Nissan PULSAR N13 Series / ASTRA LD Series. Manual — part 15

Engine

61

rear main bearing cap and engine block. Discard the
oil seal.

(3) Ensure that all main bearing and connecting

rod bearing caps are numbered to ensure correct
assembly.

(4) Remove the connecting rod bolts and caps,

keeping them in order. Push each piston and connect-
ing rod slightly up into the bore without pushing the
piston beyond its upper limit.

(5) Check the crankshaft end float by inserting a

feeler gauge between the shaft and the centre main
bearing, or by mounting a dial gauge with its plunger
against one end of the shaft.

(6) Push the crankshaft into contact with the

front edge of the centre main bearing, then lever the
shaft forward to determine the end float.

(7) If the end float exceeds the Specifications,

renew the centre main bearing on assembly.

(8) Check the main bearing clearance by the

Plastigage method as follows:

(a) Remove one bearing cap and with a piece of

rag wipe the journal and bearing clean.

(b) Position a piece of Plastigage, the approxi-

mate length of the bearing width and slightly off
centre, on the bearing surface of the crankshaft
journal.

(c) Install the bearing cap and tighten the cap

bolts to the specified torque.

NOTE: Do not rotate the crankshaft while
the Plastigage is in position.

(d) Remove the cap bolts and carefully detach

the cap and lower half bearing.

(e) With the Plastigage scale, measure the com-

pressed Plastigage strip to determine the clearance.

(f) The widest point of the strip will indicate the

minimum clearance and the narrowest point the
maximum clearance.

(g) The remaining bearings can be checked in

turn using the same procedure.

(9) Lift the crankshaft from the crankcase using

care not to dislodge or damage the upper halves of the
main bearing shells if they are to be used again.

(10) If new bearing shells are to be installed,

remove the upper halves of the bearings from the
crankcase.

TO CHECK AND INSPECT

After thoroughly cleaning the crankshaft in sol-

vent and drying it with compressed air, blow out all
the oilways and make the following checks:

(1) Check and measure the main bearing jour-

nals and crankpins for wear, taper and scoring. If wear
is excessive, the journals and/or crankpins should be
ground to accommodate the nearest underside bearing
shells.

One worn or damaged journal or crankpin will

necessitate the grinding of all the journals or crank-

View of the centre main bearing showing the side

faces which control crankshaft end float.

pins and the installation of new undersize bearing
shells.

If wear or damage is such that the journals or

crankpins cannot be reground to take any one range of
the available undersize bearings, the crankshaft will
have to be renewed.

(2) Support the crankshaft at each end in Vee

blocks and with a dial gauge, check the crankshaft for
bend at the centre main journal. Renew the crankshaft
if the bend is in excess of the allowable limit. Refer to
the Specifications.

(3) Check the centre main bearing side faces for

pitting or wear. If pitting or wear is evident, renew the
main bearing shells as a set which should restore the
crankshaft end float to the Specifications.

(4) Even when the main bearing clearance has

been found to be satisfactory, inspect the bearing
shells for scores, flaking and pitting. Renew the main
bearing shells as a set if necessary.

TO INSTAL

Installation is a reversal of the removal procedure

with attention to the following points:

(1) Ensure that all of the oilways are clear and

that all the journals and crankpins have been thor-
oughly cleaned. Ensure that the bearing shells have
been cleaned and smeared with new engine oil and that
they are correctly positioned in their respective web,
connecting rod or cap.

(2) Carefully place the crankshaft in position in

the cylinder block and guide the connecting rods to
their respective crankpins.

(3) If new bearing shells were installed, check the

bearing clearance using the Plastigage method as
previously described.

(4) Install the rear main bearing cap and inject

Permatex Ultra Grey or equivalent sealer into the grooves
in the side of the rear bearing cap. Fill the grooves.

Engine

Main bearing cap removed showing the location of the

rear seal and sealant grooves.

until the sealant appears at the inner, lower edge of the
bearing cap to cylinder block joint. Install the bearing
cap bolts and tighten to the specified torque.

(5) Tighten the remaining main bearing cap

bolts and the connecting rod cap bolts to their
respective tensions and rotate the crankshaft to check
for binding.

(6) Install the crankshaft oil seal to the end of the

crankshaft after applying lithium grease to the lip of
the oil seal. Ensure that the l i p of the seal is facing
towards the engine.

(7) Install the remainder of the engine compo-

nents by referring to the relevant headings in this
section.

TO RENEW MAIN BEARINGS -
CRANKSHAFT INSTALLED

(1) Remove the automatic transaxle or manual

transaxle as described in the appropriate section.

(2) Remove the flywheel/drive plate as outlined

under the Flywheel/Drive Plate heading.

(3) Remove the engine sump and oil pump

pickup pipe as previously described.

(4) Ensure that the main bearing caps are num-

bered to ensure correct assembly.

(5) Remove the main bearing cap bolts and

remove the bearing cap and half shell of the bearing to
be renewed. Thoroughly clean the bearing cap in
solvent.

(6) Where necessary, use the Plastigage method

to measure the bearing clearance.

(7) Position a piece of Plastigage the approxi-

mate length of the bearing width, across the bearing
shell in the cap and tighten the cap bolts to the
specified torque. Do not rotate the crankshaft.

(8) Remove the bearing cap and measure the

spread width of the Plastigage with the scale on the
packet to determine the main bearing clearance.
Compare the measurement to the Specifications and if
the bearing clearance exceeds the limit, install a new
set of bearing shells.

NOTE: Renew one bearing at a time, leav-
ing the others securely attached.

(9) Install a brass rivet in the crankshaft journal

oil drilling and rotate the crankshaft in a clockwise
direction until the head of the rivet contacts the plain
edge of the upper bearing shell.

(10) Continue to rotate the crankshaft to carry

the upper half of the bearing shell out of the crank-
case.

(11) Select a half shell of the required thickness

(standard or undersize), coat it liberally with clean
engine oil and start it, plain edge first, into position on
the crankshaft. Rotate the crankshaft anti-clockwise so
that the rivet contacts the locating lug edge of the
bearing shell, carrying it into position in the crankcase
above the main bearing journal. Slightly reverse the
rotation of the crankshaft and remove the rivet from
the oil drilling in the crankshaft.

(12) Place the other half shell of the selected

bearing shells in the bearing cap. checking the clear-
ance as detailed in operations (7) and (8).

NOTE: By checking the taper on the plas-
tigage any taper of the bearing journal can
be calculated.

(13) When the bearing has been correctly selected

to give the specified clearance, tighten the cap bolts to
the specified torque.

(14) Use the same method to renew the other

main bearings.

(15) When renewing the rear main bearings, re-

move and discard the rear crankshaft oil seal.

(16) Install the rear main bearing cap into position

and inject KP510-00150 sealant or equivalent into the
grooves in the sides of the rear bearing cap. Fill the
grooves until the sealant appears at the inner lower

View showing the numbering and correct location of

the main bearing caps.

Engine

edge of the bearing cap to cylinder block joint. Install
the bearing cap bolts and tighten to the specified
torque.

(17) Lubricate the l i p of the new oil seal with

lithium grease and carefully install the seal into
position over the crankshaft. Insert the seal as far as
possible using finger pressure and then fully install the
sea! using a tubular drift. Ensure that the seal is not
damaged during installation and that the seal is
mounted square to the block face.

(18) Install the remainder of the engine

compo-
nents by referring to the relevant headings in
this
section.

TO RENEW CRANKSHAFT OIL SEALS

Front

(1) Remove the camshaft drive belt as previ-

ously described.

(2) Disconnect the lower radiator hose and drain

the cooling system.

(3) Select fifth gear on manual transaxle models

and firmly apply the handbrake.

(4) On automatic transaxle models, remove the

torque converter inspection cover to allow access to
the ring gear. Have an assistant hold the ring gear
using a suitable lever.

(5) Remove the crankshaft timing gear retaining

bolt and discard.

(6) Remove the crankshaft timing gear from the

crankshaft. It may be necessary to lever the gear from
the crankshaft using two screwdrivers. Remove the
key and spacer from the crankshaft.

(7) Using a centre punch, tap a small hole in the

front face of the oil seal.

(8) Insert a self tapping screw into the hole.
(9) Remove the seal from the oil pump by

gripping and pulling the end of the screw with a pair
of pliers.

(10) Coat the lip of a new seal with multi-purpose

grease.

(11) Install the oil seal to the oil pump using a

tubular drift. Ensure that the lip of the oil seal faces
the inside of the housing.

(12) Install the remaining components in the re-

verse order of removal, using a new crankshaft timing
gear retaining bolt and referring to the relevant
headings in this section as necessary.

Rear

(1) Remove the automatic transaxle or manual

transaxle as described in the appropriate section.

(2) Remove the flywheel/drive plate as described

under the following heading.

(3) Lever the oil seal from the rear of the

crankcase being careful not to damage the crankshaft.

(4) Coat the lip of a new seal with Lithium

grease.

(5) Install the oil seal over the crankshaft. Ensure

that the lip of the oil seal faces towards the engine.

(6) Insert the seal as far as possible using finger

pressure, and then fully seat the seal using a tubular
drift.

(7) Install the remaining components in the

re-
verse order of removal, referring to the relevant
headings in this section as necessary.

12. FLYWHEEL/DRIVE PLATE

Special Equipment Required:

To Renew Ring Gear — Suitable heat source

TO REMOVE

(1) Remove the transaxle from the vehicle as

described in the Manual or Automatic Transaxle
sections, whichever is applicable.

(2) On manual transaxle models, mark the fly-

wheel and the clutch pressure plate cover to ensure
correct assembly.

View of the drive plate and retaining bolts.

Progressively loosen and remove the pressure

plate retaining bolts.

Using a dial gauge, check the runout of the clutch

face contacting surface of the flywheel. If the runout
exceeds 0.3 mm have the flywheel face surfaced by a
clutch specialist or authorized dealer.

(3) Suitably mark the flywheel or drive plate so

that the unit can be installed in the original position
on the crankshaft. Remove the retaining bolts.

(4) Lift the flywheel or drive plate from the

engine.

TO CHECK AND INSPECT

Inspect the clutch face contacting surface of the

flywheel for cracks or excessive scoring.

(2) Inspect the ring gear teeth for damage, cracks

or wear. The ring gear on manual transaxle models
can be renewed separately from the flywheel, but on

64

Engine

automatic transaxle models the complete drive plate
must be renewed.

(3) Inspect the drive plate bolt holes for elonga-

tion which is caused by loose retaining bolts.

(4) Inspect the drive plate for cracks.
(5) Repair or renew the flywheel if necessary.

TO INSTAL

Installation is a reversal of the removal procedure

with attention to the following points:

(1) The flywheel and drive plate retaining bolts

are special micro-encapsulated fasteners.

Install new micro-encapsulated bolts of the

correct
strength classification on assembly.

(2) Thoroughly clean the crankshaft threads with

a thread tap. Clean the threads with solvent and dry
before installing the flywheel or drive plate retaining
bolts.

(3) Tighten the flywheel or drive plate retaining

bolts to the specified torque and on manual transaxle
models, align the clutch plate as described in the
Clutch section.

TO RENEW FLYWHEEL RING GEAR

(1) With the flywheel removed from the vehicle,

drill a 6 mm diameter hole between two teeth of the
ring gear.

NOTE: Do not drill right through the ring
gear as this will damage the flange on the
flywheel.

(2) Secure the flywheel, with the drilled hole

uppermost in a soft jawed vice.

(3) Place a cold chisel above the hole in the ring

gear and hit it sharply to split the ring gear.

(4) Check the direction of the chamfered face of

the old ring gear. The new ring gear must be installed
to the flywheel with the chamfer in the same direction.

(5) Remove the ring gear, clean the mounting

face on the flywheel and remove any burrs.

(6) Polish a few spots of the ring gear with emery

cloth and heat the ring gear evenly until the polished
spots turn dark blue.

NOTE; Do not heat the ring gear past the
point required to achieve a dark blue color
or the tempering of the ring gear teeth will
be impaired.

(7) With the flywheel suitably supported, pick

the ring gear up using pliers, and place it evenly onto
the flywheel. Use a hammer and a brass drift to ensure
that the ring gear seats against the flywheel flange.

NOTE: Allow the ring gear to cool slowly.
Do not quench it in water.

13. ENGINE MOUNTINGS

TO RENEW LEFT HAND SIDE MOUNTING

(1) Disconnect the positive and negative battery

terminals, loosen the battery clamp nuts and withdraw
the battery from the engine compartment.

(2) Remove the bolts retaining the battery car-

rier to the inner mudguard and remove the battery
carrier and associated components from the engine
compartment.

(3) Support the transaxle using a jack. Interpose

a block of wood between the head of the jack and the
transaxle to prevent damage to the transaxle.

View of the flywheel and retaining bolts.

Dismantled view of the left hand side engine mounting

assembly installed to vehicles with an automatic tran-

saxle.