K L M N O P Revision: 2012 July EX-9 N17 EXHAUST SYSTEM [K9K] < PERIODIC MAINTENANCE > PERIODIC MAINTENANCE EXHAUST SYSTEM Inspection INFOID:0000000007838731 Check exhaust pipes, muffler, and mounting for improper attachment, leakage, cracks, damage or deterioration • If anything is found, repair or replace damaged parts SMA211A Revision: 2012 July EX-10 N17 CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > Degrease the gasket faces (of the cylinder block and bearing No 1) They should be clean, dry and free from grease (in particular, remove finger marks) Lay two beads of liquid sealant with a width of mm (0.04 in) on bearing No of the cylinder block Tighten the bolts of bearing cap No 1, and tighten the bolts as follows: a Tighten the bolts [K9K] A EM C : 25 N·m (2.6 kg-m, 18 ft-lb) MBIB0478E b D Turn the bolt 47 degrees ± degrees clockwise (angle tightening) CONNECTING RODS / PISTON ASSEMBLY • The pistons have a mark engraved on their heads indicating the engine rear side Oil the piston pin Check that the piston pins rotate correctly in the new piston and in the matching connecting rod E F Direction Of Installation Of The Connecting Rod In Relation To The Piston • Point the mark (A) engraved on the top of the piston upwards and the flat (B) of the big end downwards as shown in the figure G H I MBIB0342E J DIRECTION FOR INSTALLATION THE SNAP RINGS ON THE PISTON • Position the opening (C) of the snap rings opposite the removal and fitting channel (D) K L M MBIB0343E INSTALLATION OF THE SNAP RINGS N Rings set to their original adjustment must be free within their channels Ensure the snap rings are fitted the correct way, with the word TOP pointing upwards O Orientation Of The Piston Rings In The Piston P Revision: 2012 July EM-469 N17 CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > Ensure the break in each piston ring is correctly oriented as shown in the figure [K9K] MBIB0339E Apply new engine oil to the pistons Install the connecting rod/piston assemblies into the cylinder block using the ring, being careful to fit them the right way round (mark towards the flywheel) Install the connecting rods onto the oiled crankshaft pins of the crankshaft Install the connecting rod caps, ensuring they are correctly matched Tighten the big end cap bolts to a torque of 25 N·m (2.6 kg-m, 18 ft-lb), plus an angle tightening of 110°±6° MBIB0479E : 20 N·m (2.0 kg-m, 15ft-lb) Inspect that the big ends have the correct lateral clearance of 0.205 to 0.467 mm (0.0081 to 0.0184 in) CONNECTING ROD BEARING • The engine is installed with connecting rod bearing without a locator notch NOTE: The upper and lower connecting rod bearing are not the same width Connecting rod bearing width: Upper bearing : 20.625 mm (0.8120 in) Lower bearing : 17.625 mm (0.6939 in) MBIB0350E • The connecting rod bearing are installed using Tool KV113B0140 (Mot 1492) and Tool KV113B0150 (Mot 1492-03) MBIB0351E Revision: 2012 July EM-470 N17 CYLINDER BLOCK [K9K] < UNIT DISASSEMBLY AND ASSEMBLY > A EM C MBIB0352E D CHECKING PISTON PROTRUSION Clean the piston head Turn the crankshaft one turn in its operating direction to bring piston No close to TDC Install Tool KV113B0050 (Mot 252-01) (Commercial service tool) or equivalent tool on the piston Install Tool KV113B0040 (Mot 251-01) (Commercial service tool) or equivalent tool equipped with a gauge on support plate KV113B0050 (Mot 252-01) (Commercial service tool) or equivalent tool, and find TDC NOTE: All measurements must be carried out along the longitudinal axis of the engine, in order to eliminate any errors due to tilting of the piston WARNING: The gauge follower must not be in the valve clearance Inspect the piston protrusion which must be 0.099 to 0.285 mm (0.0039 to 0.0112 in) E F G MBIB0480E H I J K L MBIB0325E Height of the cylinder head: H = 127 mm (5.00 in) M Gasket face bow: Cylinder head Cylinder block N : 0.05 mm (0.0020 in) : 0.03 mm (0.0012 in) NO REGRINDING IS AUTHORIZED Test the cylinder head to detect possible cracks using the cylinder head test container (comprising a tray and a kit suited to the cylinder head, plug, sealing plate and blanking plate) O MBIB0326E P INSTALLATION OF REAR OIL SEAL RETAINER AND OIL PUMP Revision: 2012 July EM-471 N17 CYLINDER BLOCK [K9K] < UNIT DISASSEMBLY AND ASSEMBLY > Tighten the knock sensor : 22.3 N·m (2.3 kg-m, 16ft-lb) Tighten the oil pressure sensor : 27.9 N·m (2.8 kg-m, 21ft-lb) Install the oil pump sprocket and chain : 25 N·m (2.6 kg-m, 18ft-lb) MBIB0442E NOTE: The gasket faces (cylinder block, rear oil seal retainer and water pump) must be clean, dry and free from grease (in particular, remove finger marks) The rear oil seal retainer should be applied with liquid gasket The bead (A) must be 1.5 to mm (0.059 to 0.079 in) wide and be applied in accordance with the figure • Use Genuine Liquid Gasket or equivalent MBIB0481E Install the rear oil seal retainer Tighten bolts (No.1 to 6) as shown in the figure : 12 N·m (1.2 kg-m, 9ft-lb) Put a new gasket to water pump face and install the water pump Put a drop of locking sealant on the bolts (No.7 to 11) in the numerical order as shown in the figure : 11.2 N·m (1.1 kg-m, 8ft-lb) MBIB0482E • Use Genuine thread locking sealant or equivalent NOTE: The gasket faces (cylinder block and rear oil seal retainer) must be clean, dry and free from grease (in particular, remove finger marks) Apply four beads (B) of liquid gasket, with a diameter of mm (0.20 in) Apply two drops (C) of liquid gasket, with a diameter of mm (0.28 in) at the intersection of the rear oil seal retainer and the cylinder block • Use Genuine Liquid Gasket or equivalent MBIB0483E Revision: 2012 July EM-472 N17 CYLINDER BLOCK [K9K] < UNIT DISASSEMBLY AND ASSEMBLY > A EM C MBIB0484E D When installing the oil pan, ensure that the tabs (D) of the baffle plate are correctly positioned in the slots (E) When installing the oil pan, ensure that the cylinder block and the oil pan are correctly aligned on the flywheel side, to prevent the clutch housing from being damaged when installing the transaxle 10 Install the baffle plate E F G MBIB0485E 11 Install the oil pan, and tighten the bolts in the numerical order as shown in the figure H : 15.6 N·m (1.6 kg-m, 12 ft-lb) I J JSBIA0976ZZ K INSTALLATION OF THE CRANKSHAFT SEAL GASKETS Crankshaft elastomer seal, timing side Screw the threaded rod (A) of Tool KV113B0220 (Mot 1586) into the crankshaft L M N MBIB0487E O Position the spacer (B) of Tool KV113B0220 (Mot 1586) on the crankshaft P MBIB0488E Revision: 2012 July EM-473 N17 CYLINDER BLOCK [K9K] < UNIT DISASSEMBLY AND ASSEMBLY > Install the protector complete with the seal onto the spacer, taking care not to touch the seal MBIB0489E Install the cover (A) and the nut (B) (putting the threaded part (C) of the nut on the side away from the engine) of Tool KV113B0220 (Mot 1586) MBIB0490E Tighten the nut until the cover touches the spacer MBIB0491E MBIB0492E Remove the nut, the cover, the protector and the threaded rod MBIB0493E Revision: 2012 July EM-474 N17 CYLINDER BLOCK [K9K] < UNIT DISASSEMBLY AND ASSEMBLY > Crankshaft elastomer seal, flywheel side Install Tool KV113B0210 (Mot 1585) on the crankshaft, securing it with bolts (F) A EM C MBIB0494E D 10 Put the protector complete with the seal on Tool KV113B0210 (Mot 1585), being careful not to touch the seal E F G MBIB0495E 11 Install the cover (G) and nut (H) (putting the threaded part (I) of the nut on the side away from the engine) of Tool KV113B0210 (Mot 1585) H I J MBIB0496E K 12 Tighten the nut until the cover touches the cylinder block L M N MBIB0497E O P MBIB0498E Revision: 2012 July EM-475 N17 CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > 13 Remove the nut, the cover, the protector and the threaded rod [K9K] MBIB0499E 14 Install Tool KV113B0060 (Mot 582-01) and tighten the new bolts : 50 - 60 N·m (5.1 - 6.1 kg-m, 37 - 44 ft-lb) MBIB0500E 15 Install the clutch housing, tightening the bolts to the torque M6 bolt : 13 - 16 N·m (1.3 - 1.6 kg-m, 10 - 12 ft-lb) : 18 - 22 N·m (1.8 - 2.2 kg-m, 13 - 16 ft-lb) M7 bolt 16 Remove Tool KV113B0060 (Mot 582-01) MBIB0501E METHOD FOR INSTALLING THE OIL COOLER AND OIL FILTER Install oil cooler Refer to LU-41, "Removal and Installation" Install oil filter Refer to LU-38, "Removal and Installation" Inspection INFOID:0000000007838666 PISTON MARKING Direction of fitting of the piston mark towards the flywheel Height between the piston pin and the top of the piston (see table below) Used by the supplier only Used by the supplier only Used by the supplier only Piston axis of symmetry Piston pin hole axis Offset between the hole axis (7) and the piston's axis of symmetry (6) is 0.3 mm (0.012 in) MBIB0337E TABLE OF PISTON PIN HEIGHT Revision: 2012 July EM-476 N17 CYLINDER BLOCK [K9K] < UNIT DISASSEMBLY AND ASSEMBLY > Unit: mm (in) * Mark on piston Piston pin height J 41.605 - 41.646 (1.6380 - 1.6396) K 41.647 - 41.688 (1.6396 - 1.6413) L 41.689 - 41.730 (1.6413 - 1.6429) M 41.731 - 41.772 (1.6429 - 1.6446) N 41.773 - 41.814 (1.6446 - 1.6462) A EM C The tolerance on the piston pin heights is ±0.02 mm (±0.0008) * The different piston pin heights are exclusively reserved for the engine assembly plant The service parts will only supply piston classes (height) K, L, M NOTE: • If the engine is installed with a J class piston, an K class piston must be installed as a replacement • If the engine is installed with a N class piston, an M class piston must be installed as a replacement D E MEASURING THE PISTON DIAMETER The piston diameter must be measured at height A = 56 mm (2.20 in) Piston diameter F : 75.933 - 75.947 mm (2.9895 2.9900 in) Piston pin: Length Outer diameter Inner diameter : 59.7 - 60.3 mm (2.350 - 2.374 in) : 24.8 - 25.2 mm (0.976 - 0.992 in) : 13.55 - 13.95 mm (0.5335 0.5492 in) G H MBIB0338E I PISTON RING Thickness: Top ring 2nd ring Oil ring J : 1.97 - 1.99 mm (0.0776 - 0.0783 in) : 1.97 - 1.99 mm (0.0776 - 0.0783 in) : 2.47 - 2.49 mm (0.0972 - 0.0980 in) K The piston rings are supplied ready adjusted L MBIB0339E M PISTON RING END GAP Top ring 2nd ring Oil ring : 0.20 - 0.35 mm (0.0079 - 0.0138 in) : 0.70 - 0.90 mm (0.0276 - 0.0354 in) : 0.25 - 0.50 mm (0.0098 - 0.0197 in) N O CONNECTING ROD P Revision: 2012 July EM-477 N17 CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > The connecting rod is of the detachable cap type WARNING: • The bolts must be coated with engine oil under the heads and on the threads when the connecting rods are installed in the engine • The big end caps are positioned on the connecting rod by irregularities on the parting line • The occurrence of impacts or a foreign body between the body - cap mating surfaces will lead to rapid rupture of the connecting rod [K9K] MBIB0340E Lateral big end play Diametrical big end play Center distance between the big end and small end Diameter of the big end Diameter of the small end (without ring) (with ring) : 0.205 - 0.467 mm (0.0081 0.0184 in) : 0.035 - 0.045 mm (0.0014 0.0018 in) : 133.75 mm (5.2657 in) : 47.610 - 47.628 mm (1.8744 1.8751 in) : 27.24 - 27.26 mm (1.0724 1.0732 in) : 25.013 - 25.025 mm (0.9848 0.9852 in) NOTE: The connecting rod small end rings cannot be replaced The maximum weight difference for the connecting rod, piston and piston pin assemblies for the same engine must be 0.245 N (25 g, 0.88 oz) WARNING: • To avoid initiating a crack in the connecting rod, Never use a sharp point to mark the big end caps in relation to their connecting rod • Use a permanent marker pen MBIB0341E DIRECTION OF INSTALLATION OF THE CONNECTING ROD IN RELATION TO THE PISTON • Point the mark (A) engraved on the top of the piston upwards and the machined flat (B) of the big end downwards as shown in the figure MBIB0342E DIRECTION FOR INSTALLATION THE SNAP RINGS ON THE PISTON Revision: 2012 July EM-478 N17 CYLINDER BLOCK < UNIT DISASSEMBLY AND ASSEMBLY > • Position the opening (C) of the snap rings opposite of the removal and installation channel (D) [K9K] A EM C MBIB0343E D CRANKSHAFT Number of main journals Crankshaft side clearance: Without wear on side shims With wear on side shims Crankshaft diametrical clearance: Journals Crankshaft pins Journal diameter: Crankshaft pin diameter: :5 E : 0.045 - 0.252 mm (0.0018 - 0.0099 in) : 0.045 - 0.852 mm (0.0018 - 0.0335 in) F : 0.027 - 0.054 mm (0.0011 - 0.0021 in) : 0.035 - 0.045 mm (0.0014 - 0.0018 in) : 47.99 - 48.01 mm (1.8894 - 1.8902 in) : 43.96 - 43.98 mm (1.7307 - 1.7315 in) G H • The lateral shims are located on bearing No • No rectifications are allowed I WORKING OUT THE CLASS OF MAIN BEARING (ORIGINAL FITMENT) Marking (A) On The Crankshaft • Identify the category of crankshaft main journal diameter (A) withchecking the marking of crankshaft as shown in the figures NOTE: The marking has digits Left end is the diameter category of No bearing (flywheel side) and right end is the diameter category of No bearing (sprocket side) J K L E1BIA0410ZZ M N O P E1BIA0409ZZ Revision: 2012 July EM-479 N17 CYLINDER BLOCK [K9K] < UNIT DISASSEMBLY AND ASSEMBLY > - Detail of the marking (A): : Line indicating the diameter category of the journal : Diameter category of journal No 1, flywheel end : Diameter category of journal No 5, timing end : Line indicating the diameter category of the crank pin : Diameter category of crank pin No 1, flywheel end : Diameter category of crank pin No 4, timing end E1BIA0408ZZ Table Of Journal Diameter Classes Unit: mm (in) Journal class mark on the crankshaft Journal diameter A, G, K, R, W D1 = 47.990 - 47.996 (1.8894 - 1.8896) B, H, L, S,Y D2 = 47.997 - 48.003 (1.8896 - 1.8899) C, J, O, T, Z D3 = 48.004 - 48.010 (1.8899 - 1.8902) CYLINDER BLOCK ENGINE IDENTIFICATION The diameters of the bearings (A) of the cylinder block are marked by a hole on the block (B) located above the oil filter MBIB0345E MBIB0346E ENGINE IDENTIFICATION Revision: 2012 July EM-480 N17 CYLINDER BLOCK [K9K] < UNIT DISASSEMBLY AND ASSEMBLY > Identification is by means of an engraved plate on the cylinder block which carries: • A: engine type • B: engine type approval letter • D: code • E: engine suffix • F: engine serial number • G: engine assembly plant A EM C D E F G MBIB0322E TABLE OF CYLINDER BLOCK MAIN BEARING HOUSING INNER DIAMETERS H Hole position (B) Class reference Cylinder block main bearing housing inner diameter X = 33 mm (1.30 in) or blue 51.936 - 51.942 mm (2.0447 - 2.0450 in) Y = 43 mm (1.69 in) or red 51.942 - 51.949 mm (2.0450 - 2.0452 in) I J NOTE: The marking zone includes: • X - Y gives the diameter class of bearings A or B K MATCHING THE MAIN BEARING Journal diameter class L D1 D2 D3 1* C1 1.949 - 1.955 mm (0.0767 - 0.0770 in) yellow C2 1.946 - 1.952 mm (0.0766 - 0.0769 in) blue C3 1.943 - 1.949 mm (0.0765 - 0.0767 in) black 2* C4 1.953 - 1.959 mm (0.0769 - 0.0771 in) red C1 1.949 - 1.955 mm (0.0767 - 0.0770 in) yellow C2 1.946 - 1.952 mm (0.0766 - 0.0769 in) blue M N O Bearing thickness and class * Cylinder block main bearing diameter class NOTE: The service parts will only supply class C2 (blue) Revision: 2012 July P EM-481 N17 SERVICE DATA AND SPECIFICATIONS (SDS) [K9K] < SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) General Specification Engine K9K Compression ratio Bore and stroke mm (in) 17.9/1 76 x 80.5 (2.992 x 3.169) INFOID:0000000007838667 Compression pressure kPa Displacement cm3 (cu in) (bar, kg/cm2, psi) Maximum pressure must be least 1,800 (18, 18.36, 261) 1,461 (89.15) Tightening torque INFOID:0000000007838668 UPPER ENGINE Unit: N·m (kg-m, ft-lb) Tightening torque Cylinder head : *1 Camshaft bracket : 11 (1.2, 9) Vacuum pump : 27.9 (2.8, 21) Cylinder head coolant outlet unit : 11.9 (1.2, 9) Exhaust manifold : 28.9 (2.9, 21) Glow plug : 17.3 (1.8, 13) Rocker cover : 12.3 (1.3, 9) Turbocharger-manifold mounting : 33.6 (3.4, 25) Turbocharger oil return pipe : 13.3 (1.4, 10) Turbocharger oil supply pipe : 15.5 (1.6, 11) Timing tensioner : 30.0 (3.1, 22) TDC cap : 20 (2.0, 15) Cylinder head suspended mounting bracket : 13.7 (1.4, 10) *1: Refer to tightening procedure in the text BOTTOM ENGINE Unit: N·m (kg-m,ft-lb) Tightening torque Revision: 2012 July Oil cooler connector bolt : 43.5 (4.4, 32) Oil filter bracket : 31.2 (3.2, 23) Main bearing cap : 25 (2.6, 18) + 47°±6° (Angle tightening) Connecting rod : 25 (2.6, 18) + 110°±6° (Angle tightening) Knock sensor : 22.3 (2.3, 16) Oil level sensor : 27.9 (2.8, 21) Oil pump : 27.9 (2.8, 21) Oil pan : *1 Water pump : 11.2 (1.1, 8) Flywheel : 61.1 (6.2, 45) Crankshaft pulley : 120 (12, 89) + 95°±15° (Angle tightening) Water pump inlet pipe : 22 (2.2, 16) Alternator bracket : 44 (4.5, 32) Alternator : 25 (2.6, 18) A/C compressor : 25 (2.6, 18) EM-482 N17 SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [K9K] *1: Refer to tightening procedure in the text A EM C D E F G H I J K L M N O P Revision: 2012 July EM-483 N17