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Nissan Silvia. Manual - part 239

Removal and Installation

NMEM0024

CAUTION:

When installing sliding parts (bearings, pistons, etc.),
lubricate contacting surfaces with new engine oil.

Place removed parts such as bearings and bearing caps
in their proper order and direction.

When installing connecting rod nuts and main bearing cap
bolts, apply new engine oil to threads and seating sur-
faces.

Do not allow any magnetic materials to contact the ring
gear teeth of flywheel or drive plate.

SEM141FB

Disassembly

NMEM0025

PISTON AND CRANKSHAFT

NMEM0025S01

Place engine on engine stand (ST0501S000).

Remove cylinder head.
Refer to EM-39, “Removal”.

Remove oil pan.
Refer to EM-20, “Removal”.

Remove timing chain. Refer to EM-26, “Removal”.

SEM877B

Remove pistons with connecting rods.

To disassemble piston and connecting rod, first remove snap
rings. Heat piston to 60 to 70°C (140 to 158°F) then use pis-
ton pin press to remove pin.

When piston rings are not replaced, make sure that piston
rings are mounted in their original positions.

When replacing piston rings, if there is no punchmark,
install with either side up.

Remove rear oil seal retainer.

SEM007D

Remove main bearing cap and crankshaft as shown.

Bolts should be loosened in two or three steps.

Before removing thrust bearing cap, measure crankshaft
end play. Refer to EM-92.

Before removing connecting rods, measure connecting
rod side clearance. Refer to EM-91.

SEM810DA

Remove baffle plate.

Remove oil jets.

IDX

CYLINDER BLOCK

Removal and Installation

EM-69

AEM023

Inspection

NMEM0026

PISTON AND PISTON PIN CLEARANCE

NMEM0026S01

Measure inner diameter of piston pin hole “dp”.

Standard diameter “dp”:

21.987 - 21.999 mm (0.8656 - 0.8661 in)

AEM024

Measure outer diameter of piston pin “Dp”.

Standard diameter “Dp”:

21.989 - 22.001 mm (0.8657 - 0.8622 in)

Calculate interference fit of piston pin to piston.

Dp − dp: −0.004 - 0 mm (−0.0002 - 0 in)

If it exceeds the above value, replace piston assembly with pin.

SEM024AA

PISTON RING SIDE CLEARANCE

NMEM0026S02

Side clearance:

Top ring

0.045 - 0.080 mm (0.0018 - 0.0031 in)

2nd ring

0.030 - 0.065 mm (0.0012 - 0.0026 in)

Max. limit of side clearance:

Top and 2nd ring

0.1 mm (0.004 in)

If out of specification, replace piston and/or piston ring. If clearance
exceeds maximum limit with new ring, replace piston.

CYLINDER BLOCK

Inspection

EM-70

SEM822B

SEM038F

SEM003F

PISTON RING END GAP

NMEM0026S03

End gap:

Top ring 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd ring 0.35 - 0.50 mm (0.0138 - 0.0197 in)
Oil ring 0.20 - 0.60 mm (0.0079 - 0.0236 in)

Max. limit of ring gap:

Top ring 0.39 mm (0.0154 in)
2nd ring 0.59 mm (0.0232 in)
Oil ring 0.60 mm (0.236 in)

If out of specification, replace piston ring. If gap exceeds maximum
limit with a new ring, rebore cylinder and use oversized piston and
piston rings. Refer to SDS, EM-90.

When replacing the piston, check cylinder block surface for
scratches or seizure. If scratches or seizure are found, hone
or replace the cylinder block.

CONNECTING ROD BEND AND TORSION

NMEM0026S04

Bend:

Limit 0.15 mm (0.0059 in)
per 100 mm (3.94 in) length

Torsion:

Limit 0.30 mm (0.0118 in)
per 100 mm (3.94 in) length

If it exceeds the limit, replace connecting rod assembly.

AEM156

CYLINDER BLOCK DISTORTION AND WEAR

NMEM0026S05

Clean upper surface of cylinder block.
Use a reliable straightedge and feeler gauge to check the flatness
of cylinder block surface. Check along six positions shown in fig-
ure.

Block surface flatness:

Standard Less than 0.03 mm (0.0012 in)
Limit 0.10 mm (0.0039 in)

If out of specification, resurface it.
The limit for cylinder block resurfacing is determined by the amount
of cylinder head resurfacing.

SEM008D

Amount of cylinder head resurfacing is “A”.
Amount of cylinder block resurfacing is “B”.

The maximum limit is as follows:

A + B = 0.2 mm (0.008 in)

Nominal cylinder block height
from crankshaft center:

211.25 - 211.35 mm (8.3169 - 8.3208 in)

If necessary, replace cylinder block.

IDX

CYLINDER BLOCK

Inspection (Cont’d)

EM-71

SEM363EA

SEM039F

PISTON-TO-BORE CLEARANCE

NMEM0026S06

Using a bore gauge, measure cylinder bore for wear, out-of-
round and taper.

Standard inner diameter:

86.000 - 86.030 mm (3.3858 - 3.3870 in)

Wear limit:

0.20 mm (0.0079 in)

Out-of-round (X − Y) standard:

0.015 mm (0.0006 in)

Taper (A − B and A − C) standard:

0.010 mm (0.0004 in)

If it exceeds the limit, rebore all cylinders. Replace cylinder
block if necessary.

Check for score and seizure. If seizure is found, hone it.

If cylinder block and piston are replaced, match piston
grade with grade number on cylinder block upper surface.

SEM012D

Measure piston skirt diameter.

Piston diameter “A”: Refer to SDS, EM-90.
Measuring point “a” (Distance from the top):

10.5 mm (0.413 in)

Check that piston-to-bore clearance is within specification.

Piston-to-bore clearance = bore measurement “C” −
Piston diameter “A”:

0.010 - 0.030 mm (0.0004 - 0.0012 in)

Determine piston oversize according to amount of cylinder
wear.

Oversize pistons are available for service. Refer to SDS,
EM-90.
6.

Cylinder bore size is determined by adding piston-to-bore
clearance to piston diameter “A”.

Rebored size calculation:

D = A + B − C

where,
D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)

Install main bearing caps and bearing beam, and tighten to the
specified torque. This will prevent distortion of cylinder bores,
otherwise cylinder bores may be distorted in final assembly.
Refer to EM-79, “Crankshaft”.

Cut cylinder bores.

When any cylinder needs boring, all other cylinders must
also be bored.

Do not cut too much out of cylinder bore at a time. Cut
only 0.05 mm (0.0020 in) or so at a time.

Hone cylinders to obtain specified piston-to-bore clearance.

10. Measure finished cylinder bore for out-of-round and taper.

CYLINDER BLOCK

Inspection (Cont’d)

EM-72

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