engine NISSAN PICK-UP 1998 Repair Manual

2. Insert pilot bushing until distance between flange end and
bushing is specified value.
Distance:
Approx. 5.6 - 6.0 mm (0.220 - 0.236 in)
FLYWHEEL RUNOUT
Runout (Total indicator reading):
Less than 0.15 mm (0.0059 in)
FRONT PLATE
Check front plate for warpage. If not within the limit, make flat or
replace front plate.
Warpage limit:
0.2 mm (0.008 in)
GEAR TRAIN
Camshaft drive gear, injection pump drive gear, oil
pump gear, idler gear and crankshaft gear
1. If gear tooth and key have scratches or are excessively worn,
replace gear and key.
2. Check gear train backlash before disassembling and after
assembling.
Method A (Using dial gauge)
Method B (Using fuse wire)
If beyond the limit, replace gear.
Backlash: mm (in)
Standard
0.07 - 0.11 (0.0028 - 0.0043)
Limit
0.20 (0.0079)
SEM089-A
SEM059A
SEM668B
DEM051
MEM151A
ENGINE OVERHAULTD
Inspection and Replacement (Cont'd)
EM-80

IDLER GEAR BUSHING CLEARANCE
1. Measure idler gear shaft outer diameter.
2. Measure idler gear bushing inner diameter.
3. Calculate idler gear bushing clearance.
Bushing clearance: mm (in)
Standard
0.025 - 0.061 (0.0010 - 0.0024)
Limit
0.20 (0.0079)
IDLER GEAR END PLAY
Measure idler gear end play between gear plate and gear.
Idler gear end play: mm (in)
Standard
0.03 - 0.14 (0.0012 - 0.0055)
Limit
Less than 0.3 (0.012)
REPLACEMENT OF IDLER GEAR BUSHING
1. Use a suitable tool to replace bushing.
2. Ream idler gear bushing.
Finished size:
42.00 - 42.02 mm (1.6535 - 1.6543 in)
Idler gear shaft
Install idler gear shaft so that oil hole of shaft faces upward.
CAMSHAFT AND CAMSHAFT BUSHING
Camshaft bushing clearance
Measure inside diameter of camshaft bushing and outside diam-
eter of camshaft journal with a suitable gauge.
Clearance between camshaft and bushing
(A þ B): mm (in)
Standard
0.020 - 0.109 (0.0008 - 0.0043)
Limit
Less than 0.15 (0.0059)
SEM666B
SEM705
DEM052
SEM706
SEM669B
ENGINE OVERHAULTD
Inspection and Replacement (Cont'd)
EM-81

REPLACING CAMSHAFT BUSHING
1. Using Tool, remove camshaft bushings from the engine.
Some bushings must be broken in order to remove.
2. Using Tool, install camshaft bushings as follows:
(1) Install camshaft bushings in the order of ``rear'', ``4th'', ``3rd'',
``2nd'' and ``front''. All bushings must be installed from the
front.
(2) Face the cutout upward and toward the front of the engine
during installation.
(3) Rear camshaft bushing
lAlign the cutout of rear bushing with knock pin of replacer bar
before installation.
lInsert rear bushing with replacer bar into the engine.
Install guide plate with bolt holes (on the ``TD'' mark side)
facing upper side of cylinder block. Tighten bolts.
SEM106C
SEM993B
SEM686B
SEM995B
SEM110C
ENGINE OVERHAULTD
Inspection and Replacement (Cont'd)
EM-82

lDrive replacer bar until the alignment mark on replacer bar
is aligned with the end of replacer guide.
Remove replacer set.
After installation, check that oil holes in camshaft bushings
are aligned with oil holes in cylinder block.
SEM601C
ENGINE OVERHAULTD
Inspection and Replacement (Cont'd)
EM-83

(4) 4th, 3rd and 2nd camshaft bushings
lInstall in the same manner as rear camshaft bushing.
lWhen setting 4th through 2nd bushings on replacer bar, tape
the bar to prevent movement.
(5) Front camshaft bushing
lUsing 1st bushing adapter, position front camshaft bushing
so that oil hole in cylinder block is aligned with oil hole in
bushing.
SEM602C
SEM999B
SEM001C
ENGINE OVERHAULTD
Inspection and Replacement (Cont'd)
EM-84

lPress the bushing until its front end is 0.5 mm (0.020 in) from
the front surface of the cylinder block.
3. Check camshaft bushing clearance.
Refer to SDS, EM-101.
4. Install new welch plug into rear camshaft bushing hole with
a drift.
Apply liquid sealer.
CAMSHAFT ALIGNMENT
1. Check camshaft journal and cam surface for bend, wear or
damage.
If fault is beyond limit, replace.
2. Check camshaft bend at center journal.
If bend is greater than specified limit, repair or replace cam-
shaft.
Camshaft bend
(Total indicator reading): mm (in)
Standard
Less than 0.02 (0.0008)
Limit
Less than 0.06 (0.0024)
DEM053
SEM987B
SEM034
SEM670B
ENGINE OVERHAULTD
Inspection and Replacement (Cont'd)
EM-85

3. Measure camshaft end play between locating plate and gear.
If beyond the specified limit, replace camshaft locating plate.
Camshaft end play: mm (in)
Standard
0.08 - 0.28 (0.0031 - 0.0110)
Limit
Less than 0.5 (0.020)
4. Measure camshaft cam height. If beyond the specified limit,
replace camshaft.
Cam height: mm (in)
Standard
Intake
41.88 - 41.92 (1.6488 - 1.6504)
Exhaust
41.88 - 41.92 (1.6488 - 1.6504)
Limit
Intake
Less than 41.40 (1.6299)
Exhaust
Less than 41.40 (1.6299)
Assembly
PISTON
Assemble pistons, piston pins, snap rings and connecting rods.
a. Numbers are stamped on the connecting rod and cap
corresponding to each cylinder. Care should be taken to
avoid a wrong combination including bearing.
b. When inserting piston pin in connecting rod, heat piston
with a heater or hot water [approximately 60 to 70ÉC (140
to 158ÉF)] and apply engine oil to pin and small end of
connecting rod.
c. After assembling, ascertain that piston swings
smoothly.
SEM671B
SEM037
DEM054
SEM292
ENGINE OVERHAULTD
Inspection and Replacement (Cont'd)
EM-86

Install piston assembly.
CAUTION:
lStretch the piston rings only enough to fit them in the
piston grooves.
lAlways install new piston rings with the position marks
facing up.
Identification color
Top ring Yellow
2nd ring Red
lInstall No. 1 piston ring in such a way that its gap faces
the direction of the piston pin; and then install piston
rings so that their gap positioned at 180É to one another.
CRANKSHAFT
1. Install crankshaft.
(1) Set main bearings in the proper position on cylinder block.
a. If either crankshaft, cylinder block or main bearing is
reused again, it is necessary to measure main bearing
clearance.
b. Upper bearings have oil hole and oil groove, however
lower bearings do not.
(2) Apply engine oil to crankshaft journal and pin and install
crankshaft.
(3) Install main bearing caps.
a. Install main bearing cap with the number facing the front of
vehicle.
b. Apply engine oil to main bearing cap and cylinder block con-
tact surfaces.
c. Install rear oil seal assembly. Apply engine oil to contact
surface of rear end oil seal and crankshaft.
(4) Install crankshaft thrust washer at the 4th journal from front.
Install thrust washer so that oil groove can face crankshaft.
DEM059
DEM055
SEM674BA
SEM057
ENGINE OVERHAULTD
Assembly (Cont'd)
EM-87

(5) Tighten main bearing cap bolts gradually in stages, starting
from two to three separate stages, from center bearing and
moving outward in sequence.
: 167 - 177 Nzm (17.0 - 18.0 kg-m, 123 - 130 ft-lb)
(6) Measure crankshaft free end play at No. 4 bearing.
Crankshaft free end play: mm (in)
Standard
0.055 - 0.140 (0.0022 - 0.0055)
Limit
0.40 (0.0157)
If beyond the limit, replace No. 4 main bearing thrust
washer. Refer to SDS, EM-106.
2. Install pistons with connecting rods.
(1) Install them into corresponding cylinder using Tool.
lBe careful not to scratch cylinder wall with connecting
rod.
lInsert the connecting rod. Do not allow the larger end to
touch the oil jet.
lApply engine oil to cylinder wall, piston and bearing.
lThe leaf type combustion chamber on piston head must
be at right side of engine.
(2) Install connecting rod bearing caps.
SEM675B
SEM677B
SEM063
DEM056.DEM056
SEM678B
ENGINE OVERHAULTD
Assembly (Cont'd)
EM-88

3. Measure connecting rod side clearance.
Connecting rod side clearance: mm (in)
Standard
0.10 - 0.22 (0.0039 - 0.0087)
Limit
0.22 (0.0087)
If beyond the limit, replace connecting rod and/or crank-
shaft.
GEAR TRAIN
1. Set No. 1 piston at TDC on its compression stroke.
2. Align each gear mark and install gears.
TIMING GEAR CASE
Installation
1. Before installing timing gear case, remove all traces of liquid
gasket from mating surface using a scraper.
Also remove traces of liquid gasket from mating surface of
front plate.
2. Apply a continuous bead of liquid gasket to mating surface
of timing gear case and dust cover.
SEM488
DEM016
MEM120A
MEM121A
ENGINE OVERHAULTD
Assembly (Cont'd)
EM-89