1998 NISSAN PICK-UP Repair Manual

(4) 4th, 3rd and 2nd camshaft bushings
lInstall in the same manner as rear camshaft bushing.
lWhen setting 4th through 2nd bushings on replacer bar, tape
the bar to prevent movement.
(5) Front camshaft bushing
lUsing 1st bushing adapter, position front camshaft bushing
so that oil hole in cylinder block is aligned with oil hole in
bushing.
SEM602C
SEM999B
SEM001C
ENGINE OVERHAULTD
Inspection and Replacement (Cont'd)
EM-84

lPress the bushing until its front end is 0.5 mm (0.020 in) from
the front surface of the cylinder block.
3. Check camshaft bushing clearance.
Refer to SDS, EM-101.
4. Install new welch plug into rear camshaft bushing hole with
a drift.
Apply liquid sealer.
CAMSHAFT ALIGNMENT
1. Check camshaft journal and cam surface for bend, wear or
damage.
If fault is beyond limit, replace.
2. Check camshaft bend at center journal.
If bend is greater than specified limit, repair or replace cam-
shaft.
Camshaft bend
(Total indicator reading): mm (in)
Standard
Less than 0.02 (0.0008)
Limit
Less than 0.06 (0.0024)
DEM053
SEM987B
SEM034
SEM670B
ENGINE OVERHAULTD
Inspection and Replacement (Cont'd)
EM-85

3. Measure camshaft end play between locating plate and gear.
If beyond the specified limit, replace camshaft locating plate.
Camshaft end play: mm (in)
Standard
0.08 - 0.28 (0.0031 - 0.0110)
Limit
Less than 0.5 (0.020)
4. Measure camshaft cam height. If beyond the specified limit,
replace camshaft.
Cam height: mm (in)
Standard
Intake
41.88 - 41.92 (1.6488 - 1.6504)
Exhaust
41.88 - 41.92 (1.6488 - 1.6504)
Limit
Intake
Less than 41.40 (1.6299)
Exhaust
Less than 41.40 (1.6299)
Assembly
PISTON
Assemble pistons, piston pins, snap rings and connecting rods.
a. Numbers are stamped on the connecting rod and cap
corresponding to each cylinder. Care should be taken to
avoid a wrong combination including bearing.
b. When inserting piston pin in connecting rod, heat piston
with a heater or hot water [approximately 60 to 70ÉC (140
to 158ÉF)] and apply engine oil to pin and small end of
connecting rod.
c. After assembling, ascertain that piston swings
smoothly.
SEM671B
SEM037
DEM054
SEM292
ENGINE OVERHAULTD
Inspection and Replacement (Cont'd)
EM-86

Install piston assembly.
CAUTION:
lStretch the piston rings only enough to fit them in the
piston grooves.
lAlways install new piston rings with the position marks
facing up.
Identification color
Top ring Yellow
2nd ring Red
lInstall No. 1 piston ring in such a way that its gap faces
the direction of the piston pin; and then install piston
rings so that their gap positioned at 180É to one another.
CRANKSHAFT
1. Install crankshaft.
(1) Set main bearings in the proper position on cylinder block.
a. If either crankshaft, cylinder block or main bearing is
reused again, it is necessary to measure main bearing
clearance.
b. Upper bearings have oil hole and oil groove, however
lower bearings do not.
(2) Apply engine oil to crankshaft journal and pin and install
crankshaft.
(3) Install main bearing caps.
a. Install main bearing cap with the number facing the front of
vehicle.
b. Apply engine oil to main bearing cap and cylinder block con-
tact surfaces.
c. Install rear oil seal assembly. Apply engine oil to contact
surface of rear end oil seal and crankshaft.
(4) Install crankshaft thrust washer at the 4th journal from front.
Install thrust washer so that oil groove can face crankshaft.
DEM059
DEM055
SEM674BA
SEM057
ENGINE OVERHAULTD
Assembly (Cont'd)
EM-87

(5) Tighten main bearing cap bolts gradually in stages, starting
from two to three separate stages, from center bearing and
moving outward in sequence.
: 167 - 177 Nzm (17.0 - 18.0 kg-m, 123 - 130 ft-lb)
(6) Measure crankshaft free end play at No. 4 bearing.
Crankshaft free end play: mm (in)
Standard
0.055 - 0.140 (0.0022 - 0.0055)
Limit
0.40 (0.0157)
If beyond the limit, replace No. 4 main bearing thrust
washer. Refer to SDS, EM-106.
2. Install pistons with connecting rods.
(1) Install them into corresponding cylinder using Tool.
lBe careful not to scratch cylinder wall with connecting
rod.
lInsert the connecting rod. Do not allow the larger end to
touch the oil jet.
lApply engine oil to cylinder wall, piston and bearing.
lThe leaf type combustion chamber on piston head must
be at right side of engine.
(2) Install connecting rod bearing caps.
SEM675B
SEM677B
SEM063
DEM056.DEM056
SEM678B
ENGINE OVERHAULTD
Assembly (Cont'd)
EM-88

3. Measure connecting rod side clearance.
Connecting rod side clearance: mm (in)
Standard
0.10 - 0.22 (0.0039 - 0.0087)
Limit
0.22 (0.0087)
If beyond the limit, replace connecting rod and/or crank-
shaft.
GEAR TRAIN
1. Set No. 1 piston at TDC on its compression stroke.
2. Align each gear mark and install gears.
TIMING GEAR CASE
Installation
1. Before installing timing gear case, remove all traces of liquid
gasket from mating surface using a scraper.
Also remove traces of liquid gasket from mating surface of
front plate.
2. Apply a continuous bead of liquid gasket to mating surface
of timing gear case and dust cover.
SEM488
DEM016
MEM120A
MEM121A
ENGINE OVERHAULTD
Assembly (Cont'd)
EM-89

lBe sure liquid gasket diameter is 2.5 to 3.5 mm (0.098 to
0.138 in).
lAttach timing gear case to front plate within 10 minutes
after coating.
lWait at least 30 minutes before refilling engine coolant
or starting engine.
lUse Genuine Liquid Gasket or equivalent.
MEM122A
DEM064
SEM683B
ENGINE OVERHAULTD
Assembly (Cont'd)
EM-90

General Specifications
Cylinder arrangement 4, in-line
Displacement cm
3(cu in) 2,389 (145.78)
Bore x stroke mm (in) 89 x 96 (3.50 x 3.78)
Valve arrangement OHC
Firing order 1-3-4-2
Number of piston rings
Compression 2
Oil 1
Number of main bearings 5
Compression ratio 8.6
Unit: kPa (bar, kg/cm2, psi)/rpm
Compression pressure
Standard 1,324 (13.24, 13.5, 192)/300
Minimum 981 (9.8, 10, 142)/300
Differential limit between cylin-
ders98 (0.98, 1.0, 14)/300
Inspection and Adjustment
CYLINDER BLOCK
SEM618F
Unit: mm (in)
Standard Limit
DistortionÐ 0.1 (0.004)
Cylinder boreInner diameterGrade 1 89.000 - 89.010 (3.5039 - 3.5043)
0.2 (0.008)* Grade 2 89.010 - 89.020 (3.5043 - 3.5047)
Grade 3 89.020 - 89.030 (3.5047 - 3.5051)
Out-of-round (X þ Y) Less than 0.015 (0.0006) Ð
Taper (A þ B) Less than 0.010 (0.0004) Ð
Difference in inner diameter between cylinders Less than 0.05 (0.0020) 0.2 (0.008)
Piston-to-cylinder clearance 0.010 - 0.020 (0.0004 - 0.0008) Ð
Cylinder block height
(From crankshaft center)246.95 - 247.05 (9.7224 - 9.7264) 0.2 (0.008)**
* Wear limit
** Total amount of cylinder head resurfacing and cylinder block resurfacing
CYLINDER HEAD
Unit: mm (in)
Standard Limit
Height (H)98.8 - 99.0
(3.890 - 3.898)0.2 (0.008)*
Surface distortion 0.03 (0.0012) 0.1 (0.004)
* Total amount of cylinder head resurfacing and cylinder block resur-
facing
SERVICE DATA AND SPECIFICATIONS (SDS)KA
EM-91