NISSAN PICK-UP 1998 Repair Manual

10. Connect thermostat housing water inlet hose and radiator
hose.
11. After assembling all disassembled parts, fill radiator and
engine with new coolant up to filler opening.
CYLINDER HEADTD
Installation (Cont'd)
EM-66

OIL SEAL INSTALLING DIRECTION
lWhen installing a new front or rear seal, make sure its mount-
ing direction is correct.
CRANKSHAFT FRONT OIL SEAL
1. Remove radiator shroud.
2. Remove cooling fan.
3. Remove drive belts.
4. Remove crankshaft pulley.
5. Remove crankshaft oil seal.
lBe careful not to damage sealing surfaces of crankshaft.
6. Coat new oil seal with engine oil and install it in place.
lPress the oil seal until it contacts with the front cover.
CRANKSHAFT REAR OIL SEAL
1. Dismount transmission.
2. Remove clutch cover assembly.
3. Remove flywheel and rear plate.
4. Remove oil pan and oil pan gasket.
5. Remove oil seal retainer assembly and retainer gasket.
lReplace oil seal and retainer assembly as a single unit
(mono-block type combined with oil seal).
6. Coat oil seal with engine oil and install new oil seal retainer
assembly in place.
VALVE STEM OIL SEAL
1. Remove following parts.
lThrottle chamber and air intake tube
SEM715A
SEM644B
DEM042
MEM182A
DEM108
.
OIL SEAL REPLACEMENTTD
EM-67

2. Remove rocker cover.
3. Remove rocker shaft assembly.
4. Remove valve spring.
5. Remove valve oil seals.
6. Apply engine oil to valve oil seal and install it in place.
DEM029-A
SEM626BA
SEM646BA
DEM040
OIL SEAL REPLACEMENTTD
EM-68

WARNING:
lPosition vehicle on a flat and solid surface.
lPlace chocks at front and back of rear wheels.
lDo not remove engine until exhaust system has com-
pletely cooled off.
Otherwise, you may burn yourself and/or fire may break
out in fuel line.
lBe sure to hoist engine and transmission in a safe man-
ner.
lFor engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATA-
LOG.
CAUTION:
lWhen lifting engine, be sure to clear surrounding parts.
Take special care near accelerator wire casing, brake
lines and brake master cylinder.
lIn lifting the engine, always use engine slingers in a safe
manner.
lFor 4WD models, apply sealant between engine and
transmission. Refer to MT section (``Removal and Instal-
lation'').
SEM613FN
ENGINE REMOVALTD
EM-69

Removal
1. Remove engine undercover and hood.
2. Drain engine coolant.
3. Remove vacuum hoses, fuel tubes, wires, harnesses and
connectors and so on.
4. Remove radiator, shroud and cooling fan.
5. Remove drive belts.
6. Remove power steering oil pump and air conditioner com-
pressor.
7. Remove front exhaust tube.
8. Remove transmission from vehicle.
Refer to MT section.
9. Install engine slingers.
10. Hoist engine with engine slingers and remove engine mount-
ing bolts from both sides.
11. Remove engine from vehicle.
Installation
lInstall in reverse order of removal.
DEM021
ENGINE REMOVALTD
EM-70

DEM065-A
.
ENGINE OVERHAULTD
EM-71

Disassembly
PISTON AND CRANKSHAFT
1. Remove oil filter.
2. Place engine on work stand.
3. Drain coolant and oil.
4. Remove drive belts.
5. Remove cylinder head.
6. Remove oil pan.
7. Remove crankshaft pulley.
8. Remove water pump.
9. Remove timing gear case.
lRemove dust cover with a seal cutter.
lIf the timing case is hard to remove due to liquid gasket,
pry it off with a suitable tool at the cutout section.
SEM650B
SEM651B
DEM045
DEM062
DEM046
ENGINE OVERHAULTD
EM-72

10. Remove injection pump gear.
lBe careful not to lose the woodruff key during injection pump
removal.
11. Remove idler gear and idler gear shaft.
12. Remove camshaft gear, camshaft and valve lifters.
13. Remove oil pump assembly.
14. Remove crankshaft gear.
15. Remove flywheel and rear plate.
16. Remove connecting rod caps.
17. Remove pistons.
lRemove the connecting rod in such a way that it does not
interfere with oil jet.
DEM043
DEM044
DEM047
DEM048
ENGINE OVERHAULTD
Disassembly (Cont'd)
EM-73

18. Remove rear oil seal retainer assembly.
19. Remove bearing cap and crankshaft.
Place the bearings and caps in their proper order.
Inspection and Replacement
CYLINDER BLOCK DISTORTION
If beyond the specified limit, replace it.
Cylinder block distortion: mm (in)
Standard
Less than 0.05 (0.0020)
Limit
0.2 (0.008)
lRemove all traces of gasket from the cylinder block. Do not
allow pieces of the gasket to enter the oil and cooling water
passages during gasket removal.
CYLINDER LINER WEAR
1. Measure cylinder liner bore for out-of-round and taper with a
bore gauge. If beyond the limit, replace cylinder liner.
Standard inside diameter:
92.900 - 92.930 mm (3.6575 - 3.6587 in)
Refer to SDS, EM-102.
Wear limit:
0.20 mm (0.0079 in)
Out-of-round (X þ Y) standard:
0.020 mm (0.0008 in)
Taper (A þ B) standard:
0.020 mm (0.0008 in)
SEM657B
SEM658B
SEM038
DEM067
ENGINE OVERHAULTD
Disassembly (Cont'd)
EM-74

2. Check for scratches or seizure. If seizure is found, replace
cylinder liner.
3. Check amount of projection of cylinder liner.
Cylinder liner projection:
Standard
0.02 - 0.09 mm (0.0008 - 0.0035 in)
Deviation of each cylinder:
Less than 0.05 mm (0.0020 in)
CYLINDER LINER
Replacement
1. Remove cylinder liner with Tool.
2. Install cylinder liner with Tool.
3. Check amount of projection of cylinder liner.
PISTON TO CYLINDER WALL CLEARANCE
1. Measure piston and cylinder bore diameter.
Piston diameter ``A'':
Refer to SDS, EM-103.
Measuring point ``a''
(Distance from the top): mm (in)
70 (2.76)
2. Check that piston clearance is within the specification.
Piston clearance:
0.05 - 0.07 mm (0.0020 - 0.0028 in)
SEM920A
SEM849
SEM659B
SEM660B
ENGINE OVERHAULTD
Inspection and Replacement (Cont'd)
EM-75