Nissan ZD30.pdf

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ENGINE MECHANICAL
B ENGINE
A
SECTION
EM
ENGINE MECHANICAL
C
D
CONTENTS
KA24DE
PRECAUTIONS ......................................................... 5
.
Precautions for Drain Coolant ................................. 5
.
Precautions for Disconnecting Fuel Piping ............. 5
.
Precautions for Removal and Disassembly ............ 5
.
Precautions for Inspection, Repair and Replace-
ment ........................................................................ 5
.
Precautions for Assembly and Installation .............. 5
.
Parts Requiring Angular Tightening ........................ 5
.
Precautions for Liquid Gasket ................................. 6
.
REMOVAL OF LIQUID GASKET SEALING ......... 6
.
LIQUID GASKET APPLICATION PROCEDURE 6
.....
PREPARATION .......................................................... 7
.
Special Service Tools .............................................. 7
.
Commercial Service Tools ....................................... 8
.
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ............................................. 10
.
NVH Troubleshooting —Engine Noise .................. 10
.
Use the Chart Below to Help You Find the Cause
of the Symptom. .....................................................11
.
ENGINE ROOM COVER ......................................... 12
.
Removal and Installation of Engine Room Right
Side ....................................................................... 12
.
REMOVAL .......................................................... 12
.
INSTALLTION .................................................... 12
.
Removal and Installation of Engine Room Rear
Cover ..................................................................... 12
.
REMOVAL .......................................................... 12
.
INSTALLATION .................................................. 13
.
DRIVE BELTS .......................................................... 14
.
Checking Drive Belts ............................................. 14
.
Tension Adjustment ............................................... 14
.
POWER STEERING PUMP BELT ..................... 14
.
AIR CONDITIONER COMPRESSOR BELT ...... 14
.
ALTERNATOR AND WATER PUMP BELT ........ 15
.
Removal and Installation ....................................... 15
.
REMOVAL .......................................................... 15
.
INSTALLATION .................................................. 15
.
AIR CLEANER AND AIR DUCT .............................. 16
.
Removal and Installation ....................................... 16
.
REMOVAL .......................................................... 16
.
INSTALLATION .................................................. 17
.
Changing Air Cleaner Element ............................ .. 18
.
REMOVAL .......................................................... 18
.
INSTALLATION .................................................. 18
.
THROTTLE BODY ................................................... 19
.
Removal and Installation ....................................... 19
.
REMOVAL .......................................................... 19
.
INSPECTION AFTER REMOVAL ...................... 20
.
INSTALLATION .................................................. 20
.
Disassembly and Assembly ................................. .. 20
.
DISASSEMBLY .................................................. 20
.
ASSEMBLY ...................................................... .. 20
.
INTAKE MANIFOLD ................................................ 21
.
Removal and Installation ....................................... 21
.
REMOVAL .......................................................... 21
.
INSPECTION AFTER REMOVAL ...................... 22
.
INSTALLATION .................................................. 22
.
EXHAUST MANIFOLD .......................................... .. 23
.
Removal and Installation ....................................... 23
.
REMOVAL .......................................................... 23
.
INSPECTION AFTER REMOVAL ...................... 24
.
INSTALLATION .................................................. 24
.
INSPECTION AFTER INSTALLATION ............... 24
.
OIL PAN AND OIL STRAINER ................................ 25
.
Removal and Installation ....................................... 25
.
REMOVAL .......................................................... 25
.
INSPECTION AFTER REMOVAL ...................... 25
.
INSTALLATION .................................................. 25
.
INSPECTION AFTER INSTALLATION ............... 26
.
SPARK PLUG (CONVENTIONAL) .......................... 27
.
Removal and Installation ....................................... 27
.
REMOVAL .......................................................... 27
.
INSPECTION AFTER REMOVAL ...................... 27
.
INSTALLATION .................................................. 27
.
FUEL INJECTOR AND FUEL TUBE ....................... 28
.
Removal and Installation ....................................... 28
.
REMOVAL .......................................................... 28
.
INSTALLATION .................................................. 29
.
INSPECTION AFTER INSTALLATION ............... 29
.
E
F
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H
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M
EM-1
ROCKER COVER .................................................... 30
.
Removal and Installation ....................................... 30
.
REMOVAL .......................................................... 30
.
INSTALLATION ................................................... 30
.
CAMSHAFT .............................................................. 32
.
Removal and Installation ....................................... 32
.
REMOVAL .......................................................... 32
.
INSTALLATION ................................................... 34
.
INSPECTION AFTER REMOVAL ....................... 35
.
Valve Clearance ..................................................... 38
.
INSPECTION ...................................................... 38
.
ADJUSTMENT ................................................... 38
.
SECONDARY TIMING CHAIN ................................. 41
.
Removal and Installation ....................................... 41
.
REMOVAL .......................................................... 41
.
INSPECTION AFTER REMOVAL ....................... 44
.
INSTALLATION ................................................... 45
.
PRIMARY TIMING CHAIN ....................................... 49
.
Removal and Installation ....................................... 49
.
REMOVAL .......................................................... 50
.
INSPECTION AFTER REMOVAL ....................... 51
.
INSTALLATION ................................................... 51
.
CYLINDER HEAD .................................................... 55
.
On-Vehicle Service ................................................ 55
.
CHECKING COMPRESSION PRESSURE ........ 55
.
Removal and Installation ....................................... 56
.
REMOVAL AND INSTALLATION ........................ 56
.
Disassembly and Assembly ................................... 57
.
DISASSEMBLY .................................................. 57
.
ASSEMBLY ........................................................ 58
.
INSPECTION AFTER DISASSEMBLY ............... 58
.
ENGINE ASSEMBLY ............................................... 63
.
Removal and Installation ....................................... 63
.
REMOVAL .......................................................... 64
.
INSTALLATION ................................................... 65
.
INSPECTION AFTER INSTALLATION ............... 66
.
CYLINDER BLOCK .................................................. 67
.
Disassembly and Assembly ................................... 67
.
DISASSEMBLY .................................................. 68
.
ASSEMBLY ........................................................ 70
.
How to Select Piston and Bearing ......................... 74
.
DESCRIPTION ................................................... 74
.
HOW TO SELECT PISTON ................................ 75
.
HOW TO SELECT CONNECTING ROD BEAR-
ING ..................................................................... 75
.
HOW TO SELECT MAIN BEARING ................... 76
.
Inspection After Disassembly ................................ 78
.
CRANKSHAFT SIDE CLEARANCE ................... 78
.
CONNECTING ROD SIDE CLEARANCE .......... 78
.
PISTON AND PISTON PIN CLEARANCE ......... 78
.
PISTON RING SIDE CLEARANCE .................... 79
.
PISTON RING END GAP ................................... 79
.
CONNECTING ROD BEND AND TORSION ...... 80
.
CONNECTING ROD BEARING (BIG END) ....... 80
.
CONNECTING ROD BUSHING OIL CLEAR-
ANCE (SMALL END) .......................................... 80
.
CYLINDER BLOCK DISTORTION ..................... 81
.
INNER DIAMETER OF MAIN BEARING HOUS-
ING .................................................................... ..81
.
PISTON TO CYLINDER BORE CLEARANCE ...82
OUTER DIAMETER OF CRANKSHAFT JOUR-
NAL .....................................................................83
.
OUTER DIAMETER OF CRANKSHAFT PIN .....83
.
OUT-OF-ROUND AND TAPER OF CRANK-
SHAFT ................................................................83
.
CRANKSHAFT RUNOUT ...................................83
.
OIL CLEARANCE OF CONNECTING ROD
BEARING ............................................................84
.
OIL CLEARANCE OF MAIN BEARING ..............84
.
CRUSH HEIGHT OF MAIN BEARING ...............85
.
OIL JET ............................................................. ..85
.
OIL JET RELIEF VALVE ................................... ..85
.
FLY WHEEL RUNOUT .......................................86
.
SERVICE DATA AND SPECIFICATIONS (SDS) .....87
.
Standard and Limit ............................................... ..87
.
GENERAL SPECIFICATIONS .......................... ..87
.
DRIVE BELTS .....................................................87
.
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD ..................................................................87
.
SPARK PLUG .....................................................88
.
SECONDARY TIMING CHAIN ...........................88
.
CYLINDER HEAD ...............................................88
.
VALVE .................................................................88
.
CAMSHAFT AND CAMSHAFT BEARING ..........92
.
CYLINDER BLOCK .............................................92
.
PISTON, PISTON RING AND PISTON PIN .......93
.
CONNECTING ROD ...........................................94
.
CRANKSHAFT ....................................................94
.
MAIN BEARING ..................................................95
.
CONNECTING ROD BEARING ..........................95
.
FLYWHEEL .........................................................96
.
Tightening Torque ..................................................96
.
ZD30DD
PRECAUTIONS ...................................................... ..98
.
Precautions for Drain Coolant ................................98
.
Precautions for Disconnecting Fuel Piping ............98
.
Precautions for Removal and Disassembly ......... ..98
.
Precautions for Inspection, Repair and Replace-
ment .......................................................................98
.
Precautions for Assembly and Installation .............98
.
Parts Requiring Angular Tightening ..................... ..98
.
Precautions for Liquid Gasket ................................99
.
REMOVAL OF LIQUID GASKET SEALING .......99
.
LIQUID GASKET APPLICATION PROCEDURE...99
PREPARATION ...................................................... 100
.
Special Service Tools ........................................... 100
.
Commercial Service Tools ................................... 102
.
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ........................................... 103
.
NVH Troubleshooting —Engine Noise ................. 103
.
Use the Chart Below to Help You Find the Cause
of the Symptom. ................................................... 104
.
ENGINE ROOM COVER ........................................ 105
.
Removal and Installation of Engine Room Right
EM-2
Side ..................................................................... 105
.
REMOVAL ........................................................ 105
.
INSTALLATION ................................................ 105
.
Removal and Installation of Engine Room Rear
Cover ................................................................... 105
.
REMOVAL ........................................................ 105
.
INSTALLATION ................................................ 106
.
DRIVE BELTS ........................................................ 107
.
Checking Drive Belt ............................................. 107
.
Tension Adjustment ............................................. 107
.
Removal and Installation ..................................... 107
.
WATER PUMP, ALTERNATOR AND A/C COM-
PRESSOR BELT .............................................. 107
.
Drive Belt Auto Tensioner .................................... 109
.
REMOVAL ........................................................ 109
.
INSPECTION AFTER REMOVAL .................... 109
.
INSTALLATION ................................................ 109
.
Dummy Pulley ..................................................... 109
.
REMOVAL ........................................................ 109
.
INSPECTION AFTER REMOVAL .................... 109
.
INSTALLATION ................................................ 109
.
AIR CLEANER AND AIR DUCT .............................110
.
Removal and Installation ......................................110
.
REMOVAL .........................................................110
.
INSTALLATION ................................................. 111
.
Changing Air Cleaner Element .............................112
.
REMOVAL .........................................................112
.
INSTALLATION .................................................112
.
INTAKE MANIFOLD COLLECTOR AND INTAKE
MANIFOLD .............................................................113
.
Removal and Installation ......................................113
.
REMOVAL .........................................................113
.
INSPECTION AFTER REMOVAL .....................115
.
INSTALLATION .................................................115
.
EXHAUST MANIFOLD ...........................................117
.
Removal and Installation ......................................117
.
REMOVAL .........................................................117
.
INSPECTION AFTER REMOVAL .....................118
.
INSTALLATION .................................................118
.
INSPECTION AFTER INSTALLATION .............118
.
OIL PAN AND OIL STRAINER ...............................119
.
Removal and Installation ......................................119
.
REMOVAL .........................................................119
.
INSTALLATION ................................................ 120
.
INSPECTION AFTER INSTALLATION ............ 120
.
GLOW PLUG ......................................................... 121
.
Removal and Installation ..................................... 121
.
REMOVAL ........................................................ 121
.
INSTALLATION ................................................ 122
.
VACUUM PUMP .................................................... 123
.
Removal and Installation ..................................... 123
.
REMOVAL ........................................................ 123
.
INSTALLATION ................................................ 123
.
INSPECTION AFTER INSTALLATION ............ 123
.
INJECTION TUBE AND INJECTION NOZZLE ..... 125
.
Removal and Installation ..................................... 125
.
REMOVAL ........................................................ 125
.
INSPECTION AFTER REMOVAL .................... 127
.
INSTALLATION ................................................ 127
.
INSPECTION AFTER INSTALLATION ............. 128
.
ELECTRONICCONTROLFUELINJECTIONPUMP 129
.
Removal and Installation ..................................... 129
.
REMOVAL ........................................................ 129
.
INSTALLATION ................................................ 132
.
INSPECTION AFTER INSTALLATION ............. 134
.
ROCKER COVER .................................................. 135
.
Removal and Installation ..................................... 135
.
REMOVAL ........................................................ 135
.
INSTALLATION ................................................ 136
.
CAMSHAFT ........................................................... 138
.
Removal and Installation ..................................... 138
.
REMOVAL ........................................................ 139
.
INSPECTION AFTER REMOVAL .................... 139
.
INSTALLATION ................................................ 141
.
Valve Clearance .................................................. 142
.
INSPECTION ................................................... 142
.
ADJUSTMENTS ............................................... 144
.
TIMING CHAIN ....................................................... 147
.
Removal and Installation ..................................... 147
.
REMOVAL ........................................................ 147
.
INSPECTION AFTER REMOVAL .................... 149
.
INSTALLATION ................................................ 149
.
TIMING GEAR ........................................................ 151
.
Removal and Installation ..................................... 151
.
REMOVAL ........................................................ 152
.
INSPECTION AFTER REMOVAL .................... 155
.
INSTALLATION ................................................ 157
.
CYLINDER HEAD .................................................. 160
.
On-Vehicle Service .............................................. 160
.
CHECKING COMPRESSION PRESSURE ...... 160
.
Removal and Installation ..................................... 161
.
REMOVAL ........................................................ 161
.
INSPECTION AFTER REMOVAL .................... 162
.
INSTALLATION ................................................ 163
.
Disassembly and Assembly ................................. 166
.
DISASSEMBLY ................................................ 166
.
ASSEMBLY ...................................................... 167
.
INSPECTION AFTER DISASSEMBLY ............. 167
.
ENGINE ASSEMBLY ............................................. 172
.
Removal and Installation ..................................... 172
.
REMOVAL ........................................................ 172
.
INSTALLATION ................................................ 174
.
INSPECTION AFTER INSTALLATION ............. 175
.
CYLINDER BLOCK ............................................... 176
.
Disassembly and Assembly ................................. 176
.
DISASSEMBLY ................................................ 177
.
ASSEMBLY ...................................................... 181
.
How to Select Piston ........................................... 184
.
DESCRIPTION ................................................. 184
.
SELECTIVE PISTON COMBINATION ............. 184
.
INSPECTION AFTER DISASSEMBLY ............. 185
.
A
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EM-3
SERVICE DATA AND SPECIFICATIONS (SDS) ... 194
.
Standard and Limit ............................................... 194
.
GENERAL SPECIFICATIONS .......................... 194
.
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD ................................................................ 194
.
DRIVE BELTS .................................................. 194
.
CYLINDER HEAD ............................................ 195
.
VALVE ............................................................... 195
.
CAMSHAFT AND CAMSHAFT BEARING ....... 199
.
CYLINDER BLOCK ........................................... 199
.
PISTON, PISTON RING AND PISTON PIN ..... 200
.
CONNECTING ROD ......................................... 201
.
CRANKSHAFT .................................................. 201
.
AVAILABLE MAIN BEARING ............................ 202
.
AVAILABLE CONNECTING ROD BEARING .... 202
.
MISCELLANEOUS COMPONENTS ................. 202
.
Tightening torque ................................................. 203
.
EM-4
PRECAUTIONS
[KA24DE]
PRECAUTIONS
Precautions for Drain Coolant
[KA24DE]
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A
EBS007JS
Drain coolant when engine is cooled.
EM
EBS007JT
Precautions for Disconnecting Fuel Piping
q
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Before starting work, make sure no fire or spark producing items are in the work area.
Release fuel pressure before disassembly.
After disconnecting pipes, plug openings to stop fuel leakage.
EBS007JU
C
Precautions for Removal and Disassembly
q
q
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When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
Exercise maximum care to avoid damage to mating or sliding surfaces.
Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
EBS007JV
D
E
F
Precautions for Inspection, Repair and Replacement
q
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way,
and replace if necessary.
EBS007JW
G
Precautions for Assembly and Installation
q
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Use torque wrench to tighten bolts or nuts.
When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.
Replace with new gasket, packing, oil seal or O-ring.
Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
Release air within route after draining coolant.
After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems
for leakage.
EBS007JX
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Parts Requiring Angular Tightening
q
–
–
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Use an angle wrench for the final tightening of the following engine parts:
Cylinder head bolts
Connecting rod cap nuts
Do not use a torque value for final tightening.
The torque value for these parts are for a preliminary step.
Ensure thread and seat surfaces are clean and coated with engine oil.
M
EM-5

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