4575hm NISSSAN BUS

MEASURE MEASURE
SL. NO CHECK POINT D VALUE D VALUE STANDARD VALUE/
(PRE- ( POST for assembly
REPAIR) REPAIR) NOMINAL
VALUE
1 Oil Galleries Are Clean
Engine Block
1 st 70.95 70.907-70.920
2 nd 70.94 70.907-70.920
3rd 70.95 70.907-70.920
2 out side diameter of
main jornal 4th 70.95 70.907-70.920
5th 70.94 70.907-70.920
6th 70.94 70.907-70.920
7th 70.93 70.907-70.920
1 st 70.99 70.99
2 nd 70.99 109.50mm/ +0.040-0.010
Inside diameter of 3rd 71 109.50mm/ +0.040-0.010
3 main beaing 4th 109.50mm/ +0.040-0.010
Repair Limit = X + 71
0.15 5th 71 109.50mm/ +0.040-0.010
6th 70.98 109.50mm/ +0.040-0.010
7th 71 109.50mm/ +0.040-0.010
journal dimention
STD - 110mm/ 1 st
-0.050-0.070 2 nd
0.25 US- 109.75mm/
-0.050-0.070 3rd
4 0.50 US- 109.50mm/ 4th
-0.050-0.070
0.75 US- 109.25mm/ 5th
-0.050-0.070 6th
1.00 US- 109.00mm/
-0.050-0.070 7th
Repair Limit=(STD
5 Main Bearing Cap Bolt Stem Length ( 1 92
6 Main Bearing Cap Bolt Torque 30 kg.m
7 Crank Shaft End Play 0.15-0.325
1st 56.96
2nd 56.95
Connecting rod 3rd 56.95
8 journal daimention
4th 56.96
5th 56.95
6th 56.96
1 st 85mm/ +0.022-0.004
2 nd 85mm/ +0.022-0.004

9 Inside diameter of 3rd 85mm/ +0.022-0.004

Connecting rod bore 4th 85mm/ +0.022-0.004
5th 85mm/ +0.022-0.004
6th 85mm/ +0.022-0.004
1 st 79.50mm/ +0.020-0.010
Inside diameter of 2 nd 79.50mm/ +0.020-0.010
Connecting rod 3rd 79.50mm/ +0.020-0.010
10 beaing
Repair Limit = X + 4th 79.50mm/ +0.020-0.010
0.12 5th 79.50mm/ +0.020-0.010
 Inside diameter of
Connecting rod
10 beaing
Repair Limit = X +
0.12
6th 79.50mm/ +0.020-0.010
11 Clearance Between CR bush and piston 0.050-0.080mm
12 Connecting Rod Cap Bolt Length Max. 84.1mm
13 Connecting Rod Cap Bolt Torque 28 kg.m
1 st 0.1 0.10-0.22
2 nd 0.14 0.10-0.22

14 Connecting Rod End 3rd 0.14 0.10-0.22

Play / side clearance 4th 0.11 0.10-0.22
5th 0.13 0.10-0.22
6th 0.13 0.10-0.22
15 inside diameter of cyl.liner for wear 96
1 st 0.9
2 nd 0.9
Protrusion of 3rd 0.1
16
Cylinder Liner 4th 0.09
5th 0.09
6th 0.09
17 I.D of Cylinder Liner
18 O.D of Cylinder Liner (Counter bore)- Top Collar (A) N/A
19 I.D of Cylinder Liner Counter bore- Top Collar (B) -
20 Interference between Cyl Liner & Block (Counter Bore): (B-A) 0 ~ 0.113
20 Piston Cooling Nozzle Check
21 Nozzle Holder Mounting Bolt Torque 4 KGM 30 Nm{3.5 Kgm}
22 piston diameter 95.94
23 Piston pin daimeter 29.97
24 inside dimeter of piston pin hole 30.02
26 Clearnace between piston pin and pist 0.05 0.05 0.05
25 Piston Top Ring Clearance (Gap) 0.30~0.45mm
26 Piston Middle Ring Clearance (Gap) 0.35~0.50mm
27 Piston Oil Ring Clearance (Gap) 0.30~0.50 *0.4~0.7mm
28 Clearance Between Piston Ring And Rin 0.030~0.070mm
29 Piston Top Ring Thickness 2.42mm/ -0.005-0.025
30 Piston Middle Ring Thickness 2.4mm/ -0.010-0.030
31 Piston Oil Ring Thickness 4mm/ -0.010-0.030
Width Of Piston Oil Ring Groove ( top r 3.5
Width Of Piston Oil Ring Groove (middl 3.060~3.080
32 Width Of Piston Oil Ring Groove (oil ri 4.040~4.060
33 Piston Ring Arrangement As per manual
34 ID of small end bush @ CR 48mm/ +0.041+0.025
1 st 0.984-1.335mm
2 nd 0.984-1.335mm
3rd 0.984-1.335mm
35 Protrusion Of Piston
4th 0.984-1.335mm
5th 0.984-1.335mm
6th 0.984-1.335mm
36 Oil Pump Mounting Bolt Torque 68.6±4.9Nm, {7.0±0.5Kgm}
37 Oil Pump Strainer (Check The Conditio
38 Cam Bolt Torque 66.2 ± 7.4 Nm (7 Kgm)
39 Cam End Play 0.13~0.27mm
1 st
outside daimeter of 2 nd
40 cam journal 59.860~59.880
3rd
4th
41 cleanrance of cam journal and bush 0.050~0.128mm
43 Cam lobe height 52mm/ +0.395+0.195
44 Fuel Pump Gear Nut Torque 127-147 Nm (13~15 Kgm)
42 Lifter (Cam follower) Mounting Bolt T 51.5 ± 7.4 Nm {5.25kgm}
43 Lifter (Cam follower) Cover Mounting 11.3 ± 1.5 Nm (1.15 Kgm)
44 Valve stem OD Intake 9mm/ -0.045-0.065
45 Valve stem OD exhuast 9mm/ -0.050-0.070
46 Valve Spring Length (Inner) 65mm
47 Valve Spring Length (outer) 75.5mm
48 Backlash Of Crank Gear And main Idler 0.116~0.359mm
49 Backlash Of Main Idler Gear (Small sid 0.105~0.325mm
53 Backlash Of Cam Gear And Fuel Pump 0.105~0.325mm
54 Backlash Of main idler gear large And 0.076~0.366mm
55 Backlash Of main Idler Gear large side
And SmallOfoilSmall
pump 0.105~0.337mm
56 Backlash oilIdler
pump Gear
Idler Gear
And Oil Pump drive Gear 0.082~0.389mm
57 ID of main idler gear bush 47.5mm/ +0.115+0.100
58 OD of main idler gear shaft 47.5mm/ +0.165+0.140
59 clearance between main idler gear
bush and shaft 0.025~0.060mm
60 ID of oil pump idler gear bush 35mm/ +0.0650
61 OD of oil pump idler gear shaft 35mm/ -0.025-0.040
62 clearance between oil pump idler gear
bush and shaft 0.025~0.105mm
63 Oil Pump Idler (Small) Gear Bolt Torqu 147.0-176.4 Nm
64 Main Idler Gear (Large) Bolt Torque 245-294 Nm (25~30Kgm)
50 Timing Gear Mark "A" - Main idler to C/Shaft Gear "A"
51 Timing Gear Mark "B" - Main idler(S) to Cam shaft gear "B"
52 Timing Gear Mark "C" - Cam shaft gear to Fuel Pump Gear "C"
68 End Play main idler Gears (BIG) 0.05~0.17mm
69 End Play oil pump idler Gears (Small) 0.05~0.21mm
53 1- 187Nm, {19 Kgm}
Fly Wheel Housing Bolt Torque
2- 275Nm, {28 Kgm}
54 housing bolt tighting sequence as per manual
72 Face Run Out Of Fly Wheel housing 0.20mm
73 Radial Run Out Of Fly Wheel housing 0.20mm
55 1- 147Nm, {15 Kgm}
Fly Wheel Mounting Bolt Torque
2- 289Nm, {29.5 Kgm}
56 flywheel bolt tighting squance as per manual
76 Face Run Out Of Fly Wheel 0.20mm below
77 Radial Run Out Of Fly Wheel 0.15mm below
78 Prortrusion of Injector nozzle 3.25~3.95mm
79 Cylinder Head Mounting Bolt Length 171.4mm
57 Cylinder Head Mounting Bolt Torque b 28 kg.m
58 Cylinder Head Mounting Bolt Torque S 68Nm, {6.75±0.75 Kgm}
59 Head bolt tighting squance as per manual
 60 Hosing, Rocker Arm Bolt Torque 68Nm, {6~7.5 Kgm}
61 Rocker Arm Bolt Torque 66.2 ± 7.4Nm, {6.75±0.75 Kgm}
62 OD of Rocker Shaft 28.6mm/ -0.053-0.066
63 ID of Rocker arm bush 28.6mm/ +0.033-0.027
64 Clearance between rocker shaft & rocker arm bush 0.026 ~ 0.099 mm
65 Toruque of Rocker arm adjustment nut 65 Nm (6.6 Kgm)
66 Valve Clearance Intake at Hot or Cold 0.3mm
67 Valve Clearance Exhaust at Hot or Cold 0.3mm
68 ID of Crosshead 11 mm/ +0.075+0.025
69 OD of Crosshead guide 11 mm/ +0.011+0.0
70 Torque of Cross head lock nut 66 Nm (7 Kgm)
71 Injector mounting Bolt Torque 68Nm, {6~7.5 Kgm}
72 Cross Head Nut Torque 66 ± 7.4Nm (7 Kgm)
73 Rocker Adjusting Nut Torque 53-65Nm (6 Kgm)
74 Crank shaft Pulley M14 - Across Size- 22mm- 1nos 176 Nm {18 kgm}
Torque (Crank To
Pulley) M16 - Across Size- 24mm- 5nos 274 Nm {28 kgm}
98 Face Run Out Of Dumper Pulley -
99 Radial Run Out Of Dumper Pulley -
Dumper Pulley
75 Torque (Dumper To Size- M12 111 Nm, {11.3kgm}
76 Pulley)
Engine oil pan mounting bolt 54 Nm (5.5kgm)
out side diameter of tappet 19.944~19.965

Testing & Adjusting of Engine

Opearing Parameters
1 Engine Oil Pressure Low Idle
2 Engine Oil Pressure High Idle
3 Coolant Temperature
4 Engine Rpm Low Idle
5 Engine Rpm High Idle
Standard Value of for electrical Parts
51 Oil Level & Temperature Sensor(Check
STD Backlash of T Gears & their end play

Future
O.D of Cylinder Liner (Counter bore Bottom)- Top Collar (C) 145mm/ +0.090+0.040
I.D of Cylinder Liner Counter bore bottom- Top Collar (D) -
Interference between Cyl Liner & Block (Counter Bore Bottom): (D-C) 0.01 ~ 0.12 mm
O.D of Cylinder Liner (O Ring)- Top Collar (E) 141mm/ +0.386+0.361
I.D of Cylinder Liner O Ring- Top Collar (F) -
Interference between Cyl Liner & Block (O Ring): (F-E) 0.014 ~ 0.079 mm
SIGNATURES:

ENGINE TECH CHARGEHAND/FOREMAN/SUPERVISIOR

Repair limit REMARKS QC Check
for use

70.92
70.92
70.92
70.92
70.92
70.92
70.92
0.15
0.15
0.15
0.15
0.15
0.15
0.15

0.5mm

-
-
-
-
-
-
79.62mm
79.62mm
79.62mm
79.62mm
79.62mm
 79.62mm
0.12mm

0.22
0.22
0.22
0.22
0.22
0.22

New fitted

1.5mm
1.5mm
1.5mm
0.15mm
Repl
Repl
Repl

48.08mm

{7.0±0.5Kgm}
 0.3mm

0.20mm
51.73mm
(13~15 Kgm)

-
-

0.6mm

0.20mm

0.20mm

(25~30Kgm)

0.4mm
0.4mm
m, {6.75±0.75 Kgm}

0.130 mm

11.18 mm
10.95 mm
-

0.80mm
0.80mm

0.01 mm
-
WORKSHOP ENGINEER
 5219 toyota BUS
MEASURE MEASURE STANDAR Repair
SL. NO CHECK POINT D VALUE D VALUE D VALUE/ limit for REMARKS
(PRE- ( POST for use
REPAIR) REPAIR) NOMINAL assembly
VALUE
1 Oil Galleries Are Clean
Engine Block
1 st
2 nd
3rd
2 out side diameter of
main jornal 4th
5th
6th
7th
1 st
2 nd
Inside diameter of 3rd
3 main beaing 4th
Repair Limit = X +
0.15 5th
6th
journal dimention 7th
STD - 110mm/ 1 st
-0.050-0.070 2 nd
0.25 US- 109.75mm/
-0.050-0.070 3rd
4 0.50 US- 109.50mm/ 4th
-0.050-0.070
0.75 US- 109.25mm/ 5th
-0.050-0.070
1.00 US- 109.00mm/ 6th
-0.050-0.070 7th
5 Repair Limit=(STD
Main Bearing Cap Bolt Stem Lengt
6 Main Bearing Cap Bolt Torque
7 Crank Shaft End Play
1st
2nd
Connecting rod 3rd
8 journal daimention
4th
5th
6th
1 st
2 nd
Inside diameter of 3rd
9
Connecting rod bore 4th
5th
6th
1 st
Inside diameter of 2 nd
Connecting rod 3rd
10 beaing
Repair Limit = X + 4th
0.12
 Inside diameter of
Connecting rod
10 beaing
Repair Limit = X +
0.12 5th
6th
11 Clearance Between CR bush and pi
12 Connecting Rod Cap Bolt Length
13 Connecting Rod Cap Bolt Torque
1 st
2 nd

14 Connecting Rod End 3rd

Play / side clearance 4th
5th
6th
15 inside diameter of cyl.liner for wear
1 st
2 nd
Protrusion of 3rd
16
Cylinder Liner 4th
5th
6th
17 I.D of Cylinder Liner
18 O.D of Cylinder Liner ( O.D of Cyli O.D of Cyli O.D of Cylinder Liner (Counter bore)- Top Collar (A)
19 I.D of Cylinder Liner Counter bore- Top Collar (B)
20 Interference between Cyl Liner & Block (Counter Bore): (B-A)
20 Piston Cooling Nozzle Check New fitted
21 Nozzle Holder Mounting Bolt Tor
22 piston diameter
23 Piston pin daimeter
24 inside dimeter of piston pin hole
26 Clearnace between piston pin and 0.05
25 Piston Top Ring Clearance (Gap)
26 Piston Middle Ring Clearance (Gap
27 Piston Oil Ring Clearance (Gap)
28 Clearance Between Piston Ring An
29 Piston Top Ring Thickness
30 Piston Middle Ring Thickness
31 Piston Oil Ring Thickness
Width Of Piston Oil Ring Groove (
Width Of Piston Oil Ring Groove (
32 Width Of Piston Oil Ring Groove (o
33 Piston Ring Arrangement
34 ID of small end bush @ CR
1 st
2 nd
3rd
35 Protrusion Of Piston
4th
5th
6th
36 Oil Pump Mounting Bolt Torque
37 Oil Pump Strainer (Check The Con
38 Cam Bolt Torque
39 Cam End Play
1 st
outside daimeter of 2 nd
40 cam journal
3rd
4th
41 cleanrance of cam journal and bush
43 Cam lobe height
44 Fuel Pump Gear Nut Torque
42 Lifter (Cam follower) Mounting Bo
43 Lifter (Cam follower) Cover Mount
44 Valve stem OD Intake
45 Valve stem OD exhuast
46 Valve Spring Length (Inner)
47 Valve Spring Length (outer)
48 Backlash Of Crank Gear And main I
49 Backlash Of Main Idler Gear (Smal
53 Backlash Of Cam Gear And Fuel
54 Backlash
Backlash Of mainIdler
Of main idler Gear
gear large
larg
55 side And Small oil pump Idler
56 Backlash Of Small oil pump Idler
Gear
Gear And Oil Pump drive Gear
57 ID of main idler gear bush
58 OD of main idler gear shaft
59 clearance between main idler
gear bush and shaft
60 ID of oil pump idler gear bush
61 OD of oil pump idler gear shaft
62 clearance between oil pump idler
gear bush and shaft
63 Oil Pump Idler (Small) Gear Bolt
64 Main Idler Gear (Large) Bolt Torq
50 Timing Gear Mark "A" - Main idler to C/Shaft Gear
51 Timing Gear Mark "B" - Main idler(S) to Cam shaft gear
52 Timing Gear Mark "C" - Cam shaft gear to Fuel Pump Gear
68 End Play main idler Gears (BIG)
69 End Play oil pump idler Gears (Sma
53 Fly Wheel Housing Bolt Torque
54 housing bolt tighting sequence
72 Face Run Out Of Fly Wheel housin
73 Radial Run Out Of Fly Wheel hous
55 Fly Wheel Mounting Bolt Torque
56 flywheel bolt tighting squance
76 Face Run Out Of Fly Wheel
77 Radial Run Out Of Fly Wheel
78 Prortrusion of Injector nozzle
79 Cylinder Head Mounting Bolt Leng
57 Cylinder Head Mounting Bolt Torq
58 Cylinder Head Mounting Bolt Torq
59 Head bolt tighting squance
60 Hosing, Rocker Arm Bolt Torqu
61 Rocker Arm Bolt Torque
62 OD of Rocker Shaft
63 ID of Rocker arm bush
64 Clearance between rocker shaft & rocker arm bush
65 Toruque of Rocker arm adjustment nut
66 Valve Clearance Intake at Hot or C
67 Valve Clearance Exhaust at Hot or
68 ID of Crosshead
69 OD of Crosshead guide
70 Torque of Cross head lock nut
71 Injector mounting Bolt Torque
72 Cross Head Nut Torque
73 Rocker Adjusting Nut Torque
74 Crank shaft Pulley M14 - Across Size- 22mm- 1nos
Torque (Crank To
Pulley) M16 - Across Size- 24mm- 5nos
98 Face Run Out Of Dumper Pulley
99 Radial Run Out Of Dumper Pulley
Dumper Pulley
75 Torque (Dumper To Size- M12
76 Pulley)
Engine oil pan mounting bolt
out side diameter of tappet
QC Check