1984 Nissan 300ZX EM
User Manual: EM
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ENGINE MECHANICAL I SECTION EM E CONTENTS ENGINE COMPONENTS -Outer PartsCOMPRESSION PRESSURE . EM- 2 .. .. EM- 5 TIMING BELT CYLINDER HEAD EM- 4 . EM-11 OIL PAN EM-23 OIL SEAL REPLACEMENT EM-24 ENGINE REMOVAL ENGINE OVERHAUL SERVICE DATA AND SPECIFICATIONS EM-25 SPECIAL SERVICE TOOLS EM-26 (S D S ) ... EM-35 EM43 ENGINE COMPONENTS -Outer Parts- SEM234A EM-2 - D C on YL I istributar gear position .. ... Turbocharger assembly/ Use new gaskets, O-rings and bronze washers 0 Tighten collector and collector cover as shown to the right Loosen them in reverse order of removal As for tightening order of exhaust manifolds and collector, refer to Cylinder Head 0 w VI P 0 N rn Ikgrn,ft-lbl After twhtentng nu;, bend lock washers Use new lack washers Collector cover I I COMPRESSION PRESSURE Measurement of C 1 2 npression Pressure Warm up engine Remove all spark plugs Use a suitable plug wrench shown below. Wrench with a magnet to hold spark plug 16 mm ( 0 63 in) / - SEM294A 3 Attach a compression tester SEM237A 4 Depress accelerator pedal t o fully open throttle. 5 Crank engine and read gauge indication Compression pressure: kPa (kg/cm*, psi) a t rpm Standard Non-turbo 1,196 (12.2, 173)/300 Turbo 1,138 (11.6, 16511300 Minimum Non-turbo 883 (9.0,128)/300 Turbo 834 (8.5,121)/300 Differential limit between cylinders: 98 (1.0. 14)/300 EM-4 I f cylinder compression in one or more cylinders is low, pour a small amount of engine oil into cylinders through the spark plug holes and retest cornpression If adding oil helps the compression pressure, chances are that piston rings are worn or damaged. If pressure stays low, valve may be sticking or seating improperly If cylinder compression in any two adjacent cylinders is low, and if adding 011 does not help the compression, there i s leakage past the gasketed surface TIMING BELT Timing belt a Ensure timing belt IS clean and free from 011 or water b Before installing timing belt, confirm that No 1 cylinder 86 set at T 0 C on compression stroke c Align arrow on timing belt forward d Adlust belt tenrian with all plugs removed and both rocker shafts loosened completely e Align white lines on timing belt with punch mark on camshaft pulleys and crankshaft Pulley Rear belt cover Cylinder block \ %, , m 7 8 - 8 8 1 8 0 - 9 0 . 5 8 65) Conical washer Belt tensloner nut 4 3 - 5 8 ( 4 4 - 5 9 . 3 2 - 431 Front upper belt cover 3 - 5 10 3 0 5 . 2 2 361 to threads of c o m a Belt tensioner Front lower belt cover -4 Timing belt plate Crank pulley plate 123.132 1125.135.90.98) \Crank m pulley N m (kg-m, ft-lbl SEM238A Ren Non-turbo model Air conditioner cammessor 7 Turbo model Air conditioner comoressor 7 After removing cylinder head, do not rotate crankshaft and camshaft separately, because valves will hit piston heads 1 Remove radiator shroud, fan and pulleys Refer t o Cooling System-Radiator (Section LC). 2 Drain coolant from radiator and remove water pump hose Be careful not t o attach coolant t o drive belts 3. Remove the following belts Power steering drive belt Compressor drive belt Alternator drive belt f- Alternator EM-5 SEMZ39A 9-w3 ilaq 6 u i u i i aAouai uaqi Guilds u i n i a i pue lauoisuai ilaq 6uiluii uasool '9 'siaho3 ilaq lam01 pue laddn 1uoi4 anouau 5 1138 9NIWIl TIMING BELT Inspection Visually check t h e condition of the timing belt Replace if any abnormality IS found Item to check Belt is Cause Problem Improper handling broken Poor belt cover sealing Coolant leakage a t water pump SEM393A Camshaft jamming Tooth is broken1 tooth root i s cracked Distributor jamming Damaged camshaftlcrankshaft oil seal SEM394A Tensioner jamming Back surface i s crackedlworn Overheated engine Interference with belt covei SEM395A EM-7 TIMING BELT inspection (Cont'd1 Cause Problem Item to check Improper installation of belt Side surface is worn Malfunctioning crank pulley plateltiming belt plate 0 Side surface of belt i s worn to such an extent that there is no trace of cutoff performed during manufacturing process 0 Belt corners are worn and round 0 Wicks are frayed and coming out * ~ ~ ~ ~ ~ * Poor belt cover sealing Teeth are worn 0 Coolant leakage a t water pump 0 Camshaft not functioning properly 0 Distributor not functioning properly 0 Excessive belt tension 0 Poor oil sealing of each oil seal 0 Coolant leakage at water pump 0 Poor belt cover sealing Canvas o n tooth face is worn down 0 Canvas o n tooth is fluffy, rubber layer is worn down and faded white, or weft IS worn down and invisible SEM397A ~~~ OiVCoolant or water is stuck t o belt EM-8 TIMING BELT 1 Confirm that No. 1 cylinder i t s compression stroke. IS set a t T D C on Rear . . belt cover Aligning marks I I 7 / \ 4 Set timing belt a. Ensure timing belt is clean and free from oil or water Do not bend it Align white lines on timing belt with punch mark on camshaft pulleys and crankshaft pulley. Have arrow on timing belt pointing toward front belt covers b Al~gntngmarks C Aligning marks 7 = + = = i i ~ $ A l t g n ! n g o,ipump Crank pulley (Inner) A - Aligning marks marks No 1 cylinder at IOP dead center in compression stroke SEM241A 2 Remove both rocker covers and loosen all rocker shaft securing bolts Loosen all rocker shaft securing bolts thoroughly so t h a t timing belt tension can be adjusted correctly. 3 ~ncompression stroke SEM242A 5 Install tensloner and return spring Slowly turn tensioner with hexagon wrench clockwise and counterclockwise two or three times Arrow A SEM243A If coarse stud IS once removed, apply locking sealer to threads of stud before installing SEM244A 6 Tighten tensioner lock nut ps1 . EM-9 43-58N.m (4 4 - 5.9 kgm, 32 - 43 ft-lb) TIMING BELT Installation (Cont'd) 7 Tighten rocker shaft securlng bolts in two or three stages. L H rocker shafts n 18-22N.m Intake manifold ride (1.8-2.2kg-m, 13-16ft-lb) R H. rocker shafts Exhaust manifold side SEM245A Before tightening, be sure to set camshaft lobe at the position where lobe IS not lifted. Intake 8 Install lower and umer belt covers Belt cover front (upper) I 9 Belt cover (rear) , BOli c 14 PSI I I 0 Belt cover front (lower) SEM: .EA EM-I0 CYLINDER HEAD m l . 3 I O 1 - 0 3,O 7 . 2 2)- L H rocker cave! (1 8 - 2 2.13 - 161 Valve hfter guide Cylinder head bolt Tbghten them in 5 Valve spring retainer 2nd Tighten them to 59 N m 16 0 kg-m. 43 ft-lbl 3rd Loosen them completely Valve outer spnng Valve inner spring Valve oil seal 0 1 1 idler cap Outer spring seat Exhaust valve n - 78 88 (8 0 . 9 0 . 5 8 . 6 5 ) ~ s w i t h i nthe specification 0 When installing sliding parts such as bearings, be sure to apply engine oil on the sliding surfaces Use new gaskets and oil seals N rn l k g m , f t - l b ) SEM250A EM-I1 CYLINDER HEAD Rer To facilitate removal of both cylinder heads, it is advisable t o dismount the engine as a unit in advance. 1 val 4 Remove power steering pump bracket Remove timing belt. Set No 1 cylinder a t T D C on its compression stroke After removing cylinder head, do not rotate crankshaft and camshaft separately, because valves will h i t piston heads. 2 Remove collector cover and collector Before removing collector, be sure to drain coolant removing drain cocks in cylinder block SEM253A 5 Loosen in numerical order and tighten m reverse order of removal 3 Remove intake manifold with assembly. I II SEM251A fuel tube Remove exhaust manifold covers SEM297A 6 Disconnect exhaust manifold connecting tube Loosen m numerical order SEM252A EM-I2 SEM298A CYLINDER HEAD Removal (Cont’d) 7. Remove camshaft pulleys and rear timing cover securing bolts. 8 Remove compressor and rocker covers 1. Remove exhaust manifold. R.H exhaust manifold L.H exhaust manifold No 2 9. Remove cylinder head with exhaust manifold NO 1 NO 3 No4 No6 ~ a o s e nan numerical order NO 5 2 SEM536A Remove rocker shafts with rocker arms. The bolts should be loosened in two or three Stages. SEM258A EM-I3 CYLINDER HEAD Inspection Disassembly (Cont'd) 3 Remove hydraulic valve lifters and lifter guide CAMSHAFT END PLAY a. Hold hydraulic valve lifters with wire so that they will not drop from lifter guide. Camshaft end play 0 03 - 0.06 mm (0.0012 - 0 0024 in) b. Do n o t put hydraulic valve lifters upside down, otherwise air will enter valve lifter, causing it t o make a noise. c. Do not disassemble hydraulic valve lifter. d. Put identification mark on valve lifters not to avoid mixing them up. 4. End ~ l a v Remove camshaft , Camshaft Locate p l a t e SEM260A If camshaft end play exceeds the specified limit, select thickness of cam locate plate so that end play is within the specification. SEM259A Identjfication mark C Unit mm im) EM-I4 No ldentification mark A Punched identif cation mark SEM26lA CYLINDER HEAD Inspection (Cont'd) Example When camshaft end play is 0 08 mm (00031 in) with shim @ used, change shim @ t o shim @ so that camshaft end play is 0 05 mm (00020 in) VALVE GUIDE CLEARANCE Valve guide clearance should be measured parallel with rocker arm (Generally, a large amount of wear occurs in this direction.) Stem t o guide clearance: Maximum limit 0 10 m m (0.0039in) Maximum allowable deflection (Dial indicator reading) 0.2 mm ( 0 008 in) CYLINDER HEAD DISTORTION Measuring points SEMZ63A Replacement SEM262A If beyond the specified limit, resurface it Replace valve and/or valve guide 1 To remove valve guide heat cylinder head t o 150 t o 160°C (302 t o 320°F) and drive out valve guide with a press [under a 20 kN (2t, 2 2 US ton, 2 0 Imp ton) pressure] or hammer, and suitable tool Resurfacing limit. The resurfacing limit of cylinder head IS determined by the cylinder block resurfacing in an engine Amount of cylinder head resurfacing is " A ' Amount of cylinder block resurfacing is " B The maximum limit is as follows: A + B = 0.2 mm (0.008 in) SEMOOBA EM-I5 CYLINDER HEAD 4 Ream valve guide Finished size: Intake 7 000 - 7 018 mm (0.2756 - 0.2763 in) Exhaust 8.000 - 8.018 rnrn (0.3150 - 0.3157 in) SEM264A 2 Ream cylinder head valve guide hole Valve gwda hole inride diameter Intake11 175-11 196(04400-04408) Exhaust 12175-12196(04793-04802~ , , SEM272A VALVE INSERTS Check valve inserts for any evidence of pitting a t valve contact surface, and reseat or replace if worn out excessively When repairing valve inserts, check valve and valve guide for wear beforehand. I f worn, replace them. Then correct valve seat. The cutting should be done with both hands for uniform cutting. 3. Heat cylinder head t o 150 t o 160°C (302 t o 320°F) and press service valve guide onto cylinder head Replacement If necessary, replace valve inserts as follows. 1 After removing valve insert, ream the cylinder head recess 2. Heat cylinder head t o a temperature of 150 t o 160°C (302 t o 320°F) 3 Press fit insert until it seats on the bottom, and caulk more than 4 points 4. Cut or grind valve inserts using suitable tool a t the soecified dimensions as shown in S D.S SEMt71A E M - I6 CYLINDER HEAD VALVE DIMENSIONS Check dimensions in each valve. For dimensions, refer to S D S When valve head has been worn down t o 0 5 mm (0.020 in) in margin thickness, replace the valve. Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or less T (Margin thickness1 4iSEM265A 5 After cutting, lap valve inserts with a lapping 6 compound Check contact condition of valve inserts * F- SEM188A CAMSHAFT JOURNAL CLEARANCE Wear limit 0.15 mm (0.0059 in) VALVE SPRING SQUARENESS Out of square Outer Less than 2.2 mm (0.087 in) Inner Less than 1.9 mm (0.075 in) Standard mxde diameter 47 00 47 025 rnrn - (1 8504. 1.8514 m) SEM288A VALVE SPRING PRESSURE LOAD REfer to S.D SEMZ67A EM-I 7 S CYLINDER HEAD Inspection (Cont'd) HYDRAULIC VALVE LIFTER 1 Check contact and sliding surfaces for wear or scratches. Install outer valve spring (uneven pitch type) with i t s narrow pitch side toward cylinder head side Install valve component parts. #T &+ SEMZBOA SEM052 2 3 If valve lifters are noisy, check valve lifter (1) Depress plunger forcibly with your finger Wide pitch 4 Install camshaft Apply engine oil t o camshaft oil seal and install it in place Adjust camshaft end play with locate plate installed If it moves about 1 mm (0.04 in), it indicates air is inside valve lifter (2) Re-install rocker arm and rocker cover. (3) Bleed air by running engine a t 1,000 rpm under no-load for about 10 minutes. (4) Next, remove rocker cover and rocker arm and check to ensure all air IS bled. (Refer t o step (1) above) (5) If there is still air, replace valve lifter. E M - I8 CYLINDER HEAD 1 Before installing cyllnder head, make sure that No 1 cylinder is set a t T D C on i t s compression stroke as follows (1) Crankshaft timing pulley mark should be aligned with mark on oil pump housing CgF 3. Tighten cylinder head bolts with washers using ST10120000. Tightening order R H side No 1 No 3 NO 5 L.H side SEM278A (2) Have knock pin in front end of camshaft facing upward Knock pin No 2 No 4 No 6 SEMSSSA Tightening procedures 1st 2nd 3rd 4th Do not rotate crankshaft and camshaft separately, because valves will hit piston heads. 2 Install cylinder head with new gasket 5th Tighten all bolts t o 29 N.m (3 0 kg-m, 22 ft-lb) Tighten all bolts t o 59 N m (6 0 kgm, 43 ft-lb) Loosen all bolts completely. Tighten all bolts t o 29 N m (3.0 kg-m, 22 ft-lb) Tighten all bolts to 54 to 64 N m (5.5 t o 6.5 kg-m, 40 to 47 ft-lb) or if you have an angle wench, turn all bolts 60.65 degrees clockwise After engine has been operated for several minutes, retighten if necessary. EM-19 CYLINDER HEAD Installatic 4 Tighten rear timing cover. 5 Install camshaft pulleys PJ) . (Cont'd) 6 7 8 Camshaftpulley. 78.88 N m (8.0 - 9 0 k g m , 58 - 65 ft-lb) Assemble valve lifters to their original position and hold all valve lifters with wire SEM305A R H. camshaft pulley and L.H. camshaft pulley are different parts. Be sure t o install them in the right positions. L A SEM303A Identification mark R H camshaft pulley L H camshaft pulley Install timing belt and adjust belt tension Install front upper and lower belt covers Install valve lifters and lifter guide 0'53' -3'27' EM-20 -. SEM280A CYLINDER HEAD Installation (Cont'd) 9 Install rocker shafts with rocker arms a n d tighten rocker shaft securmg bolts R H rocker shafts in two or three stages Exhaust manbfald side rn m iNo3 Rocker shaft direction -@7lmHW7 @I ~ l l a . ... Intake manifold side L H rocker shafts intake manifold ride Exhaust manifold ride SEM281A 10 Install rocker cover Confirm rocker cover bolts, washers and trays are free from oil. 11 Install intake m a n i f o l d a n d fuel tube Tighten in two or three stages. . Nut 1st 2nd Bolt 1st 2nd 3-5N.m (0.3 - 0.5 k g m , 2.2 - 3.6 ft-lb) 24-27N.m (2.4 2.8 k g m , 17 - 20 ft-lb) - Tighten In numerical order SEM529A 3-5N.m (0.3 - 0.5 kgm, 2.2 3.6 ft-lb) 24-27N.m (2.4 2.8 kgm, 17 - 20 ft-lb) - - EM-21 CYLINDER MEAD Installation (Cont'd) 12 Install exhaust manifolds and connecting tube R H exhaust manlfold No 5 No 3 No 1 L H exhaust manifold No 2 NO 4 No 6 Tighren m numerical order SEM535A 13 After assembling all disassembled parts, fill radiator with coolant up to the specified level Refer t o Changing Engine Coolant (Sections MA and LC) EM-22 OIL PAN Ren 1 2 INSTALLATION Drain engine oil Raise vehicle and support it with safety stands . I 1 Apply sealant ” A\ 011 Seal Sealant 3 4 5 6 7 8 9 10 11 12 13 14 15 Remove front stabilizer bar securing bolts and nuts from suspension crossmember Remove steering column shaft from gear housing Remove tension rod securing nuts from transverse link Lift engine Remove rear plate cover from transmission case Remove oil pan securing bolts Remove suspension crossmember securing bolts Remove strut mounting insulator securing nuts Remove screws securing refrigerant lines and power steering tubes t o suspension crossmember Lower suspension crossmember Remove oil pan from rear side Remove oil strainer from oil pump assembly and cylinder block. Remove oil pump assembly 2 m 106-07.43 5 1 N rn Ikg-m, ft-lbl I 1 2 . 1 6 . 9 - 121 SLC547 EM-23 reta,ner 7 SEM542A Install oil pan 5-7Nm (0 5 - 0 7 kg-m, 3 6 - 5 1 ft-lb) Tighten !n numerical order SEM543A OIL SEAL REPLACEMENT -Replacement 1 2 3 4 of Camshaft Oil Seal- Remove timing belt Remove camshaft pulleys Remove camshaft oil seal Apply engine oil to camshaft oil seal and install it in place 4 Remove valve oil seals SEM28SA 5 Apply engine oil to valve oil seal and install in place. it SEM284A 5 Install timing belt -Replacement of Valve Oil Seal 1 2 3 Remove collector and rocker cover ( L H only) Remove rocker shaft assembly and valve lifters w i t h valve guide Remove valve springs, retainer and collets SEM286A When installing valve oil seal in exhaust manifold side, tool is not necessary. Valve 011 real- Valve rpr'ng =at SEM257A 1 pi b+ (0.0391 SEM287A EM-24 ENGINE REMOVAL CAUTION. When installing engine gussets, tighten bolts in a. 6 stages as shown below b Before disconnecting fuel hose, release f u e l pressure from fuel line Refer to t h e "Releasing A (Two bolts) Rear plate cover E (i bolt) w0 Fuel Pressure" in section MA A f t e r separating engine and transmission, remove engine from t h e vehicle A t this t i m e use a suitable safety stand such as hydraulic hoist to support transmission Remove R H exhaust manifold and exhaust connecting tube, then separate engine and transmission 1Gusset istarter ridel ,-Gasket SEM54OA Ttghtening order IIt A.1 '1 Exhaust connecting tube L '2 2nd 3rd 41h 5th 61h D'2 A'2 F'Zand G.2 E.2 8'2 and C'2 Toghien temporarity Tqhfen mrnplefely R H exhaust manifold SEM526A. . 4 2 13 2 . 4 3,23- 311 45 - 60 ( 4 6 - 6 1,33.44) 25- 34 ( 2 5 - 3 5 . 1 8 - 25) N rn (kg-m. ft-lbl SEM307A EM-25 ENGINE OVERHAUL - PISTON AND PISTON PIN CLEARANCE PISTON AND CRANKSHAFT 1 Inspection Confirm the fitting of piston pin into piston pin hole to such an extent that it can be pressed smoothly by finger a t room temperature Place engine on work stand KL. 10106500 Piston pin t o piston clearance: 0 008 - 0.012 mm (0.0003 - 0.0005 in) SEM308A 2 3 4 5. 6 7 8 Remove timing belt Drain coolant and remove water pump Drain oil Remove oil pan and oil pump Remove cylinder heads Remove pistons Remove bearing cap and crankshaft \ SEM312A PISTON RING SIDE CLEARANCE Side clearance: Top ring 0 040 - 0.073 mm (0 0016.0.0029 in) 2nd ring 0.030 - 0.063 mm (0.0012.0.0025 in) Oil ring 0.015 - 0.190 mm (0.0006.0.0075 in) Max. limit of side clearance (Top and 2nd rings) 0 1 mm (0.004 in) Loosen numerical order y- Thickness gauge I SEM3llA SEM313A EM-27 ENGINE OVERHAUL Inspection (Cont'd) PISTON RING GAP Ring gap: Top ring 0 21 - 0 44 mm (0 0083 - 0.0173 in) 2nd ring 0.18 - 0.44 mm (0.0071 - 0.0173 in) Oil ring 0 20 - 0.76 mm ( 0 0079 0.0299 in) - ' I yic--J / EM142 Method B Main bearing 1 2 SEM314A Install main bearings to cylinder block and main bearing cap Install main bearing cap to cylinder block Tighten all bolts in correct order and in two or three stages : BEARING CLEARANCE Bearing clearance: Main bearing 0.028 - 0.055 mm (0.0011 0.0022 in) Limit 0.090 mm (0.0035 in) Connecting rod bearing 0.010 .0.052 mm (0.0004 0.0020 in) Limit 0.090 mm (0.0035 in) 3 ~ ~ Method A CAUTl ON : 8 Do not turn crankshaft or connecting rod while the plastigage is being inserted. When bearing clearance exceeds the specified limit, ensure that the proper bearing has been installed. Then if excessive bearing clearance exists, use thicker main bearing or undersized bearing so that the specified bearing clearance is obtained. EM-28 90-l00Nm (9.2 - 10 2 kg-m, 67. 74 ft-lb) Measure inside diameter "A" of main journal ENGINE OVERHAUL Inspection (Cont'd) 4 Measure outside diameter in crankshaft "B" of main journal CRANKSHAFT INSPECTION 1 2 Check crankshaft journals for score, bias, wear or cracks If faults are minor, correct wlth fine crocus cloth Check journals with a micrometer for taper and out-of-round. Out-of-round (X-Y): 0 006 mm (0.0002 in) Taper (A-B). Less than 0.006 mm ((LO002 in) SEM506A 5 Calculate main bearing clearance Main bearing clearance =A-B U Connecting rod bearing 1 2 p-l 3 Install connecting rod bearing t o connecting rod and cap Install connecting rod cap t o connecting rod a 44-54N.m (4.5 - 5.5 kg-m, 33 40 ft-lb) - Measure inside diameter "C" of bearing When regrinding crank pin and crank journal, measure "L" dimension in fillet roll. Make sure the measurements exceed the specified limit. If the measurements are within the specified limit, do not regrind L. More than 0.13 mm (0.0051 in) I SEM507A W 4 Measure outside diameter "D" of connecting rod bearing in crankshaft. Calculate connecting rod bearing clearance Connecting rod bearing clearance =C-D 04 .@-@ SEM316A A 5 Taper Outuf-round SEMl84A b. Do not grind off fillet roll. c Refer to S.D.S for regrinding crankshaft and available service parts EM-29 ENGINE OVERHAUL Inspection (Cont'd) Amount of cylinder head resurfacing is "A" Amount of cylinder block resurfacing IS "B" The maximum limit is as follows. A + B = 0.2 mm ( 0 008 in) CRANKSHAFT RUNOUT Check crankshaft runout Runout fT I R (Total indicator Reading11 Less than 0 10 rnrn IO 0039 in1 Using a bore gauge, measure cylinder bore for wear, out-of-round or taper Standard inside diameter. 87.00 87.05 mm (3.4252 - 3 4272 in) Wear limit: 0.20 mm (0.0079 in) Out-of-round (X-Y) limit: 0.015 mm (0.0006 in) Taper (A-B) limit: 0.015 mm (0.0006 in) - SEM318A CYLINDER BLOCK DISTORTION AND WEAR Warpage of plrfam Less than 0 1 rnm ( 0 SEM3tSA If beyond the specified limit, resurface it. Unit Resurfacing limit. The resurfacing limit of cylinder block is determined by the cylinder head resurfacing in an engine. mrn I d SEM321A Check for scratches or seizure If seizure is found, hone it. Never bore it. I f wear exceeds the specified limit, replace cylinder block. EM-30 ENGINE OVERHAUL Inspection (Cont’d) 0 If either cylmder block or plston is replaced with new one, select the same piston as plston grade number punched on cylinder block upper surfaces. Piston orade number and ring set SEM557A PISTON TO CYLINDER WALL CLEARANCE 1 Measure piston diameter 2 Check that piston clearance specification IS withln the Piston clearance 0.025 - 0 045 mm (0.0010 - 0.0018 in) EM-31 ENGINE OVERHAUL Assernbly Inspection (Cont'd) PISTON PISTON-TO-CYLINDER CLEARANCE (Using feeler gauge) a. When pulling feeler gauge straight upward, measure t h e extracting force It IS recommended that piston and cylinder be heated t o 20°C (68°F) Feeler gauge thickness: 0.04 mm (0.0016 in) Extracting force. 2.0 - 14.7 N (0 2 - 1 5 kg, 0 4 - 3.3 Ib) Numbers are stamped on the connecting rod and cap corresponding t o each cylinder'. Care should be taken t o avoid a wrong combination including bearing. b. When pressing piston pin in connecting rod, apply engine oil t o pin and small end of connecting rod. n 10300 SEM32SA 5EM324A CRANKSHAFT Set main bearings in the proper position on cylinder block 1 FLYWHEEL RUNOUT Runout (Total indicator reading). Less than 0 15 mm (0.0059 in) Upper main bearmg Dial gauge A No 1. * With 081 groove Lower main bearing No 4 SEM327A Install ring on flywheel, heating ring gear t o about 180 to 220°C (356t o 428°F) EM-32 ENGINE OVERHAUL :Cont'd) 2 If either crankshaft, cylinder block or main bearing is reused again, it IS necessary t o measure main bearing clearance. If all of crankshaft, cylinder block and main bearing are replaced with new ones, it IS necessary t o select thickness of main bearings as follows a Grade number of each cylinder block main journal is punched on the respective cylinder block No 1 ioumal No 4 No 2 NO 3 p/ c Select suitable thickness of main bearing according t o the following table Main journal grade number Main bearing grade number Crankshaft journal grade number 1 1 2 3 2 2 3 4 For example Main journal grade number 1 Crankshaft journal grade number 2 Main bearing grade number = 1 + 2 =3 W Main bearing: Refer t o S.D.S. SEM508A b Grade number of each crankshaft main journal is punched on the respective crankshaft 3 Install main bearing cap and tighten bolts t o the specified torque . 9 0 - 100N.m (92 - 10 2 kg-m, 67 - 74 ft-lb) Tighten in two or three stages SEM510A After securing bearing cap bolts, ascertain that crankshaft turns smoothly by hand. EM-33 ENGINE OVERHAUL Assernbll 4 6 install piston assembly Measure connecting rod clearance Connecting rod clearance: Standard 0.20 - 0.35 m m (0.0079 - 0 0138 in) Limit 0.40 mm (0.0157 in) Set piston rings as shown below. ton pin direcrion Thrust direction SEM180A Mark should be faclng upward 5. Measure crankshaft free end play at No 4 bearing Crankshaft free end play: Standard 0.05 - 0.17 mm (0.0020 - 0.0067 in) Limit 0.30 mm ( 0 0118 in) SEMSllA EM-34 SEMSlZA SERVICE DATA AND SPECIFICATIONS (S. D.S.) General Specifications Inspection and Adjustment I HEAD - CYLINDER VG30E Unit mrn Id V-6 Cylinder arrangement Displacement cm' lcu in) 8oreandStroke mm (In1 Head surface flatnerr 2.960 1180 621 Standard Limit Less than 0 05 I O 00201 0 1 100041 87 x 83 I 3 4 3 x 3 271 VALVE OHC Valve arrangement 1-2 3 4 - 5 5 Firing order Number of piston rings Compresston T IMargn thtcknerrl 2 I f 1 011 Number of main bearings 4 Camprerrion ratlo Non-turbo 90 Tiirho 78 Valve timing e TDC 2 1 . Engine VG30E Item Valve head diameter "D ' Intake Ethaust Valve length "L' Intake Echaurt 4 2 0 - 4 2 2 I 1 654-16611 35 0 - 3 5 2 I 1 378.1 386) 1 2 5 3 - 125 9 I 4 93 - 4 961 124 2 - 124 8 1 4 8 9 - 4 911 EM120 ~~ BDC Unit degree a b c d e f 252' 252' 20" 52' 16" 62" Valve stem diameter '*d" Intake Exhaust 6 965 - 6 980 IO 2742 - 0 27481 7 945-7 960 103128-031341 Valve seat angle "a" Intake Exhaust Unit kPa lkglcm2, prd/rpm Non-turbo ' ' Standard Minimum ~~~ Differential limit between cylinders I Valve margin "T" Intake Turbo Exhaust 1,1961122,173~ 1.138111 6,1651 883 I 9 0, 1281 /300 1300 98 I 1 0. 141 1300 834 I8 5,121) ~ T O 98 ( 1 0.14) 1300 13100511 1 5 ( 0 0591 Valve margin '7" limit 0 5 10 0201 Valve stem end surface grinding limit 0 2 I O 008) Valve clearance Intake 0 101 Exhaust 0 I01 EM-35 SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and A Valve guide Valve spring Free height Outer 51 2 I 2 0161 l""W 44 9 ( 1 7681 m m (ml Outer Pressure height m m / N lmmlkg, m/lb) l""W mm 30 01523 7 1300/534. 1 181111771 40 O D 5 0 1 ( 4 0 0/255, 1 575/56 21 Inner 350/1206 135 0/12 3, 1 378/27 11 Outer 2 2 (00871 Inner 1 9 10 0751 Service Intake 11023-11034 104340 043441 11223 11234 (04418-04423) Exhaust 12 023 - 12 034 (04733.04738) 12 223.12 234 104812 04817) Outer diameter Valve guide Inner diameter [Finished Intake 7 000-7 018 10 2756.0 27631 rml Exhaust 8 000 - 8 018 (03150.031571 (in) Cylinder head Intake valve gwde hole diameter Exhaust Hydraulic valve lifter Unit m m (in1 Lifter outride diameter 1 5 9 4 7 - 15 957 I O 6278 - 0 62821 Lifter guide inside diameter 16 000 - 16 013 (06299 - 0 63041 Clearance between lifter and lifter guide Standard Valve guide 24 51250 1 (24 5/25 5, 0 965/56 21 Outer Assembled heioht mm/N lmm/kg, d l b l Out of square Jstment (Cont'd) 0 043.0066 10 001 7 . 0 00261 Interference f t t of valve guide 10975-10996 IO4321 -043291 11 175 11 196 104400 044081 11 975 11 996 104715-047231 12175 1 2 1 9 6 (04793-04802) 0 027 - 0 059 I O 0011 0 00231 Intake 0 027 - 0 059 (0001 1 - 0 00231 Exhaust Standard Stem t o gu& clearance Intake limn EM-36 0 020.0 053 (00 0 0 8 ~ 0 00211 0 1 (0004) Exhaust Valve deflection Max tolerance O M 0 -0073 (00016 - 0 0029) - 0 2 10 0081 SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and P ustment (Cont'd) CAMSHAFT AND CAMSHAFT BEARING Valve seat Unit EXHAUST mm (in1 I 3 4 4 - 34 6 I 1 354. 1 3621 dia Standard Max tolerance Camshaft Journal to bearing clearance Ogo I O 0018.0 00351 0 15 IO 00591 Inner diameter of cam,,haft bearing 47 00.47 025 I1 8504 185141 - Outer diameter of camshaft ioumal 46 935.46 955 I1 8478.1 84861 Camshaft runout LT 113.1 Less than 0 02 I O 00081 01 I O O M I SEM533A Camshaft INTAKE 0 0 3 006 I O 0012.0 00241 I1 638. 1 6461 dia - EM671 45 I 1 77) dia Cam height "A" unit Intake mm Iinl Exhaust SEM534A Wear limit of cam height 'Total mdtcator reading EM-37 39 607 - 39 657 I 1 5593 1 56131 0 15 (000591 SERVICE DATA AND SPECIFICATiBNS (S. D.S.) inspection and f ustrnent (Cont'd) PISTON, PISTON RING AND PISTON PIN CYLINDER BLOCK m m Iinl Unit Available piston Unit m m ( i n ) % SEM321A Surface flatness Standard Less than 0 03 10 00121 Cvlmder bore Inner diameter Standard Grade NO Grade NO Grade N o GradeNo GradeNo Model 0 10 I O 00391 Limit Non-turbo 1 2 3 4 5 0 02 10 WO81 overs1ze ISerwceI GradeNo 3 GradeNo 4 GradeNo 5 GradeNo 6 GradeNo 7 Wear limit 870W-87010(34252.342561 87 010 - 87 020 (3 4256.3 42601 87 020 - 87 030 13 4260.3 42641 87 030 - 87 040 13 4264.3 4268) 87 040 - 8 7 050 13 4268 3 42721 87 87 87 87 87 020.87 030 13 4260.3 030 - 87 040 13 4264 .3 040.87 050 13 4268.3 050.87 060 13 4272.3 060 - 87 070 13 4276.3 PlLtO" skirt dimeter ',A" 42641 42681 42721 42761 4279) Standard GradeNo 1 GradeNo 2 Grade NO 3 Grade N o 4 Grade N o 5 86 965 - 86 86 9 7 5 . 8 6 86 985 85 86 995 - 87 87 005 - 87 975 13 4238 3 42421 985 13 4242.3 42461 995 13 4246.3 4250) 005 13 4250.3 42541 015 13 4254 - 3 42581 0 02 I O 00081 oversize ISewiceI GradeNo 3 Grade N o 4 GradeNo 5 Grade NO 6 Grade NO 7 86 985 - 86 86 995 87 87 0 0 5 . 8 7 87 0 1 5 . 8 7 87 025 87 995 13 4246.3 4250) 005 13 4250.3 42541 015 13 4254.3 42581 025 13 4258 3 42621 035 13 4262 - 3 42661 "a" dimension 0 20 10 00791 Outuf-round IX-YI Less than 0 015 10 00061 P i s t o n pin hole diameter Taper IA-E-Cl Less than 0 015 IO OOO6) Ptston clearance to cylinder block Main journal mner diameter GradeNo 0 66 645 -66654 (26238.262421 GradeNo 1 66 654 - 66 663 I2 6242.2 62451 GradeNo 2 66 663.66 672 12 6245.2 62491 Ddfference in inner dnameter between cylinders Standard Wear limit Less than 0 05 10 0020) 0 20 (00079) EM-38 Turbo - 1 200f0787) 21 5108461 21 001 .21 008 IO 8268 .O 82711 0025-0045f00010-000181 SERVICE DATA AND SPEClfflCATlONS (S.D.S.) Inspection and A ustment (Cont'd) CRANKSHAFT Piston ring Unit mm linl Unit m m l i d Main lournel dia "Dm' Limit Standard Side clearance 0040 0073 I O 0016 - 0 0029) TOP 2nd 0 030 - 0 063 I O 0012 0 0025) 081 0015 0190 100006 000751 Ring gap TOP I 021 - 0 4 4 I O 0083 - 0 01 731 62 967.62 975 12 4790 2 4793) GiadeNo 1 62 959 62 967 ( 2 4787 - 2 47901 GiadeNo 2 6 2 951 .62 959 12 4784.2 47871 0 1 10 004) P~niournal dla "DP" - 1 49 961 49 974 ( 1 9670 - 1 96751 Center distance "r" 38 0 I 1 4961 Out of round ( X - Y l Standard Less than 0 006 I O 0002) Taper IA-Bl Standard 2nd 041 Ira11 rlngl GiadeNo 0 Runout IT I R Standard 0 20-0 7 6 10 0079 0 0299) 0 006 I O 00021 1 Less than 0 1 0 10 00391 Free end play 0 05.0 17 (00020 - 0 00671 Standard 0 3 0 10 01 181 Llrnlt Piston pin Unit m m l i d Piston pin outer diameter 20 993 - 20 998 10 8265.0 82671 Plrton pm t o prston clearance 0008.0012 100003 00005) Interference f i t of piston pin t o connecting rod 0022 0040 I O 009 - 0 00161 n OP Out-of-round Taper CONNECTING ROD Unit Center distance Bend. tonion [per 100 13 941 1 Limit Piston pin bore dia SEM645 X Y A.B m m lid 15410-15420 16 0669 - 6 07091 0 10 I O 00391 20 958.20 971 (08251 - 0 82561 EM715 Big end play Standard 0 20.0 35 I O 0079 - 0 01381 Ltmit 0 6 I O 0241 EM-39 (ZZLO 0. OZLO 01 &&8 1 - 628 L FOdZO 6CZZ1 Mollah l&ZLO 0. ZZLO 01 L E 8 1 - &E8 1 WdZO-6EZZL an18 ~LLLOO-91LO01 128 L - LL8 L OOdZO-6CZZ L 3114M (6LLOO-LLLO01 5 Z 8 L - 17.8 1 LOdZO GCZZL uMoJ8 (OZLO 0 - 6LLO 01 628 1 .928 L ZO~Z~SEZZL uaaa 18bL 01 6L (an0016 110 inoqiiM) 6ui~eaquiew & pue & (CZLO 0. ZZLO 01 L E 8 1 &&8 1 COdZO-SLZZL Mollah WdZoSLZZL anin OOdZOEZZZL WrlM LOdZOEZZZL UMoJ8 ZOdZOEZZZL u a w (ZZLO 0. OZLO 0) &E8 1 .628 I COdZO-EZZZL MollaA - wdzo-&zzzt anis uaar3 ZOdZOSLZZL UMoJ8 allqM z 'ON & (98801 l O Z L O O - 6 L L O O ) pz2 628 Sz8, (6LLOO-LLLO01 528 1 . 128 L (LLLOO 5LLOO) 1 2 8 1 L18L (CZLOO Z Z L O 0 1 L E 8 L .CE8 1 (ZZLO 0 - OZLO 01 &E8 1 .628 L (98801 z2 & , ~OZLOO-6LLOOl 6z8 .8z8 (6LLOO'LLLOOl 5 2 8 1 . 128 L LOdZO-51ZZ1 (LLLOO-91LOO~ 128 L - L18 1 OOdZO-81ZZL V'LZEW3S b ON Z ON 1 ON SERVICE DATA AND SPECIFICATIONS (S.D.S.) Inspection and A AVAILABLE CONNECTING ROD BEARING No. 4 main bearing (With oil groove) Grade number Thickness '7 mm I d 1 2 Identrf!catmn Part number Color 12247 02POO White 821 IO0717 007191 12247-02POl Brown 829 100719-00720 12247-02PO2 Green 12247-02PO3 Yellow 12247-02PM Blue 100715 007171 833 100720 007221 833 837 100722 007231 istrnent (Cont'd) Connecting rod bearing undersize - Unit mm Ion1 Crank pin journal diameter "Dp" Standard 49 961 - 49 974 ( 1 9670 - 1 96751 Under size 0 08 I O 00311 0121000471 0 25 (000981 49 881 49 894 I 1 9638.1 96431 49 841 49 854 ( 1 9622 - 1 96281 49711 4 9 7 2 4 1 1 9 5 7 1 - 1 9 5 7 6 1 MISCELLANEOUS COMPONENTS Unit mm I d Flywheel Runout I T I R No. 4 main bearing (Without oil groove) Grade number Thickness "T" mm 11nI Part number 821 100715 007171 1225502POO 1 Less than 0 15 I O 00591 Identification Color White Bearing clearance -~~ Unit mm 11nI ~ Main bearing clearance ' 825 100717-007191 12255 02P01 Brown Standard Limit I O 0719 - 0 07201 833 10 0720 - 0 07221 833. 837 I O 0722.0 07231 12255-02P02 Green 12255-02PO3 Yellow Connecting rod bearing clearance Standard Limit 12255-02P04 Blue EM-41 0 025 - 0 055 (00010 - 0 00221 0 090 I O 00351 0 010.0 052 I O 0004 0 00201 0 090 I O 00351 SERVICE DATA AND SPECIFICATIONS (S.D.S.) Tig htenii TIGHTENING TORQUE Torque Engine internal parts Engine outer parts Nm kg-m Nm kq-m ft-lb ft-lb Rocker cover 1-3 01-03 07-22 Tenrmner nut 43 - 58 44-59 32.43 Collector cover 6 8 06-08 43-58 Collector 18-22 18-22 13-16 Belt cover 3 5 03-05 22-36 18 22 18-22 13 - 16 Throttle chamber 18.22 18-22 13-16 Rocker shaft E G R control valve 18-22 18-22 13 16 Camshaft pulley 78.88 80-90 58.65 22-29 Cyl~nderhead 54.64 55-65 40 - 47 12-14 Camshaft locate plate 78 - 88 80-90 58.65 17-20 Water pump 16 - 21 16-21 12-15 29.39 30-40 22.29 Intake relief valve 29.39 Intake manifold bolt 16 20 Intake manifold nut 24 - 27 30-40 16-20 24-28 Injector holder 3-5 03-05 22-36 Drain plug Water temperature sensor 15 - 20 15-20 11 14 011 pan 5-7 05-07 36-51 Thermal transmltter 15-20 15-20 11-14 29.39 30-40 22.29 Exhaust manifold 18 22 18-22 13-16 011 strainer regulator valve Plug Exhaust manifold stay 22 - 27 22-28 16-20 Exhaust outlet 25 29 25-30 18 22 E G R tube 34 44 35-45 25-33 Exhaust connecting tube 22 - 27 22-28 16-20 Exhaust gas sensor 40-50 41-51 30-37 Crank pulley 123 132 125-135 90-98 Water mlet 16 - 21 16-21 12-15 Detowtion sensor 25-34 25-35 18-25 Pc v 29-39 30-40 22 29 Dirtnbutor bolt 5-6 05-06 36-43 Alternator adjusting bar 14 - 17 14-17 10-12 5-6 05-06 36-43 WlYe bolt Air regulator 011 strainer bracket 16.21 16-21 12-15 Flywheel 98 - 108 10-11 72 - 80 Rear 011 seal retalner 6 06 43 Connecting rod 44 - 54 45-55 33 .40 Main bearing cap 90 100 92-102 67-74 35-45 25.33 20-30 14 - 22 kg-m ft Water drain plug 34 - 44 Spark plug 20.29 Turbocharger related parts Nm Ib 011 feed tube 15.20 15-20 11-14 011return tube 10-12 10-12 7-9 Turbocharger unlt 44.54 45 EM-42 55 33-40 SPECIAL SERVICE TOOLS Tool number (Kent-Moore No ST0501S000 0ST05011000 ( - - @ - Engine stand Base Engine attachment 1 KVlOllOOOO ( Engine stand assembly 1 0 KV10106500 ( Tool name ) @ ST05012000 ( I - P Sub attachment 1 KV10110600 ) ( KV10107501 I - Valve oil seal drift ) ST10120000 Cylinder head bolt wrench (J25613l EM-43 SPECIAL SERVICE TOOLS Tool number (Kent-Moore No 1 Tool name KVlOllO300 Piston pin press stand assembly ( @ - 1 KV10110310 I @ - KVV0110330 ( - - @ - Drift ) KV10110320 ( Spring ) @ KV10110340 ( Press stand 1 @ ST13030030 ( Spacer ) @ ST13030020 ( Cap ) Center shaft ) EM-44
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File Type : PDF File Type Extension : pdf MIME Type : application/pdf PDF Version : 1.5 Linearized : No Page Count : 44 Page Layout : SinglePage Has XFA : No XMP Toolkit : XMP toolkit 2.9.1-13, framework 1.6 About : uuid:0f912123-36fb-4920-9509-73ad3bb0e850 Producer : Adobe PDF Library 4.0 Keywords : Style : Searchable Image (Exact) Modify Date : 2004:02:06 23:04:19-05:00 Create Date : 2001:04:10 22:59:43-05:00 Metadata Date : 2004:02:06 23:04:19-05:00 Creator Tool : Acrobat Capture 3.0 Document ID : uuid:996a985a-7577-475a-864c-7c8bb03cdb17 Format : application/pdf Title : 1984 Nissan 300ZX Description : Nissan Factory Service Manual Creator : Produced and Digitized by Courtesy Nissan Author : Produced and Digitized by Courtesy Nissan Subject : Nissan Factory Service ManualEXIF Metadata provided by EXIF.tools