ENGINE MECHANICAL SECTION EM CONTENTS EM-1 IDX MODIFICATION NOTICE:

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Adrian Jacobs
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1 ENNE MNICAL STION EM MODIFICION NOTICE: TB45E engine models with three way catalyst have been provided for the Middle East and General areas. Turbocharger for engine has been changed. For information not included here, refer to information for engine in NISSAN model Y61 series RVICE NUAL SUPPLEMENT-III 2nd Revision (Publication No. SM9E-Y61CG2). TB45E OUTER COMPONENT PARTS...2 CALY AND TURBOCRGER...3 Removal and Installation...3 Inspection...4 OIL PAN & OIL INER...5 Removal and Installation...5 CAMSFT...6 Removal and Installation...6 Inspection...6 VALVE EANCE INSPTIONS AND ADJUMENTS...8 Adjustments...8 TIMING GEAR...9 Removal and Installation...9 Inspection...10 CYLINDER HEAD...11 Inspection...11 CONTENTS Disassembly and Assembly...11 Inspection...11 CYLINDER BLOCK...15 Inspection...15 TB45E RVICE DA AND SPIFICIONS (SDS)...17 Valve...17 Camshaft and Camshaft Bushing...17 RVICE DA AND SPIFICIONS (SDS)...18 Valve...18 Valve Seat...21 Camshaft and Camshaft Bearing...22 Crankshaft...22 Available Connecting Rod Bearing...23 Miscellaneous Components...23 EM-1

2 OUTER COMPONENT PARTS TB45E EM-2 M190H

3 CALY AND TURBOCRGER Removal and Installation M296G M182H REMOVAL 1. Remove the following parts. Undercover Under guard Battery (on left side) (for cold areas) Exhaust front tube Refer to -7, EXU SYEM in NISSAN model Y61 series RVICE NUAL SUPPLEMENT-III 2nd Revision (Publication No. SM9E-Y61CG2). Remove wires, harnesses, tubes and pipes. EM-3

4 CALY AND TURBOCRGER Removal and Installation (Cont d) 2. Remove catalyst. CAUTION: Do not disassemble catalyst. Inspection TURBOCRGER M184H CAUTION: When the compressor wheel, turbine wheel, or rotor shaft is damaged, remove all the fragments and foreign matter left in the following passages in order to prevent a secondary failure: Suction side: Between turbocharger and intercooler Exhaust side: Between turbocharger and catalytic converter Rotor shaft Check that the rotor shaft rotates smoothly without any resistance when it is rotated by your fingertips. Check that the rotor shaft is not loose when it is moved vertically or horizontally. Standard value for rotor shaft oil clearance: mm ( in) M298G EM-4

5 OIL PAN & OIL INER M345GA Removal and Installation INALLION [OIL PAN (LOWER)] Install oil pan (Lower). Apply liquid gasket to inner sealing surface as shown in figure. Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to in). Attaching should be done within 5 minutes after coating. Use Genuine Liquid Gasket or equivalent. INALLION [OIL PAN (UPPER) AND OIL INER] Install oil pan (Upper). Apply liquid gasket to inner sealing surface as shown in figure. Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to in). Attaching should be done within 5 minutes after coating. Use Genuine Liquid Gasket or equivalent. M347GA EM-5

6 CAMSFT Removal and Installation M189H Inspection CAMSFT RUNOUT Prepare V-block on a flat surface and secure camshaft journals No. 1 and No. 5. Set the dial gauge vertically on journal No. 3. Rotate camshaft in one direction by hand, then read needle movement on dial indicator. (Total indicator reading) Limit: 0.02 mm ( in) If it exceeds the limit, replace camshaft. PBIC0365E CAMSFT END PLAY Set the dial gauge to the front end of the camshaft. Measure the end play by moving the camshaft in the direction of the axle. Standard: mm ( in) Limit: 0.2 mm ( in) PBIC0366E EM-6

7 KBIA2318E CAMSFT Inspection (Cont d) Replace the following parts if outside the limit. a. Dimension A for camshaft (No. 2 journal) Standard: mm ( in) b. Dimension B for No. 2 camshaft bracket Standard: mm ( in) Replace camshaft and/or cylinder head referring to the standards above. NOTE: It is impossible to replace only the camshaft bracket as the camshaft bracket is manufactured with the cylinder head. VISUAL INSPTION OF VALVE LIFTER Check if surface of valve lifter has any wear or cracks. Replace valve lifter if necessary. Select the thickness of the head so that valve clearance is the standard when replacing. Refer to EM-46, Inspection in NISSAN model Y61 series RVICE NUAL SUPPLE- MENT-III 2nd Revision(Publication No. SM9E-Y61CG2). KBIA2285E VALVE LIFTER OUTER DIAMETER Measure the outer diameter of the valve lifter with a micrometer. Standard: mm ( in) dia. KBIA2286E LIFTER GUIDE INNER DIAMETER Measure the lifter guide inner diameter of the cylinder head with an inside micrometer. Standard: mm ( in) dia. PBIC0367E VALVE LIFTER EANCE CAULIONS Clearance = Lifter guide inner diameter Valve lifter outer diameter Standard: mm ( in) If it exceeds the standard value, refer to the outer diameter and bore diameter standard values and replace valve lifter and/or cylinder head. EM-7

8 VALVE EANCE INSPTIONS AND ADJUMENTS Adjustments Perform adjustment depending on selected head thickness of valve lifter. 1. Remove camshaft. Refer to EM-41, Removal in NISSAN model Y61 series RVICE NUAL SUPPLEMENT-III 2nd Revision (Publication No. SM9E-Y61CG2). 2. Remove valve lifters at the locations that are outside the standard. 3. Measure the center thickness of the removed valve lifters with a micrometer. KBIA0057E 4. Use the equation below to calculate valve lifter thickness for replacement. Valve lifter thickness calculation: Thickness of replacement valve lifter = t1 + (C1 C2) t1 = Thickness of removed valve lifter C1 = Measured valve clearance C2 = Standard valve clearance: When engine is cool [Approximately 20 C (68 F)]: Intake and exhaust 0.35 mm (0.014 in) KBIA2292E Thickness of a new valve lifter can be identified by stamp marks on the reverse side (inside the cylinder). Stamp mark 535 indicates 5.35 mm ( in) in thickness. Available thickness of valve lifter: 15 sizes with range 5.35 to 6.05 mm ( to in) in steps of 0.05 mm ( in) (when manufactured at factory). Refer to EM-19, AVAILABLE VALVE LIFTER. 5. Install the selected valve lifter. 6. Install camshaft. Refer to EM-44, Installation in NISSAN model Y61 series RVICE NUAL SUPPLEMENT-III 2nd Revision (Publication No. SM9E-Y61CG2), EM Manually turn crankshaft pulley a few turns. 8. Make sure that valve clearances for cold engine are within specifications by referring to the specified values. Valve clearance: When engine is cool [Approximately 20 C (68 F)] Intake and exhaust mm ( in) EM-8

9 TIMING GEAR Removal and Installation 2 idler gears are shown in this chapter. Idler gear (A) has scissors gear, and idler gear (B) does not. EM-9 M185H

10 TIMING GEAR M039 Inspection BALANCER SFT OIL EANCE Outer diameter of balancer shaft journal Measure the outer diameter of the balancer shaft journal with a micrometer. Standard: Front side mm ( in) dia. Rear side mm ( in) dia. Inner diameter of balancer shaft bearing Measure the inner diameter of the balancer shaft bearing using a bore gauge. Standard: Front side mm ( in) dia. Rear side mm ( in) dia. M040A Oil clearance calculations Oil clearance = Bearing inner diameter Journal outer diameter Standard: mm ( in) Limit: mm ( in) Replace the balancer shaft and/or cylinder block if it exceeds the limit. NOTE: It is impossible to replace only balancer shaft bearing because balancer shaft bearing is manufactured with cylinder block. EM-10

11 CYLINDER HEAD M057 Inspection IDLER GEAR OIL EANCE Measure the inner diameter (d 1 ) of idler gear shaft hole. Standard: mm ( in) Measure the outer diameter (d 2 ) of idler shaft. Standard: mm ( in) Calculate gear clearance. Clearance = d 1 d 2 Standard: mm ( in) Replace idler gear and/or idler shaft if it is outside of the standard. Disassembly and Assembly PBIC1749E PBIC0413E Inspection VALVE DIMENSION Using micrometer, measure the dimensions of each part. Standard Unit: mm (in) Intake valve Exhaust valve a (4.468) (4.468) b ( ) ( ) c 1.5 (0.059) 1.5 (0.059) d ( ) ( ) D ( ) ( ) α EM-11

12 M938C CYLINDER HEAD Inspection (Cont d) VALVE GUIDE EANCE Calculate the clearance by measuring valve stem outer diameter and valve guide inner diameter. Unit: mm (in) Intake Exhaust Standard ( ) ( ) Limit 0.18 (0.0071) 0.10 (0.0039) If the measured value exceeds the limit, replace valve guide and/or valve. VALVE GUIDE REPLACEMENT There is no setup for oversized valve guide. 1. Heat cylinder head to 110 to 130 C (230 to 266 F) in oil bath. M Using valve guide drift (multi-purpose tool: for 7.0 mm dia.), tap valve guides out from the combustion chamber side. CAUTION: Cylinder head contains heat. Wear protective equipment to avoid getting burned when working. M070A 3. Heat cylinder head to 110 to 130 C (230 to 266 F) in oil bath. 4. Using valve guide drift (multi-purpose tool: for 7.0 mm dia.), press fit valve guides from camshaft side, referring to the dimension shown in the figure. CAUTION: Cylinder head contains heat. Wear protective equipment to avoid getting burned when working. M071 EM-12

13 CYLINDER HEAD Inspection (Cont d) 5. Using suitable valve guide reamer, perform reaming to the press-fitted valve guides. Reaming specifications: Intake/Exhaust mm ( in) M072A VALVE CONTACT Check valve for any evidence of pitting at valve contact surface, and reseat or replace if worn out excessively. When repairing valve seats, check valve and valve guide for wear beforehand. If worn, replace them. Then check valve seat. M073 VALVE REPLACEMENT 1. Cut valve seat to make it thin, and pull it out. CAUTION: Cutting valve seat too much may cause damage of cylinder head. NOTE: After removing valve seat, check cylinder head inner area for cracks. If any cracks or deformation, replace cylinder head with new one. Check inner diameter of valve seat mounting area. Refer to EM-21, Valve Seat. 2. Heat cylinder head to approximately 110 to 130 C (230 to 266 F) in oil bath. 3. After cooling valve seats sufficiently with dry ice, press fit it to cylinder head. CAUTION: Cylinder head contains heat. Wear protective equipment to avoid getting burned when working. Do not touch the cooled valve seats directly by bare hand. EM-13

14 CYLINDER HEAD Inspection (Cont d) 4. Make sure that contacting status is satisfactory. M191H EM-14

15 CYLINDER BLOCK Inspection STIVE PION COMBINION Selective combination chart New pistons are classified into 4 weight classes at factory. The same class pistons are used on a engine. Weight grade symbol Weight class g (oz) E ( ) F ( ) G ( ) H ( ) PBIC1756E CNKSFT RUNOUT Place V-block onto surface plate to support No. 2 and No. 4 journals. Position dial indicator vertically onto No. 1, No. 3 and No. 5 journals. Rotate crankshaft to read needle movement on dial indicator. (Total indicator reading) Standard: Less than 0.01 mm ( in) Limit: 0.03 mm ( in) Replace crankshaft if it exceeds the limit. CONNTING ROD BEARING CRUSH HEIGHT Tighten connecting rod caps to the specified torque with connecting rod bearings installed. :79-83N m ( kg-m, ft-lb) Remove connecting rod caps. The connecting rod bearing end must then be higher than the flat surface. Standard: Crush height must exist. If out of specification, replace connecting rod bearings. PBIC1646E MOVEMENT AMOUNT OF FLYWHE (M/T MODS) NOTE: Inspect for double mass flywheel only. Do not disassembly double mass flywheel. EM-15

16 CYLINDER BLOCK Inspection (Cont d) Flywheel Deflection Measure deflection of flywheel contact surface to the clutch with a dial gauge. Measure deflection at 250 mm (9.84 in) dia. Standard: 0.3 mm (0.012 in) or less Limit: 0.7 mm (0.028 in) or less When measured value exceeds the limit, replace it with a new one. PBIC1045E Movement Amount in Rotation Direction Check the movement amount in the following procedure. 1. Install a bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel center line. Tighten bolt at a force of 9.8 N m (1 kg-m, 87 in-lb) to keep it from loosening. PBIC2070E 2. Put a mating mark on circumferences of the two flywheel masses without applying any load (Measurement standard points). 3. Apply a force of 9.8 N m (1 kg-m, 87 in-lb) in each direction, and mark the movement amount on the mass on the transmission side. 4. Measure dimensions of movement amounts A and B on circumference of the flywheel on the transmission side. Standard: 5.9 mm (0.232 in) or less When measured value is outside the standard, replace flywheel. OIL JET Check nozzle for deformation and damage. Blow compressed air from nozzle, and check for clogs. Standard: No deformation and no damage Replace oil jet if it is out of the standard. PBIC0392E OIL JET RIEF VALVE Using a clean plastic stick, press check valve in oil jet relief valve. Make sure that valve moves smoothly with proper reaction force. Standard: Valve moves smoothly with proper reaction force. If it is not satisfied, replace oil jet relief valve. E0186D EM-16

17 RVICE DA AND SPIFICIONS (SDS) TB45E VALVE EANCE Intake and Exhaust Valve Unit: mm (in)/ C ( F) Cold Hot (*1) 0.16 (0.006)/8-12 (46-54) 0.17 (0.007)/13-17 (55-63) 0.19 (0.007)/18-22 (64-72) 0.20 (0.008)/23-27 (73-81) 0.21 (0.008)/28-32 (82-90) 0.23 (0.009)/33-37 (91-99) 0.24 (0.009)/38-42 ( ) 0.25 (0.010)/43-47 ( ) 0.26 (0.010)/48-52 ( ) ( ) Whenever valve clearances are adjusted to cold specifications: Based on the engine coolant temperature (the value indicated by CONSULT-II) during valve clearance adjustment, select the setting value from above table. Determine setting value based on radiator coolant temperature if CONSULT-II could not be used. *1: Reference data at engine coolant temperature 82 C (180 F) Camshaft and Camshaft Bushing Unit: mm (in) Valve timing EM671 Cam height A Intake Exhaust TB45E ( ) EM120 Unit: degree a b c d e f TB45E EM-17

18 VALVE RVICE DA AND SPIFICIONS (SDS) Valve Unit: mm (in) PBIC0413E Valve length a b Valve margin c Valve stem diameter d Valve head diameter D Valve seat angle α Intake (4.468) Exhaust Intake ( ) Exhaust Intake 1.5 (0.059) Exhaust Intake ( ) Exhaust ( ) Intake ( ) Exhaust ( ) Intake Exhaust VALVE EANCE Unit: mm (in) Cold* Intake and exhaust ( ) *: Approximately 20 C (68 F) EM-18

19 RVICE DA AND SPIFICIONS (SDS) Valve (Cont d) AVAILABLE VALVE LIFTER Identification mark Thickness (0.2106) (0.2126) (0.2146) (0.2165) (0.2185) (0.2205) (0.2224) (0.2244) (0.2264) (0.2283) (0.2303) (0.2323) (0.2343) (0.2362) (0.2382) VALVE LIFTER Valve lifter outer diameter ( ) Lifter guide inner diameter ( ) Clearance between lifter and lifter guide ( ) KBIA2292E Unit: mm (in) EM-19

20 VALVE GUIDE RVICE DA AND SPIFICIONS (SDS) Valve (Cont d) Unit: mm (in) M071 Standard Limit Outer diameter ( ) Valve guide Inner diameter (Finished size) ( ) Cylinder head valve guide hole diameter ( ) Interference fit of valve guide ( ) Intake ( ) 0.18 (0.0071) Stem to guide clearance Exhaust ( ) 0.10 (0.0039) Projection length ( ) EM-20

21 RVICE DA AND SPIFICIONS (SDS) Valve Seat Unit: mm (in) PBIC1726E M373G PBIC0421E Cylinder head seat recess diameter (D) Valve seat interference fit Standard Intake ( ) Exhaust ( ) Intake ( ) Exhaust ( ) EM-21

22 RVICE DA AND SPIFICIONS (SDS) Valve Seat (Cont d) Valve seat outer diameter (d) Height (h) Depth (L) Intake ( ) Exhaust ( ) Intake ( ) Exhaust ( ) Intake ( ) Exhaust ( ) Camshaft and Camshaft Bearing Standard Limit Camshaft runout [TIR*] 0.02 (0.0008) Camshaft end play ( ) 0.2 (0.008) Camshaft (No. 2 journal) A dimension ( ) No. 2 camshaft bracket B dimension ( ) KBIA2318E Valve timing PBIC0517E Unit: degree a b c d e *: Total indicator reading Crankshaft Unit: mm (in) Runout [TIR*] *: Total indicator reading Standard Less than 0.01 (0.0004) Limit 0.03 (0.0012) EM-22

23 RVICE DA AND SPIFICIONS (SDS) BALANCER SFT BEARING Balancer shaft journal outer diameter Balancer shaft bearing inner diameter Balancer shaft journal oil clearance Available Connecting Rod Bearing Unit: mm (in) Front ( ) Rear ( ) Front ( ) Rear ( ) Standard ( ) Limit (0.0071) Miscellaneous Components Unit: mm (in) Flywheel deflection [TIR]* Flywheel movement in rotation direction *: Total indicator reading Standard 0.3 (0.012) or less Limit 0.7 (0.028) 5.9 (0.232) or less EM-23

ENGINE MECHANICAL SECTIONEM CONTENTS EM-1 IDX MODIFICATION NOTICE:

ENGINE MECHANICAL SECTIONEM CONTENTS EM-1 IDX MODIFICATION NOTICE: ENNE MNICAL STIONEM MODIFICION NOTICE: Valve lifter of 30DDT engine has been changed from a type without shim to a type with adjusting shim For information not included here, refer to information for 30DDT