ESP NISSAN 350Z 2007 Z33 Engine Mechanical Workshop Manual

FUEL INJECTOR AND FUEL TUBE
EM-35
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Revision: 2006 November2007 350Z
CAUTION:
Perform this step when engine is cold.
4. Remove intake manifold collector. Refer to EM-17, "
INTAKE MANIFOLD COLLECTOR" .
5. Remove fuel feed hose (with damper) (1) from fuel sub-tube (2)
and harness bracket (3).
NOTE:
There is no fuel return route.
CAUTION:

While hoses are disconnected, plug them to prevent fuel
from draining.

Do not separate fuel damper and fuel feed hose.
6. When separating fuel feed hose (with damper) and centralized under-floor piping connection, disconnect
quick connector as follows:
a. Remove quick connector cap (2) from quick connector connec-
tion on right member side.
b. Disconnect fuel feed hose (with damper) (1) from bracket hose
clamp.
c. Disconnect quick connector from centralized under-floor piping as follows:
CAUTION:
Disconnect quick connector by using quick connector release [SST: — (J-45488)], not by picking
out retainer tabs.
i. With the sleeve side of quick connector release facing quick connector, install quick connector release
onto centralized under-floor piping.
ii. Insert quick connector release into quick connector until sleeve
contacts and goes no further. Hold quick connector release on
that position.
CAUTION:
Inserting quick connector release hard will not disconnect
quick connector. Hold quick connector release where it
contacts and goes no further.
iii. Draw and pull out quick connector straight from centralized
under-floor piping.
CAUTION:

Pull quick connector holding “A” position as shown in
the figure.

Do not pull with lateral force applied. O-ring inside quick connector may be damaged.

Prepare container and cloth beforehand as fuel will leak out.

Avoid fire and sparks.

Keep parts away from heat source. Especially, be careful when welding is performed around
them.

Do not expose parts to battery electrolyte or other acids.

Do not bend or twist connection between quick connector and fuel feed hose (with damper) dur-
ing installation/removal.
: Engine front
PBIC4961E
PBIC4962E
PBIC1898E

EM-60
TIMING CHAIN
Revision: 2006 November2007 350Z
b. Remove timing chain tensioners (secondary) with stopper pin
attached.
23. Use scraper to remove all traces of old liquid gasket from front
and rear timing chain cases, and opposite mating surfaces.

Remove old liquid gasket from bolt hole and thread.
INSPECTION AFTER REMOVAL
Timing Chain
Check for cracks and any excessive wear at link plates and roller
links of timing chain. Replace timing chain as necessary.
INSTALLATION
NOTE:

The below figure shows the relationship between the mating mark on each timing chain and that on the
corresponding sprocket, with the components installed.
SEM430G
PBIC4970E
PBIC2084E
PBIC0282E

EM-64
TIMING CHAIN
Revision: 2006 November2007 350Z
a. Push plunger of timing chain tensioner (secondary) and keep it
pressed in with stopper pin.
b. Install timing chains (secondary) and camshaft sprockets.
NOTE:
Figure shows right bank (rear view).

Align the mating marks on timing chain (secondary) (orange
link) with the ones on intake and exhaust camshaft sprockets
(punched), and install them.
NOTE:

Mating marks for intake camshaft sprocket are on the back
side of camshaft sprocket (secondary).

There are two types of mating marks, circle and oval types.
They should be used for the right and left banks, respec-
tively.

Align dowel pin hole on the small diameter side of the camshaft front end with dowel pin on the back
side of camshaft sprockets, and install them.

In case that positions of each mating mark and each dowel pin are not fit on mating parts, make fine
adjustment to the position holding the hexagonal portion on camshaft with wrench or equivalent.

Mounting bolts for camshaft sprockets must be tightened in the step “d”. Tightening them by hand is
enough to prevent the dislocation of dowel pins.
c. Make sure that timing chain (secondary) is not loose from each camshaft sprocket.

Make sure the mating marks (punched) (D) on each camshaft
sprocket are positioned on the mating marks (orange link) (C)
on timing chain (secondary).
NOTE:
Mating mark (punched) in the figure is for checking loose at
this step.
SEM430G
A : Camshaft sprocket (INT) back face
B : Orange link
C : Dowel groove or hole
D : Mating mark (oval)
E : Mating mark (2 oval)
F : Mating mark (circle)
G : Camshaft sprocket (EXH) back face
H : Mating mark (2 circle)
I : Timing chain (secondary)
Right bank : Use circle type (F, H)
Left bank : Use oval type (D, E)
A : Intake side
B : Exhaust side
PBIC5044E
PBIC4982E

EM-90
CYLINDER HEAD
Revision: 2006 November2007 350Z

If the engine speed is out of specified range, check battery liquid for proper gravity. Check engine
speed again with normal battery gravity.

If compression pressure is below minimum value, check valve clearances and parts associated with
combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure compression pressure again.

If some cylinders have low compression pressure, pour small amount of engine oil into the spark plug
hole of the cylinder to re-check it for compression.
–If the added engine oil improves the compression, piston rings may be worn out or damaged. Check the
piston rings and replace if necessary.
–If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-
functioning. Check valves for damage. Replace valve or valve seat accordingly.

If two adjacent cylinders have respectively low compression pressure and their compression remains
low even after the addition of engine oil, cylinder head gaskets are leaking. In such a case, replace cyl-
inder head gaskets.
9. After inspection is completed, install removed parts.
10. Start engine, and make sure that engine runs smoothly.
11. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-81, "
TROUBLE DIAGNOSIS" .
Removal and InstallationNBS0000Z

Refer to GI-11, "Components" for symbol marks in the figure.
REMOVAL
1. Remove engine assembly from vehicle, and separate front suspension member and transmission from
engine. Refer to EM-101, "
ENGINE ASSEMBLY" .
2. Remove the following parts:
1. Engine rear lower slinger 2. Cylinder head (left bank) 3. Cylinder head bolt
4. Cylinder head (right bank) 5. Cylinder head gasket (right bank) 6. Cylinder head gasket (left bank)
7. Oil level gauge guide
A. Refer to EM-92
PBIC4985E

CYLINDER BLOCK
EM-109
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Revision: 2006 November2007 350Z
7. Drain engine coolant by removing water drain plugs (1, 4) from
cylinder block both sides as shown in the figure.
8. Remove oil pan (upper, lower). Refer to EM-26, "
OIL PAN AND OIL STRAINER" .
9. Remove front timing chain case, timing chain and rear timing chain case. Refer to EM-53, "
TIMING
CHAIN" .
10. Remove cylinder head. Refer to EM-89, "
CYLINDER HEAD" .
11. Remove knock sensor.
CAUTION:
Carefully handle sensor avoiding shocks.
12. Remove rear oil seal.
13. Remove baffle plate from lower cylinder block.
14. Remove piston and connecting rod assembly as follows:

Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer
to EM-125, "
CONNECTING ROD SIDE CLEARANCE" .
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod bearing cap.
c. Using hammer handle or similar tool, push piston and connect-
ing rod assembly out to the cylinder head side.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod big
end.
15. Remove connecting rod bearings from connecting rod and connecting rod bearing cap.
CAUTION:
Identify installation position, and store them without mixing them up.
16. Remove piston rings form piston.

Before removing piston rings, check the piston ring side clearance. Refer to EM-126, "PISTON RING
SIDE CLEARANCE" .
2 : Washer
3: Plug
: Engine front
PBIC5014E
PBIC2940E

CYLINDER BLOCK
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Revision: 2006 November2007 350Z
c. Install main bearings paying attention to the direction.

Main bearing with oil hole (B) and groove (C) goes on cylinder
block. The one without them goes on lower cylinder block.

Before installing main bearings, apply engine oil to the bear-
ing surface (inside). Do not apply engine oil to the back sur-
face, but thoroughly clean it.

When installing, align main bearing stopper protrusion to cut-
out of cylinder block and lower cylinder block.

Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.
5. Install crankshaft to cylinder block.

While turning crankshaft by hand, check that it turns smoothly.
6. Install lower cylinder block.
NOTE:
Lower cylinder block cannot be replaced as a single part, because it is machined together with cylinder
block.

Apply a continuous bead of liquid gasket with the tube presser [SST: WS39930000( — )] to lower
cylinder block as shown in the figure.
7. Inspect the outer diameter of lower cylinder block bolt. Refer to EM-133, "
LOWER CYLINDER BLOCK
BOLT OUTER DIAMETER" .
8. Install lower cylinder block bolts in numerical order as shown in the figure as follows:
a. Apply new engine oil to threads and seat surfaces of lower cylinder block bolts.
b. Tighten lower cylinder block bolt (No.17 to 26) in numerical order
as shown in the figure.
c. Repeat step b.
d. Tighten lower cylinder block bolts (No.1 to 16) in numerical order
as shown in the figure.
NOTE:
Use TORX socket (size E14) for bolts No.1 to 16.
A : Cylinder block side
D : Lower cylinder block side
: Engine front
PBIC5048E
a : 3.5 – 4.5 mm (0.138 – 0.177 in) dia
b: Apply to end
PBIC5017E
: 25.0 N·m (2.6 kg-m, 18 ft-lb)
: Engine front
: 35.3 N·m (3.6 kg-m, 26 ft-lb)
PBIC5016E

CYLINDER BLOCK
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If there is stamped mark on ring, mount it with marked side
up.

Mount second ring with cut out side down.

Position each ring with the gap as shown in the figure refer-
ring to the piston front mark.

Check the piston ring side clearance. Refer to EM-126, "PISTON RING SIDE CLEARANCE" .
11. Install connecting rod bearings to connecting rod and connecting rod bearing cap.

Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply
engine oil to the back surface, but thoroughly clean it.

When installing, align connecting rod bearing stopper protru-
sion with cutout of connecting rods and connecting rod bear-
ing caps to install.

Ensure the oil hole on connecting rod and that on the corre-
sponding bearing are aligned.
12. Install piston and connecting rod assembly to crankshaft.

Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.

Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal.

Match the cylinder position with the cylinder number on connecting rod to install.

Be sure that front mark on piston head is facing front of engine.

Using piston ring compressor [SST: EM03470000 (J8037)] (A)
or suitable tool, install piston with the front mark on the piston
head facing the front of engine.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod big
end.Stamped mark:
To p r i n g ( A ) : 1 N
Second ring (B) : 2N
PBIC5019E
PBIC0808E
PBIC2067E
PBIC5020E

EM-120
CYLINDER BLOCK
Revision: 2006 November2007 350Z
2. Determine the bore grade by comparing the measurement with
the values under the cylinder bore inner diameter of the “Piston
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.

Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no
piston pin grades can be selected. (Only “0” grade is available.)

No second grade mark is available on piston.
HOW TO SELECT CONNECTING ROD BEARING
When New Connecting Rod and Crankshaft are Used
1. “Connecting Rod Bearing Selection Table” rows correspond to
connecting rod big end diameter grade (D) stamped on side face
of connecting rod.
2. “Connecting Rod Bearing Selection Table” columns correspond
to pin journal diameter grade (E - J) on front side of crankshafts.
A : Piston grade number
B : Front mark
C : Piston pin grade number
PBIC4994E
Grade 1 2 3
Cylinder bore inner diameter95.500 - 95.510
(3.7598 - 3.7602)95.510 - 95.520
(3.7602 - 3.7606)95.520 - 95.530
(3.7606 - 3.7610)
Piston skirt diameter95.480 - 95.490
(3.7590 - 3.7594)95.490 - 95.500
(3.7594 - 3.7598)95.500 - 95.510
(3.7598 - 3.7602)
A : Sample code
B : Bearing stopper groove
C : Small end diameter grade
D : Big end diameter grade
E : Weight grade
F : Cylinder No.
G : Management code
H : Front mark
I : Management code
A : Main journal diameter grade No. 1
B : Main journal diameter grade No. 2
C : Main journal diameter grade No. 3
D : Main journal diameter grade No. 4
E : Pin diameter grade No. 1
F : Pin diameter grade No. 2
G : Pin diameter grade No. 3
H : Pin diameter grade No. 4
I : Pin diameter grade No. 5
J : Pin diameter grade No. 6
K : Identification code
PBIC5046E
PBIC4996E

CYLINDER BLOCK
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Revision: 2006 November2007 350Z
3. Select connecting rod bearing grade at the point where selected row and column meet in “Connecting
Rod Bearing Selection Table”.
When Crankshaft and Connecting Rod are Reused
1. Measure the connecting rod big end diameter and crankshaft pin journal diameter. Refer to EM-127,
"CONNECTING ROD BIG END DIAMETER" . and EM-131, "CRANKSHAFT PIN JOURNAL DIAMETER"
.
2. Correspond the measured dimension in “Connecting rod big end diameter” row of “Connecting Rod Bear-
ing Selection Table”.
3. Correspond the measured dimension in “Crankshaft pin journal diameter” column of “Connecting Rod
Bearing Selection Table”.
4. Select connecting rod bearing grade at the point where selected row and column meet in following selec-
tion table.
Connecting Rod Bearing Selection Table
Connecting Rod Bearing Grade Table
PBIC5023E
Grade number Thickness mm (in) Identification color (mark)
0 1.497 – 1.500 (0.0589 – 0.0591) Black
1 1.500 – 1.503 (0.0591 – 0.0592) Brown

EM-122
CYLINDER BLOCK
Revision: 2006 November2007 350Z
Undersize Bearings Usage Guide

When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod
bearings, use undersize (US) bearings.

When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing
installed, and grind crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard.
CAUTION:
In grinding crankshaft pin to use undersize bearings, keep
the fillet R [1.5 – 1.7 mm (0.059 – 0.067 in)].
Bearing undersize table
Unit: mm (in)
HOW TO SELECT MAIN BEARING
When New Cylinder Block and Crankshaft are Used
1. “Main Bearing Selection Table” rows correspond to bearing
housing grade on rear left side of cylinder block.
2. “Main Bearing Selection Table” columns correspond to journal
diameter grade on front side of crankshaft.
2 1.503 – 1.506 (0.0592 – 0.0593) Green
3 1.506 – 1.509 (0.0593 – 0.0594) Yellow
4 1.509 – 1.512 (0.0594 – 0.0595) Blue Grade number Thickness mm (in) Identification color (mark)
PBIC1908E
Size Thickness
US 0.25 (0.0098) 1.626 - 1.634 (0.0640 - 0.0643)
A : Bearing housing grade No. 1
B : Bearing housing grade No. 2
C : Bearing housing grade No. 3
D : Bearing housing grade No. 4
E : Cylinder bore grade No. 1
F : Cylinder bore grade No. 2
G : Cylinder bore grade No. 3
H : Cylinder bore grade No. 4
I : Cylinder bore grade No. 5
J : Cylinder bore grade No. 6
K : Identification code
: Engine front
A : Main journal diameter grade No. 1
B : Main journal diameter grade No. 2
C : Main journal diameter grade No. 3
D : Main journal diameter grade No. 4
E : Pin diameter grade No. 1
F : Pin diameter grade No. 2
G : Pin diameter grade No. 3
H : Pin diameter grade No. 4
PBIC4995E
PBIC4996E