Nissan Silvia. Manual — part 222
ENGINE MECHANICAL
CONTENTS
PRECAUTIONS . . . . . . . . . . . . . . . ...3
Parts Requiring Angular Tightening. . . . . . . .3
Liquid Gasket Application Procedure . . . . . . ..3
Special Cautions to Ensure the Safe Disposal of
Sodium-filled Exhaust Valves . . . . . . . . . ..3
. . . . . . .4
PREPARATION . . . . . . . . . . . . . . . ...6
Special Service Tools . . . . . . . . . . . . ..6
Commercial Service Tools . . . . . . . . . . ...8
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING . . . . . . . . . . . . ...10
NVH Troubleshooting - Engine Noise . . . . . ... 11
OUTER COMPONENT PARTS . . . . . . . . . .12
Removal and Installation . . . . . . . . . . ...12
MEASUREMENT OF COMPRESSION PRESSURE . 15
DRIVE BELTS. . . . . . . . . . . . . . . . 16
Checking . . . . . . . . . . . . . . . . . 16
AIR CLEANER. . . . . . . . . . . . . . . ...17
Changing. . . . . . . . . . . . . . . . . 17
. . . . . . . . . . ...17
SPARK PLUG. . . . . . . . . . . . . . . . 18
Changing. . . . . . . . . . . . . . . . . 18
. . . . . . . . . . 18
OIL PAN. . . . . . . . . . . . . . . . . . .20
Components. . . . . . . . . . . . . . . ...20
Removal. . . . . . . . . . . . . . . . . .20
Installation. . . . . . . . . . . . . . . . ..23
TIMING CHAIN . . . . . . . . . . . . . . . ..25
Components. . . . . . . . . . . . . . . ...25
Removal. . . . . . . . . . . . . . . . . .26
Inspection. . . . . . . . . . . . . . . . ...28
Installation. . . . . . . . . . . . . . . . ..29
OIL SEAL. . . . . . . . . . . . . . . . . ...34
Replacement. . . . . . . . . . . . . . . ..34
. . . . . . . . . . . . . .34
. . . . . . . . . . . . . 34
. . . . . . . . . . . . . ..35
INTAKE MANIFOLD . . . . . . . . . . . . . ..36
Removal. . . . . . . . . . . . . . . . . .36
Installation. . . . . . . . . . . . . . . . ..37
CYLINDER HEAD. . . . . . . . . . . . . . ..38
Components. . . . . . . . . . . . . . . ...38
Removal. . . . . . . . . . . . . . . . . .39
Disassembly. . . . . . . . . . . . . . . ...41
Inspection. . . . . . . . . . . . . . . . ...43
. . . . . . . ...43
. . . . . . . . . 43
. . . . . . . . . . . ..43
. . . . . . . . . ...43
. . . . . . 44
. . . . . . ...45
. . . . . . . . . 45
. . . . . . . . 45
. . . . . . . . . . . . . . .46
REPLACING VALVE SEAT FOR SERVICE PARTS
. 47
. . . . . . . . . . . ...48
. . . . . . . . . . . . . ...48
. . . . . . . . 48
ROCKER ARM, SHIM AND ROCKER ARM GUIDE
. .49
Assembly . . . . . . . . . . . . . . . . ...49
Installation. . . . . . . . . . . . . . . . ..52
TURBOCHARGER. . . . . . . . . . . . . . .58
Removal. . . . . . . . . . . . . . . . . .58
Disassembly. . . . . . . . . . . . . . . ...59
Inspection. . . . . . . . . . . . . . . . ...60
. . . . . . . . . . .60
. . . . . . . . . . . . . ...60
. . . . . . . . . . . . . 61
. . . . . . . . . . ...61
. . . . . . . . . . . ...61
. . . . . . . 62
Assembly . . . . . . . . . . . . . . . . ...62
Installation. . . . . . . . . . . . . . . . ..62
. . . . . . . . . . . . . . . ..63
. . . . . . . . . . . . . ...63
CHARGE AIR COOLER . . . . . . . . . . . . 64
Removal and Installation . . . . . . . . . . ...64
Inspection. . . . . . . . . . . . . . . . ...64
ENGINE ASSEMBLY. . . . . . . . . . . . . .65
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Removal and Installation . . . . . . . . . . ...65
. . . . . . . . . . . . . . . ...66
. . . . . . . . . . . . . . 67
CYLINDER BLOCK . . . . . . . . . . . . . ...68
Components. . . . . . . . . . . . . . . ...68
Removal and Installation . . . . . . . . . . ...69
Disassembly. . . . . . . . . . . . . . . ...69
. . . . . . . . . 69
Inspection. . . . . . . . . . . . . . . . ...70
PISTON AND PISTON PIN CLEARANCE
. . . . ..70
. . . . . . . 70
CONNECTING ROD BEND AND TORSION
. . . ...71
CYLINDER BLOCK DISTORTION AND WEAR
. . ...71
. . . . . . . ..72
. . . . . . . . . . . . . . .73
. . . . . . . . . . ...73
CONNECTING ROD BUSHING CLEARANCE
(SMALL END)
. . . . . . . . . . . . . . ..76
REPLACEMENT OF CONNECTING ROD
BUSHING (SMALL END)
. . . . . . . . . . ..76
REPLACEMENT OF PILOT BUSHING (M/T) OR
PILOT CONVERTER (A/T)
. . . . . . 77
. . . . . . . . . . ...77
Assembly . . . . . . . . . . . . . . . . ...78
. . . . . . . . . . . . . . . . ..78
. . . . . . . . . . . . . . .79
SERVICE DATA AND SPECIFICATIONS (SDS) . . .82
General Specifications. . . . . . . . . . . ...82
Compression Pressure . . . . . . . . . . . ..82
Drive Belt Deflection and Tension . . . . . . . .83
Spark Plug . . . . . . . . . . . . . . . . .83
Cylinder Head . . . . . . . . . . . . . . . 83
Valve . . . . . . . . . . . . . . . . . . ..84
. . . . . . . . . . . . . . . . . 84
. . . . . . . . . . . . . ...84
. . . . . ...84
. . . . . . . . . . . . . . .85
VALVE SHIM CLEARANCE ADJUSTMENT
. . . . 85
. . . . . . . . . . . . . 86
. . . . . . . . . . . . . . ...87
. . . . . . . .88
Camshaft and Camshaft Bearing . . . . . . . ..88
Cylinder Block. . . . . . . . . . . . . . . 89
Piston, Piston Ring and Piston pin. . . . . . . 90
. . . . . . . . . . . . . . . . ..90
. . . . . . . . . . . . . . .90
. . . . . . . . . . . . . . . 90
Connecting Rod . . . . . . . . . . . . . . .91
Crankshaft. . . . . . . . . . . . . . . . ..92
Main Bearing. . . . . . . . . . . . . . . ..93
. . . . . . . . . . . . . . . .93
. . . . . . . . . . . . . . . 93
Connecting Rod Bearing . . . . . . . . . . ...93
. . . . . . . . . . . . . 93
. . . . . . . . . . . . . . . 93
Bearing Clearance . . . . . . . . . . . . . .94
Miscellaneous Components. . . . . . . . . ...94
CONTENTS
(Cont’d)
EM-2
Parts Requiring Angular Tightening
NMEM0001
I
Use an angle wrench for the final tightening of the following
engine parts:
a)
Cylinder head bolts
b)
Main bearing cap bolts
c)
Connecting rod cap nuts
I
Do not use a torque value for final tightening.
I
The torque value for these parts are for a preliminary step.
I
Ensure thread and seat surfaces are clean and coated with
engine oil.
SEM164F
AEM080
Liquid Gasket Application Procedure
NMEM0002
1.
Use a scraper to remove old liquid gasket from mating
surfaces and grooves. Also, completely clean any oil from
these areas.
2.
Apply a continuous bead of liquid gasket to mating sur-
faces. (Use Genuine Liquid Gasket or equivalent.)
I
For oil pan, be sure liquid gasket diameter is 4.0 to 5.0 mm
(0.157 to 0.197 in).
I
For areas except oil pan, be sure liquid gasket diameter is
2.0 to 3.0 mm (0.079 to 0.118 in).
3.
Apply liquid gasket around the inner side of bolt holes
(unless otherwise specified).
4.
Assembly should be done within 5 minutes after coating.
5.
Wait at least 30 minutes before refilling engine oil and
engine coolant.
Special Cautions to Ensure the Safe Disposal
of Sodium-filled Exhaust Valves
NMEM0042
The handling and disposal of sodium-filled exhaust valves requires
special care and consideration. Under conditions such as breakage
with subsequent exposure to water, the sodium metal will react
violently. The sodium metal, which lines the inner portion of the
exhaust valve, forms sodium hydroxide. Also, it releases hydrogen
gas which may result in an explosion or fire.
SEM969E
A sodium-filled exhaust valve is identified on the top of its stem as
shown in illustration.
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PRECAUTIONS
Parts Requiring Angular Tightening
EM-3
DEALER DISPOSAL INSTRUCTIONS
NMEM0042S01
CAUTION:
I
Use approved shatter-resistant eye protection when per-
forming this procedure.
I
Perform this and all subsequent disposal work proce-
dures in an open room, away from flammable liquids.
Keep a fire extinguisher, rated at least 10 ABC, in close
proximity to the work area.
I
Be sure to wear rubber gloves when performing the fol-
lowing operations.
1.
Clamp valve stem in a vice.
SEM959C
2.
The valve has a specially-hardened surface. To cut through it,
first remove a half-round section, approximately 30 mm (1.18
in) long. Use an air-powered grinder until the black iron color
is removed and the silver-colored metal appears.
SEM960C
3.
Use a hacksaw to cut through approximately half the diameter
of the valve stem. Make the serration at a point 40 mm (1.57
in) from the end of the stem.
SEM961C
4.
Cover the serrated end of the valve with a large shop towel.
Strike the valve face end with a hammer, separating it into two
pieces.
SEM509D
5.
Fill a bucket (such as a 20
oil can) with at least 10
(2-5/8
US gal, 2-1/4 Imp gal) of water. Using a pair of large tweezers,
carefully place the already-cut (serrated) valves into the water
one at a time. Quickly move away at least 2.7 m (9 ft). Place
the valves in a standing position as shown in the figure. This
allows complete reaction of the sodium with the water. The
major portion of the resultant chemical reaction lasts 1 to 2
minutes. After the bubbling action has subsided, additional
valves can be placed into the water. Wait until each subse-
quent chemical reaction subsides before placing additional
valves into the water. However, no more than 8 valves should
be placed in the same 10
(2-5/8 US gal, 2-1/4 Imp gal)
PRECAUTIONS
Special Cautions to Ensure the Safe Disposal of Sodium-filled Exhaust Valves (Cont’d)
EM-4
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