engine NISSAN PATROL 1998 Y61 / 5.G Engine Mechanical Workshop Manual

ENGINE MECHANICAL
SECTION
EM
CONTENTS
PRECAUTIONS...............................................................1
Parts Requiring Angular Tightening .............................1
Liquid Gasket Application Procedure ..........................1
PREPARATION................................................................2
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING.....................................................6
NVH Troubleshooting Chart Ð Engine Noise .............7
OUTER COMPONENT PARTS.......................................8
COMPRESSION PRESSURE........................................10
Measurement of Compression Pressure ...................10
OIL PAN.........................................................................13
Removal .....................................................................13
Installation ..................................................................14
TIMING BELT.................................................................15
Removal .....................................................................15
Inspection...................................................................17
Installation ..................................................................18
OIL SEAL REPLACEMENT..........................................20
TURBOCHARGER.........................................................23
Removal and Installation ...........................................23
Inspection...................................................................24CHARGE AIR COOLERS..............................................27
CYLINDER HEAD..........................................................28
Removal .....................................................................29
Disassembly...............................................................30
Inspection...................................................................31
Assembly ...................................................................37
Installation ..................................................................37
VALVE CLEARANCE....................................................40
Checking ....................................................................40
Adjusting ....................................................................41
ENGINE REMOVAL.......................................................43
Removal .....................................................................44
Installation ..................................................................44
CYLINDER BLOCK.......................................................45
Disassembly...............................................................46
Inspection...................................................................46
Assembly ...................................................................53
SERVICE DATA AND SPECIFICATIONS (SDS)..........56
General Speci®cations ...............................................56
Inspection and Adjustment ........................................56
EM

Parts Requiring Angular Tightening
+Some important engine parts are tightened using an angular-
tightening method rather than a torque setting method.
+If these parts are tightened using a torque setting method, dis-
persal of the tightening force (axial bolt force) will be two or
three times that of the dispersal produced by using the correct
angular-tightening method.
+Although the torque setting values (described in this manual)
are equivalent to those used when bolts and nuts are tightened
with an angular-tightening method, they should be used for
reference only.
+To assure the satisfactory maintenance of the engine, bolts and
nuts must be tightened using an angular-tightening method.
+Before tightening the bolts and nuts, ensure that the thread and
seating surfaces are clean and then coated with engine oil.
+The bolts and nuts which require the angular-tightening method
are cylinder head bolts.
Liquid Gasket Application Procedure
a. Before applying liquid gasket, use a scraper to remove all
traces of old liquid gasket from mating surface.
b. Apply a continuous bead of liquid gasket to mating sur-
faces. (Use Genuine Liquid Gasket or equivalent.)
+Be sure liquid gasket is speci®ed width (for oil pan) 3.5
to 4.5 mm (0.138 to 0.177 in) for gasoline engine.
+Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118
in) wide in areas except oil pan for TB and RD series
engines and 2.5 to 3.5 mm (0.098 to 0.138 in) for TD
series engine.
c. Apply liquid gasket to inner surface around hole perimeter
area.
(Assembly should be done within 5 minutes after coating.)
d. Wait at least 30 minutes before re®lling engine oil and
engine coolant.
SEM371C
PRECAUTIONS
EM-1

SPECIAL SERVICE TOOLS
* Special tool or commercial equivalent
Tool number
Tool nameDescription
ST0501S000*
Engine stand assembly
V1ST05011000
Engine stand
V2ST05012000
Base
NT042
Disassembling and assembling
KV10106500*
Engine stand shaft
NT028
KV1011070
Engine sub-attachment
NT582
KV101092S0
Valve spring compressor
V1KV10109210
Compressor
V2KV10109220
Adapter
NT718
Disassembling and assembling
valve components
KV10107902
Valve oil seal puller
V1KV10116100
Valve oil seal puller
adapter
NT605
PREPARATION
EM-2

* Special tool or commercial equivalent
Tool number
Tool nameDescription
WS39930000*
Tube presser
NT052
Pressing the tube of liquid gasket
KV10107501
Valve oil seal drift
NT741
KV111033S0
Engine stopper
V1KV10105610
Stopper plate
V2KV10105630
Stopper gear
NT616
Preventing crankshaft from rotating
a: 3 (0.12)
b: 6.4 (0.252)
c: 2.8 (0.110)
d: 6.6 (0.260)
e: 119 (4.69)
f: 12 (0.47)
g: 18 (0.71)
Unit: mm (in)
PREPARATION
EM-4

COMMERCIAL SERVICE TOOLS
Tool name Description
Valve guide drift
NT015
Removing and installing valve guide
Intake & Exhaust
TB and TD engines
a = 11.5 mm (0.453 in) dia.
b = 7.6 mm (0.299 in) dia.
RD engine
a = 11.5 mm (0.453 in) dia.
b = 6.5 mm (0.256 in) dia.
Valve guide reamer
NT016
Reaming valve guideV1or hole for oversize valve
guide
V2
Intake & Exhaust
TB engine
d
1= 8.0 mm (0.315 in) dia.
d
2= 12.2 mm (0.480 in) dia.
RD engine
d
1= 7.000 mm (0.2756 in) dia.
d
2= 11.19 mm (0.4406 in) dia.
TD engine
d
1= 8.0 mm (0.315 in) dia.
Valve seat cutter set
NT048
Finishing valve seat dimensions
Front oil seal drift
NT049
Installing front oil seal
TB engine
a = 80 mm (3.15 in) dia.
b = 58 mm (2.28 in) dia.
RD engine
a = 52 mm (2.05 in) dia.
b = 41 mm (1.61 in) dia.
Rear oil seal drift
NT049
Installing rear oil seal
a = 100 mm (3.94 in) dia.
b = 78 mm (3.07 in) dia.
Piston pin drift
NT074
Removing and installing piston pin
a = 22.5 mm (0.886 in) dia.
b = 12.5 mm (0.492 in) dia.
PREPARATION
EM-5

NVH Troubleshooting Chart Ð Engine Noise
Use the chart below to help you ®nd the cause of the problem.
1. Locate the area where noise occurs.
2. Con®rm the type of noise.
3. Specify the operating condition of engine.
4. Check speci®ed noise source.
If necessary, repair or replace these parts.
Location of
noiseType of
noiseOperating condition of engine
Source of
noiseCheck itemReference
page Before
warm-upAfter
warm-upWhen
startingWhen
idlingWhen
racingWhile
driving
To p o f
engine
Rocker
cover
Cylinder
headTicking or
clickingCAÐABÐTappet
noiseValve clearance EM-41
Rattle C A Ð A B CCamshaft
bearing
noiseCamshaft journal clearance
Camshaft runoutEM-37
Crankshaft
pulley
Cylinder
block (Side
of engine)
Oil panSlap or
knockÐAÐB BÐPiston pin
noisePiston and piston pin clear-
ance
Connecting rod bushing
clearanceEM-47, 53
Slap or rap A Ð Ð B B APiston slap
noisePiston-to-bore clearance
Piston ring side clearance
Piston ring end gap
Connecting rod bend and
torsionEM-48, 49
Knock A B C B B BConnecting
rod bearing
noiseConnecting rod bushing
clearance (Small end)
Connecting rod bearing
clearance (Big end)EM-52, 53
Knock A B Ð A B CMain bear-
ing noiseMain bearing oil clearance
Crankshaft runoutEM-51
Timing belt
coverWhine or
hissingCAÐAAÐTiming belt
noise (too
tight)
Loose timing belt
Belt contacting caseEM-18
Clatter A B Ð C A ÐTiming belt
noise (too
loose)
Front of
engineSqueaking
or ®zzingABÐBÐCOther drive
belts
(Sticking or
slipping)Drive belts de¯ection
*1
CreakingABABABOther drive
belts (Slip-
ping)Idler pulley bearing operation
Squall
CreakABÐBABWater pump
noiseWater pump operation *2
A: Closely related B: Related C: Sometimes related Ð: Not related
*1: MA section (``Checking Drive Belts'', ``ENGINE MAINTENANCE'')
*2: LC section (``Water Pump Inspection'', ``ENGINE COOLING SYSTEM'')
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
EM-8

Measurement of Compression Pressure
1. Warm up engine sufficiently.
2. Disconnect injection tube on nozzle side and loosen injection
tubes on pump side. Release clamps on injection tubes.
+Use two wrenches to prevent delivery holder on pump side
from loosening.
3. Remove spill-tube assembly.
+To prevent spill tube from breaking, remove it by gripping
nozzle holder.
4. Remove all injection nozzles using Tool or a suitable tool.
5. Turn ignition switch OFF and disconnect harness connector
(black colored) at injection pump.
SEM702B
SEM703B
SEM704B
SEM705B
SEM789F
COMPRESSION PRESSURE
EM-11

6. Fit compression gauge adapter to cylinder head.
7. Crank engine and read gauge indication.
Crank speed: 200 rpm
Compression pressure:
Standard
3,040 kPa (30.4 bar, 31 kg/cm
2, 441 psi)
Limit
2,452 kPa (24.5 bar, 25 kg/cm
2, 356 psi)
Differential limit between cylinders
490 kPa (4.9 bar, 5 kg/cm
2, 71 psi)
8. If the pressure appears low, pour about 3 m!(0.11 Imp ¯ oz)
of engine oil through nozzle holes and repeat test.
For indications of test, refer to the following table.
Gauge indication during tests Trouble diagnosis
SEM857
+Piston rings are worn or
damaged.
SEM858
+If two adjacent cylinders
are low, gasket is dam-
aged.
+Valve is sticking.
+Valve seat or valve con-
tact surface is incorrected.
9. Replace nozzle gaskets and install injection nozzles.
New nozzle gasket installation direction is as shown.
Nozzle to cylinder head:
:59-69Nzm
(6.0 - 7.0 kg-m, 43 - 51 ft-lb)
SEM706B
SEM708B
COMPRESSION PRESSURE
Measurement of Compression Pressure
(Cont'd)
EM-12
First readingSecond
reading
Increased
reading
Same reading
maintained

Removal
1. Remove oil pan guard.
2. Drain engine oil.
+When installing drain plug washer, ensure it faces in correct
direction.
+Discard oil drain plug washer and install a new one.
Drain plug:
:29-39Nzm (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
SEM782F
SEM783F
SEM063B
OIL PAN
EM-14

3. Remove engine gussets and oil pan bolts.
+Remove bolts/nuts in numerical order shown in ®gure, alternat-
ing left and right ones toward the center.
4. Remove oil pump assembly.
Installation
Always install with new oil seal.
1. Install oil pump assembly.
Location Bolt length mm (in)
V120 (0.79)
V235 (1.38)
V345 (1.77)
V455 (2.17)
2. Install oil pan. Tighten bolts in the order shown in the ®gure.
+Always replace oil pan gaskets with new ones when reas-
sembling.
+Install oil pan gasket after cleaning the contacting surface.
+Oil pan bolts/nuts:
Bolt
:8-12Nzm (0.8 - 1.2 kg-m, 69 - 104 in-lb)
Nut
:10-14Nzm (1.0 - 1.4 kg-m, 87 - 122 in-lb)
3. Install engine gusset and oil pan guard.
SEM739B
SEM432C
SEM794F
SEM739BA
OIL PAN
Removal (Cont'd)
EM-15