Nissan PULSAR N13 Series / ASTRA LD Series. Manual — part 9

37

ENGINE

SPECIFICATIONS

ENGINE ASSEMBLY

Type. . . . . . . . . . . . . . ...4cyl OHC

Models . . . . . . . . . . . . 1.6 liter, 1.8 liter

Capacity:

1.6 liter . . . . . . . . . . . . ... 1 598 cc

1.8 liter . . . . . . . . . . . . ... 1 796 cc

Firing order. . . . . . . . . . . . . .. 1 -3-4-2

Bore:

1.6 liter . . . . . . . . . . . . .. 80.0 mm

1.8 liter . . . . . . . . . . . . .. 84.8 mm

Stroke . . . . . . . . . . . . . . ... 79.5 mm

Maximum compression pressure

variation between cylinders . . . . . . . 100 kPa

NOTE: Specifications regarding engine tun-
ing arc listed in the Engine Tune-up section.

CYLINDER BLOCK

Type. . . . . . . . . . . . . . . 4 cyl in line

Material . . . . . . . . . . . . . . Cast iron

Bore diameter:

1.6 liter . . . ... 79.995-80.065 in three groups

1.8 liter . . . . .84.755-84.905 in four groups

Bore taper limit . . . . . . . . . . . 0.013 mm

Bore ovality limit . . . . . . . . . . 0.013 mm

Block face distortion limit . . . . . . .. 0.10 mm

Maximum height of piston above block
face at top dead centre:

1.6 liter . . . . . . . . . . . . ..0.00 mm

1.8 liter . . . . . . . . . . . . .. 0.50 mm

Bore oversize. . . . . . . . . . . . 0.50 mm

CYLINDER HEAD

Type. . . . . . . . . . ... One piece, cross flow

Material . . . . . . . . . . . Aluminum alloy

Distortion limit . . . . . . . . . . .. 0.025 mm

Machining limit . . . . . . . . . . ... 0.25 mm

Minimum overall height after machining:

1.6 liter. . . . . . . . . . . . .95.50 mm

1.8 liter. . . . . . . . . . . . .94.80 mm

Valve seat angle . . . . . . . . . . ..45 degrees

Valve seat contact width:

Inlet. . . . . . . . . . . . ... 1.0-1.5 mm

Exhaust . . . . . . . . . . . . 1.7-2.2 mm

Valve stem protrusion . . . . . 18.4 mm from top

of cylinder head

Valve guide height . . ..12.2-12.5 mm from top of

cylinder head

VALVES AND SPRINGS

Valve length . . . . . . . . . . . .. 104.2 mm

Valve head diameter:

1.6 liter —

Inlet. . . . . . . . . . . . . . 36.0 mm

Exhaust . . . . . . . . . . . . .. 32.0 mm

1.8 liter -

Inlet. . . . . . . . . . . . . ... 41.8 mm

Exhaust . . . . . . . . . . . . . 36.5 mm

Valve stem diameter:

Inlet. . . . . . . . . . ...6.998-7.012 mm

Exhaust . . . . . . . . . .6.978-6.992 mm

Valve stem to guide clearance:

Inlet. . . . . . . . . . ...0.018-0.052 mm

Exhaust . . . . . . . . . .0.038-0.072 mm

Oversize valve system availability . . . 0.075, 0.150

and 0.250 mm

Valve face angle . . . . . . . . . . . 44 degrees

Valve spring tension:

Valve closed . . . . . . ..300 N at 37.5 mm

Valve open. . . . . . . .765 N at 26.5 mm

TAPPETS

Type . . . . . . . . . . . . . . . .Hydraulic

Operating length . . . . . . . . . . 63.26 mm

Diameter . . . . . . . . . ... 21.392-21.405mm

Leak down rate. . . . 2-10 seconds for 3.175 mm

PISTONS AND GUDGEON PINS

Piston type . . . . . . . . . ... Aluminum alloy

Diameter:

1.6 liter . . 79.955-80.035 mm in 8 categories

in increments of 0.01 mm

1.8 liter . ...84.725-84.885 mm in 16 categories

in increments of 0.01 mm

38

Engine

*Piston skirt to cylinder bore clearance:

1.6 liter . . . . . . . . . .0.020-0.040 mm

1.8 liter . . . . . . . . . .0.010-0.030 mm

Gudgeon pin length:

1.6 liter . . . . . . . . . . . . . .. 53 mm

1.8 liter . . . . . . . . . . . . .. 61.5 mm

Gudgeon pin diameter. . . . .20.990-20.995 mm

Gudgeon pin clearance in piston:

1.6 liter . . . . . . . . . .0.010-0.020 mm

1.8 liter . . . . . . . . ..0.0055-0.0115 mm

Gudgeon pin offset in piston:

1.6 liter . . . 0.35-0.65 mm towards thrust side

1.8 liter . . . . ... 0.8 mm towards thrust side

*Measured 9 mm from the bottom of the piston skirt

for 1.6 liter models and 6 mm from the bottom of the

piston skirt for 1.8 liter models.

PISTON RINGS

Rings per piston:

Compression . . . . . . . . . . . . . ...2

Oil control . . . . . . . . . . . . . . .. 1

End gap:

Compression . . . . . . . . 0.30-0.50 mm

Oil control —

1.6 liter . . . . . . . . . . . 0.33-1.10 mm

1.8 liter . . . . . . . . . . . 0.40-1.40 mm

CONNECTING RODS AND BEARINGS

Connecting rod side clearance. . . 0.07-0.24 mm

Maximum connecting rod weight variation..8 grams
Crankpin bearing oil clearance. ...0.019-0.063 mm

CRANKSHAFT AND MAIN BEARINGS

Number of bearings. . . . . . . . . . . . .. 5

End float taken at . . . . . .. No. 3 main bearing

End float. . . . . . . . . . ..0.070-0.302 mm

Bend limit . . . . . . . . . . . . ...0.03 mm

Main bearing oil clearance . . . .0.015-0.040 mm

Main bearing journal diameter.. .57.982-57.995 mm
Crankpin diameter . . . . . ...48.971-48.987 mm

FLYWHEEL

Ring gear run out limit. . . . . . . . .. 0.3 mm

Clutch face regrind limit . . . . . . . .. 0.3 mm

CAMSHAFT

Drive . . . . . . . . . . . . . ..Toothed belt

End float . . . . . . . . . . . .. 0.04-0.14 mm

Bend limit . . . . . . . . . . . . ... 0.03 mm

Bearings. . . . . . . . . . ...Direct in housing

Journal diameter:

Standard —

No. 1 . . . . . . . . . .42.455-42.470 mm

No. 2 . . . . . . . . . .42.705-42.720 mm

No. 3 . . . . . . . . . .42.955-42.970 mm

No. 4 . . . . . . . . . .43.205-43.220 mm

No. 5 . . . . . . . . . .43.455-43.470 mm

Undersize —

No. 1 . . . . . . . . . .42.355-42.370 mm

No. 2. . . . . . . . . ..42.605-42.620 mm

No. 3 . . . . . . . . . .42.855-42.880 mm

No. 4. . . . . . . . . ..43.105-43.120 mm

No. 5 . . . . . . . . . .43.355-43.370 mm

*An undersize camshaft can be identified by a violet
flash between the inlet and exhaust lobes of No. 2
cylinder.

Housing diameter;

Standard —

No. 1 . . . . . . . . . .42.500-42.525 mm

No. 2 . . . . . . . . . .42.750-42.775 mm

No. 3 . . . . . . . . . .43.000-43.025 mm

No. 4. . . . . . . . . ..43.250-43.275 mm

No. 5 . . . . . . . . . .43.500-43.525 mm

*Undersize —

No. 1 . . . . . . . . . .42.400-42.425 mm

No. 2 . . . . . . . . . .42.650-42.675 mm

No. 3 . . . . . . . . . .42.900-42.925 mm

No. 4. . . . . . . . . ..43.150-43.175 mm

No. 5 . . . . . . . . . .43.400-43.425 mm

*An undersize camshaft housing can be identified by
a violet flash on the centre camshaft bearing support.

LUBRICATION

Oil pump type . . . . . . . . . ...Involute gear

Filter type. . . . . . . . ... Full flow disposable

Oil pressure at 4 000 rpm. . . . . .480-620 kPa

Rotor assembly end float. . . . .. 0.03-0.010 mm

Rotor teeth backlash. . . . . . . 0.010-0.20 mm

TORQUE WRENCH SETTINGS

*Cylinder head bolts:

Initial torque. . . . . . . . . . . . 25 Nm

1st stage . . . . . . . . . . . + 60 degrees

2nd stage . . . . . . . . . . + 60 degrees

3rd stage. . . . . . . . . . . + 60 degrees

4th stage, engine at operating

temperature . . . . . . . .. + 30-50 degrees

Exhaust manifold nuts . . . . . . . . . 22 Nm

Exhaust manifold flange nuts . . . . . . . 22 Nm

Inlet manifold nuts. . . . . . . . . . .. 22 Nm

Throttle body to inlet manifold nuts. . . ..12 Nm

Camshaft liming gear bolt. . . . . . . ...45 Nm

Camshaft retaining plate bolts . . . . . . . 7 Nm

Camshaft cover bolts. . . . . . . . . . . 8 Nm

Thermostat cover bolts. . . . . . . . . 15 Nm

*Main bearing bolts. . . . ..60 Nm + 45 degrees

Connecting rod bearing

cap nuts. . . . . . . . ... 35 Nm + 45 degrees

* Crankshaft timing

gear bolt. . . . . . . . ..145 Nm + 35 degrees

*Flywheel bolts

(microencapsulated) . . . . 60 Nm + 30 degrees

*Drive plate bolts (microencapsulated). . ...60 Nm

Water pump bolts. . . . . . . . . . . 25 Nm

Engine

39

Oil pump cover plate screws. . . . . . . 6 Nm

Oil pump mounting bolts. . . . . . . . .. 6 Nm

Oil pump pickup bolts

(coat with Loctite 242) . . . . . . . . . . 8 Nm

Sump bolts (coat with Loctite 242). . . . .. 5 Nm

Sump drain plug . . . . . . . . . . . ..35 Nm

*Use new bolts
Head bolts maximum torque 135 Nm

1. ENGINE MECHANICAL TROUBLE

SHOOTING

ENGINE MISSES AT IDLING SPEED

NOTE: For other causes of engine misfire,
refer to the Fuel and Engine Management
section.

(1) Blown head gasket: Check the cylinder com-

pressions and renew the head gasket as necessary.

(2) Burnt valves or seats in the cylinder head:

Check the cylinder compressions and overhaul the
cylinder head as necessary.

(3) Broken or worn piston rings: Check the

cylinder compressions and renew the piston rings as
necessary.

(4) Weak or broken valve springs: Remove the

camshaft housing top cover and check the condition
of the valve springs.

(5) Air leak at the inlet manifold gasket; Check

for air leaks by applying oil around the manifold
joints. Renew the gasket if an air leak is evident.

NOTE: Use a compression gauge and check
the compression pressure in each cylinder as
described in the Engine Tune-up section. If
a low pressure reading is indicated in one or
more cylinders, remove the cylinder head for
gasket and valve inspection. Should the

gasket and valves prove satisfactory, inspect
the cylinder bores, pistons and rings.

Check for air leaks at the inlet manifold

by applying engine oil around the manifold
joints. If the oil can be seen or heard sucking
into the manifold or excessive smoke begins
to issue from the exhaust system, there is an
air leak at the inlet manifold.

NOISY VALVE OPERATION

(1) Faulty hydraulic tappets: Renew the faulty

tappet assemblies.

(2) Weak or broken valve springs: Remove the

camshaft housing top cover and check the condition
of the valve springs.

(3) Worn valve guides: Overhaul the cylinder

head as described in this section.

(4) Worn rocker gear: Remove (he rocker gear

and check the components for wear.

Camshaft lobe wear is also a cause of noisy valve

operation.

BIG END BEARING NOISE

(1) Inadequate oil supply: Check the oil level in

the sump and the condition of the oil pump and relief
valve. Renew the oil filter.

(2) Excessive bearing clearance: Renew the bear-

ing shells, check and regrind the big end journals if
oval or tapered.

(3) Thin oil or oil diluted by petrol or water:

Change to the correct oil grade. Check and rectify the
cause of the oil dilution. Check that the engine is not
operating in overheat conditions.

(4) Low oil pressure: Check the engine oil level.

Check the pressure relief valve and spring and the oil
filter bypass valve.

(5) Misaligned big end bearings: Align the con-

necting rods and renew the big end bearing shells.

NOTE: Big end bearing noise is indicated
by a metallic knock which is usually loudest
at approximately 60 km/h with the throttle

Air leaks at the inlet manifold can be located by

applying engine oil around the suspect joints.

40

Engine

Check the engine oil for level and dilution on the

dipstick.

dosed. Before dismantling the engine to
inspect the big ends check the engine oil for
correct level and dilution on the dipstick.
Also, remove the oil pressure sender unit
and connect an oil pressure gauge into the
oil gallery to check the oil pressure readings.

MAIN BEARING NOISE (APPARENT)

(1) Loose flywheel: Tighten the flywheel securing

bolls to the specified torque.

(2) Low oil pressure: Check the bearing to

journal clearance. Check the condition of the oil
pump and pressure relief valve. Recondition the oil
pump as necessary.

(3) Excessive crankshaft end float: Renew the

main bearings.

(4) Crankshaft journals out of round and exces-

sive bearing to journal clearance: Regrind the journals
and renew the bearings (undersize).

(5) Insufficient oil supply: Replenish the oil in

the sump to the correct level.

NOTE: Main bearing noise is indicated by a
heavy but dull knock when the engine is
under load. A loose flywheel is indicated by
a thud or dull click when the ignition is
turned off. It is usually accompanied by
vibration.

Crankshaft end float noise is indicated by

a sharp rap at idle speed. The crankshaft
can be readily checked for excessive end
float by levering the crankshaft backwards
and forwards.

If the oil pressure is not satisfactory,

remove the main bearing caps and assess
the bearing clearance using the Plastigage
method as described in this section. Ovality
and wear on the main bearing journals can
only be checked with a micrometer after the
crankshaft has been removed.

EXCESSIVE OIL CONSUMPTION

(1) Oil leaks: Check and renew the engine gas-

kets or seals as necessary.

(2) Damaged or worn valve stem oil seals:

Dismantle the cylinder head and renew the damaged
or worn oil seals.

(3) Excessive valve stem to valve guide clear-

ance: Ream the valve guides and renew the valves as
necessary.

(4) Worn or broken piston rings: Renew the

piston rings on all pistons.

(5) Rings too tight or stuck in the grooves:

Renew the rings and clean the ring grooves.

(6) Excessive wear in the cylinders, pistons and

rings: Recondition the cylinders and renew the pistons
and rings.

(7) Compression rings incorrectly installed. Oil

rings clogged or broken: Renew the piston rings.

NOTE: Before checking the engine for oil
leaks the engine should be completely de-
greased and cleaned. Run the engine at
operating temperature for a period and
visually check for oil leakage. By placing
white paper on the floor directly beneath the
engine any excessive leak can be readily
pinpointed.

Damaged or worn valve stem oil seals

which allow oil to be drawn down past the
valve stems into the combustion chambers
can be diagnosed by allowing the engine to
idle for a few minutes and then opening the
throttle. If oil is being drawn past the valve
stems a heavy discharge of blue smoke will
be seen at the tailpipe.

Piston, ring and cylinder bore troubles are

normally accompanied by a loss of compres-
sion. Cylinder compression can only be
accurately assessed by using a compression
gauge.

Run the engine over white paper to check for oil leaks.