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nsxb07003a.pdf

Engine Block
Illustrated Index
Lubricate all internal parts with engine oil during reassembly.
NOTE:
• Apply liquid gasket to the mating surfaces of the
left side cover and oil pump case before install-
ing them.
• Use liquid gasket, part No. 08718-0001.
If the bottom of the oil pan is deformed, it should
be repaired or the oil pan should be replaced re-
tain proper clearance between the screen and
the bottom.
COVER
DRIVE PLATE (A/T)
Check for cracks.
SPECIAL WASHER
12 x 1.0 mm
75 N-m (7.5 kg-m, 54 Ib-ft)
Torque sequence, page 7-6
12 x 1.0 mm
105 N-m (10.5 kg-m. 76 Ib-ft)
Torque sequence, page 7-6
6 x 1.0 mm
14 N-m (1.4 kg-m, 10 Ib-ft)
OIL PAN
• Do not deform
the bottom.
• Refer to page 8-10
when installing.
OIL PAN GASKET
Replace
6 x 1.0 mm
12 N-m (1.2 kg-m, 9 Ib-ft)
O-RING
Replace.
CRANKSHAFT
OIL SEAL
Installation, page 8-9
Replace.
CRANKSHAFT OIL SEAL
Installation, page 7-18
Replace.
SPECIAL BOLT
6 x 1.0 mm
12 N-m (1.2 kg-m,
9 Ib-ft)
Replace.
OIL PASS
PIPE/JOINT
LEFT
SIDE COVER
Apply liquid gasket
to mating surface.
DOWEL PINS
OIL PUMP
Overhaul, page 8-7
Removal/Inspection,
page 8-8
Apply liquid gasket
to mating surface.
SPECIAL BOLTS
8 x 1.25 mm
22 N-m (2.2 kg-n
16 Ib-ft)
Replace.
SPECIAL BOLTS
6 x 1.0 mm
12 N-m (1.2 kg-m, 9 Ib-ft)
Replace.
DOWEL PINS
O-RINGS
Replace.
OIL SCREEN
FLYWHEEL (M/T)
Runout, section 12
BAFFLE PLATE
6 x 1.0 mm
12 N-m (1.2 kg-m,
9 Ib-ft)
COVER

Engine Block
Illustrated Index
Lubricate all internal parts with engine oil during reassembly.
MAIN BEARING
CAP BRIDGE
10 x 1.25 mm
50 N-m (5.0 kg-m, 36 Ib-ft)
Apply engine oil to the
bolt threads and the washers.
MAIN BEARING
CAP
CRANKSHAFT
End play, page 7-6
Runout, Taper, and
Out-of-Round, page 7-11
Installation, page 7-18 to 7-21
THRUST WASHERS
Replacement, page 7-6
Grooved sides face outward.
NOTE: Thrust washer thickness
is fixed and must not be changed
by grinding or shimming.
11 x 1.5 mm
66 N-m
(6.6 kg-m, 48 Ib-ft)
Apply engine oil to the bolt
threads and the washers.
NOTE: After torquing
each cap, turn crankshaft
to check for binding.
9 x 1.25 mm
40 N-m (4.0 kg-m, 29 Ib-ft)
Apply engine oil to the
bolt threads
DOWEL PIN
MAIN BEARINGS
Radial clearance, page 7-7
Selection, page 7-8
NOTE: New main bearings
must be selected by matching
crank and block identification
markings.
6 x 1.0 mm
12 N-m (1.2 kg-m,
9 Ib-ft)
DOWEL PIN
OIL BREATHING
COVER
O-RING
Replace.

NOTE: New rod bearings must be selected by matching
connecting rod assembly and crankshaft identification
markings (see page 7-8).
TIMING
BELT
SIDE
CAUTION:
• The piston skirt is coated with molybdenum;
handle the piston carefully to prevent any
damage.
• The connecting rods are made of titanium. At-
tempting to remove the piston pin with conven-
tional shop equipment will damage the connec-
ting rod.
• If the piston, connecting rod, or piston pin re-
quire replacement, all three must be replaced as
an assembly.
PISTON
Inspection, page 7-13
NOTE:
• Before removing piston, inspect the top
of the cylinder bore for carbon build-up
or ridge. Remove ridge if necessary, page 7-9.
• To maintain proper piston clearance, match
the letter on the piston top (No letter denotes A.)
with the letter for each cylinder stamped on the
block.
CONNECTING ROD ASSEMBLY
End play, page 7-6
Selection, page 7-14
CONNECTING ROD
BEARINGS
Clearance, page 7-7
Selection, page 7-8
CONNECTING ROD
WASHER
CONNECTING ROD CAP NUT
8 x 0.75 mm
20 N-m (2.0 kg-m, 14 Ib-ft)
then turn 95°
After torquing each bearing
cap, rotate crankshaft to
check for binding.
CYLINDER BORE SIZES
NOTE: To maintain proper piston clearance,
match these letters with the letters on the
pistons. The letters on the block read from
left to right, No. 1 through No. 3. cylinders
on the first line and No. 4 through No. 6
cylinders on the second line.
CONNECTING ROD BEARING CAP
Installation, page 7-18 to 7-21
NOTE: Install caps so the bearing recess is
on the same side as the recess in the rod.
PISTON RINGS
Replacement, page 7-15
Measurement, pages 7-15 and 7-16
Alignment, page 7-16
CONNECTING ROD BOLT
Inspect top of each cylinder bore
for carbon build-up or ridge
before removing piston.
Remove ridge if necessary, page 7-9
ENGINE BLOCK
Cylinder bore inspection, page 7-12
Warpage inspection, page 7-12
Cylinder bore honing, page 7-13

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nsxb07009a.pdf

Piston/Connecting Rod Assemblies and Crankshaft
Removal
1. Remove the left side cover.
LEFT SIDE COVER
2. Remove the oil screen.
BAFFLE PLATE
OIL PASS OIL SCREEN
PIPE
O-RINGS
Replace
OIL PUMP
3. Remove the baffle plate.
4. Remove the oil pass pipe and joint.
5. Remove the oil pump.
6. If you can feel a ridge of metal or hard carbon
around the top of any cylinder, remove it with a
ridge reamer. Follow reamer manufacturer’s
instructions.
CAUTION: If the ridge is not removed, it may
damage the pistons as they are pushed out.
RIDGE REAMER
7. Remove the bearing cap bridge.
BEARING CAP
BRIDGE

Piston/Connecting Rod Assemblies and Crankshaft
Removal
• Remove the connecting rod caps after setting
the crank pin at BDC for each cylinder. Remove
the piston assembly by pushing on the connec-
ting rod.
CAUTION: Take care not to damage the crank pin
or cylinder with the connecting rod.
CORRECT PISTONS
INCORRECT
8. Remove the bearing from the cap. Keep all
caps/bearings in order.
9. Remove the upper bearing halves from the connect-
ing rods. Set them aside with their respective caps.
10. Reinstall the cap on the rod after removing each
piston/connecting rod assembly.
11. Mark the piston/connecting rod assemblies with
their cylinder numbers to avoid mixup on reassem-
bly.
NOTE: The existing number on the connecting rod
does not indicate its position in the engine, it in-
dicates the rod bore size.
12. Remove the bearing cap bolts and bearing cap side
bolts, then remove the bearing caps.
BEARING CAP
BEARING CAP
BOLT
BEARING CAP
SIDE BOLT
To help with removal of the caps, install the bear-
ing cap bridge bolts in the bearing cap bolt holes.
BEARING CAP
BRIDGE BOLT
BEARING CAPS
13. Lift the crankshaft out of engine, being careful not
to damage the journals.
CRANKSHAFT
14. Reinstall the main caps and bearings on the block in
proper order.

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nsxb07012a.pdf

Cylinder Block
Inspection
1. Measure wear and taper in directions X and Y at
three levels in each cylinder as shown.
CYLINDER BORE SIZES (A or B)
NOTE: To maintain proper piston
clearance, match these letters with
the letters on the pistons. The let-
ters on the block read from left to
right, No. 1 through No. 3 cylinders
on the first line and No.4 through
No.6 cylinders on the second line.
Cylinder Bore Size
Standard (New):
A or I 90.010-90.020 mm (3.5437-3.5441 in)
B or 90.000-90.010 mm (3.5433-3.5437 in)
Service Limit: 90.07 mm (3.546 in)
Oversize
0.25: 90.25-90.26 mm (3.553-3.554 in)
0.50: 90.50-90.51 mm (3.563-3.564 in)
Bore Taper
Limit: (Difference between first and third measure-
ment) 0.05 mm (0.002 in)
• If measurements in any cylinder are beyond
Oversize Bore Service Limit, replace the block.
• If block is to be rebored, refer to Piston Clearance
Inspection (see page 7-13) after reboring.
NOTE: Scored or scratched cylinder bores must be
honed.
Reboring Limit: 0.50 mm (0.020 in)
2. Check the top of the block for warpage.
Measure along the edges and across the center as
shown.
SURFACES TO BE MEASURED
Engine Block Warpage:
Standard (New): 0.07 mm (0.003 in) max.
Service Limit: 0.10 mm (0.004 in)
PRECISION STRAIGHT EDGE
CYLINDER
BORE
GAUGE

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5e4c7d79268a4e41b086045b117414e76952ce6f4b2c15b7bc2309c2da583b48

nsxb07014a.pdf

Connecting Rods
Selection
Each rod is sorted into one of four tolerance ranges
(from 0 to 0.024 mm, in 0.006 mm increments) depen-
ding on the size of its big end bore. It’s then stamped
with a number (1, 2, 3 or 4) indicating that tolerance.
You may find any combination of 1, 2, 3 or 4 in any
engine.
Normal Bore Size: 53 mm (2.09 in)
NOTE:
• Reference numbers are for big end bore size and
do NOT indicate the position of the rod in the
engine.
• Inspect each connecting rod for cracks and heat
damage.
CONNECTING ROD BORE
REFERENCE NUMBER
Half of number is stamped on
bearing cap, the other half on
connecting rad.
Inspect bolts
and nuts for
stress cracks.

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f61470afd065b7bd4e855174243a18f66f517a9e47ed14640881b85dd83f019e

nsxb07007a.pdf

Main Bearings
Clearance
1. To check main bearing-to-journal oil clearance,
remove the main caps and bearing halves.
2. Clean each main journal and bearing half with a
clean shop towel.
3. Place one strip of plastigage across each main jour-
nal.
NOTE: If the engine is still in the car when you bolt
the main cap down to check clearance, the weight
of the crankshaft and flywheel will flatten the plasti-
gage further than just the torque on the cap bolts,
and give you an incorrect reading. For an accurate
reading, support the crank with a jack under the
counterweights, and check only one bearing at a
time.
4. Reinstall the bearings, caps and cap bridge, then
torque the 9 mm bridge bolts to 40 N-m (4.0 kg-m,
29 Ib-ft). Torque the 11 mm cap bolts to 66 N-m
(6.6 kg-m, 48 Ib-ft).
5. Torque the side bolts to 50 N-m (5.0 kg-m, 36 Ib-
ft).
6. Remove the bridge, caps and bearings, and
measure the widest part of the plastigage.
Main Bearing-to-journal Oil Clearance:
Standard (New): 0.024-0.048 mm
(0.0009-0.0019 in)
Service Limit: 0.050 mm (0.0020 in)
PLASTIGAGE STRIP
7. If the plastigage measures too wide or too narrow,
(remove the engine if it’s still in the car), remove the
crankshaft, and remove the upper half of the bear-
ing. Install a new, complete bearing with the same
color code (select the color as shown on next page),
and recheck the clearance.
CAUTION: Do not file, shim, or scrape the bear-
ings or the caps to adjust clearance.
8. If the plastigage shows the clearance is still incor-
rect, try the next larger or smaller bearing (the color
listed above or below that one), and check again.
NOTE: If the proper clearance cannot be obtained
by using the appropriate larger or smaller bearings,
replace the crankshaft and start over.
Connecting
Rod Bearings
Clearance
1. Remove the connecting rod cap and bearing half.
2. Clean the crankshaft rod journal and bearing half
with a clean shop towel.
3. Place plastigage across the rod journal.
4. Reinstall the bearing half and cap, and torque the
nuts as shown on page 7-19.
NOTE: Do not rotate the crankshaft during inspection.
5. Remove the rod cap and bearing half and measure
the widest part of the plastigage. Make sure the
clearance between the connecting rod and the
bearing is within the standard shown below.
Connecting Rod Bearing-to-Journal Oil Clearance:
Standard (New): 0.040—0.060 mm
(0.0016-0.0024 in)
Service Limit: 0.060 mm (0.0024 in)
PLASTIGAGE STRIP
6. If the plastigage measures too wide or too narrow,
remove the upper half of the bearing, install a new,
complete bearing with the same color code (select
color as shown on next page), and recheck the
clearance.
CAUTION: Do not file, shim, or scrape the bearing
or the caps to adjust clearance.
7. If the plastigage shows the clearance is still incor-
rect, try the next larger or smaller bearing (the color
listed above or below that one), and check
clearance again.
NOTE: If the proper clearance cannot be obtained
by using the appropriate larger or smaller bearings,
replace the crankshaft and start over.

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nsxb07015a.pdf

Piston Rings
End Gap
1. Using a piston, push a new ring into the cylinder
bore 15 – 20 mm (0.6 – 0.8 in) from the bottom.
2. Measure the piston ring end-gap with a feeler
gauge:
• If the gap is too small, check to see if you have
the proper rings for your engine.
• If the gap is too large, recheck the cylinder bore
diameter against the wear limits on page 7-12. If
the bore is over limit, the cylinder block must be
rebored.
Piston Ring End-Gap:
Top Ring
Standard (New): 0.25-0.40 mm
(0.010-0.016 in)
Service Limit: 0.60 mm (0.024 in)
Second Ring
Standard (New): 0.35-0.50 mm
(0.014-0.020 in)
Service Limit 0.75 mm (0.03 in)
Oil Ring
Standard (New): 0.20-0.70 mm (0.008-0.028
in)
Service Limit: 0.80 mm (0.031 in)
Replacement
1. Using a ring expander, remove the old piston rings.
2. Clean all ring grooves thoroughly.
NOTE:
• Use a squared-off broken ring or ring groove
cleaner with blade to fit piston grooves.
• Top and 2nd ring grooves are 1.2 mm (0.05 in)
wide and the oil ring groove is 2.8 mm (0.11 in)
wide.
• File down the blade if necessary.
CAUTION: Do not use a wire brush to clean the ring
grooves, or cut ring grooves deeper with a cleaning
tool.
3. Install new rings in the proper sequence and posi-
tion (see page 7-16).
NOTE: Do not reuse old piston rings.

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54961e6e1f303494f3df8059a71f1a0f4894fc84b12b084d17b35d5122f3d0da

nsxb07018b.pdf

Crankshaft
Installation
Before installing the crankshaft, apply a coat of
engine oil to the main bearings and rod
bearings.
1. Insert bearing halves in the engine block and con-
necting rods.
2. Lower the crankshaft into the block.
3. Install the thrust washers on the No. 3 journal. Oil
thrust washer surfaces.
4. Install the bearings and caps. Tighten 9 x 1.25 mm
cap bolts to the specified torque.

NOTE:
• Guide the piston carefully to prevent damage.
• Fit long rubber hoses (about 30 cm long) to con-
necting rod bolts to protect the crankshaft.
• Install the pistons after setting the crankshaft to
BDC for each cylinder.
CORRECT INCORRECT
RUBBER HOSES
9 x 0.75 mm
20 N-m (2.0 kg-m, 14 Ib-ft)
after turn to 95°
MARK
• Line up the marks when installing connecting
rod cap.
5. Check the rod bearing clearance with plastigage
(see page 7-7), then torque the connecting rod cap
nuts.
NOTE: Reference numbers on connecting rods are
for big-end bore tolerance and do NOT indicate the
position of piston in engine.
CONNECTING ROD CAP NUT TORQUING
METHOD
1) Torque the connecting rod cap nut to 20 N-m
(2.0 kg-m, 14 Ib-ft) with a beam-type torque
wrench.
2) Install a torque angle gauge to the cap nut, then
turn the cap nut 95 degrees.
Snap-on
TA360 or
equivalent
BEARING CAP
WASHERS

Crankshaft
Installation
6. Install the bearing cap bridge, and tighten 11 x 1.5
mm bolts to the specified torque diagonally out-
ward from the center.
Torque 66 N-m (6.6 kg-m, 48 Ib-ft)
7. Tighten cap side bolts (10 x 1.25 mm) to the
specified torque.
Torque: 50 N-m (5.0 kg-m, 36 Ib-ft)
• Coat the bolt thread and seat surface with
engine oil.
NOTE: The shorter side bolts are for the front side.
BEARING CAP
BRIDGE CAP BRIDGE BOLT
11 x 1.5 mm
66 N-m (6.6 kg-m,
48 Ib-ft)
SIDE BOLT
10 x 1.25 mm
50 N-m (5.0 kg-m,
36 Ib-ft) CAP BOLT9 x 1.25 mm
40 N-m (4.0 kg-m,
29 Ib-ft)
8. Apply liquid gasket to the block mating surface of
the left side cover and oil pump case, and install
them on the engine block.
NOTE: The seal surface on the block should be
dry. Apply a light coat of oil to the crankshaft and
to the lip of seal.
LEFT SIDE:
Apply liquid
gasket to block
mating surface.
LEFT SIDE COVER
SPECIAL BOLTS
6 x 1.0 mm
12 N-m (1.2 kg-m,
9 Ib-ft)
Replace.
DOWEL PIN
BEARING CAP BOLTS TORQUE SEQUENCE

6 x 1.0 mm
12 N-m (1.2 kg-m,
9 Ib-ft)
OIL PUMP
Apply liquid
gasket to block
mating surfaces.
SPECIAL BOLTS
6 x 1.0 mm
12 N-m (1.2 kg-m,
9 Ib-ft)
Replace.
SPECIAL BOLTS
8 x 1.25 mm
22 N-m (2.2 kg-m,
16 Ib-ft)
Replace.
NOTE:
• Use liquid gasket, Part No. 08718-0001.
• Check that the mating surfaces are clean and
dry before applying liquid gasket.
• Apply liquid gasket evenly, being careful to cover
all of the mating surface.
• To prevent leakage of oil, apply liquid gasket to
the inner threads of the bolt holes.
LEFT
SIDE COVER
Apply liquid gasket
along the broken line.
OIL PUMP
Apply liquid gasket
along the broken line.
• Do not install the parts if five minutes or more
have elapsed since applying liquid gasket.
Instead reapply liquid gasket after removing old
residue.
• After assembly, wait at least 20 minutes before
filling the engine with oil.
9. Install the oil pass pipe and joint.
10. Install the baffle plate.
11. Install the oil screen.
12. Install the oil pan (see page 8-10).
CAUTION: Whenever any crankshaft or connec-
ting rod bearing is replaced, after reassembly, run
the engine at idling speed until it reaches normal
operating temperature, then continue to run for ap-
proximately 15 minutes.
OIL PUMP SIDE:
6 x 1.0 mm
12 N-m (1.2 kg-m, 9 Ib-ft)
OIL SCREENBAFFLE PLATE
OIL PASS
PIPE

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nsxb07013b.pdf

Piston/Connecting Rod
Assemblies
Inspection
1. Check the piston for distortion or cracks.
NOTE: If cylinder is bored, an oversized piston
must be used.
2. Measure piston diameter at a point 17 mm (0.67 in)
from the bottom of the skirt.
NOTE: There are two standard-size pistons (A =
no letter and B). The letter is stamped on the top of
the piston. These letters are also stamped on the
block as cylinder bore sizes.

Piston/Connecting Rod
Assemblies
Inspection
3. Calculate the difference between cylinder bore diam-
eter on page 7-12 and piston diameter.
Piston-to-Block Clearance
Standard (New): 0.006—0.034 mm
(0.0002-0.0014 in)
Service Limit: 0.0825 mm (0.0032 in)
0.0825 mm (0.0032 in)
Oversize Piston Diameter
0.25: 90.226-90.244 mm (3.5522-3.5530 in)
0.50: 90.476-90.494 mm (3.5620-3.5627 in)

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a6949495d3d7a212eef5e88ba1978efca040182bb338cfbead5595a934920bf3

nsxb07002a.pdf

Special Tools
7-6
7-18
7-18
Mam Menu
Table of Contents
Special Tools
1
(¿j
Ref. No. Tool Number Description Qty Page Reference
G) 07LAB — PV00100 Ring Gear Holder 1 7—6
or 07924 — PD20003
® 07749 — 0010000 Driver ‘I 7-18
® 07948 — 5300101 Driver Attachment 1 7-18
G:)

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d5131ee095ad81f5b7a7ec6d3597c3d3f7925680945b6be7f8671b6990bcee5d

nsxb07011a.pdf

Crankshaft
Inspection
• Clean the crankshaft oil passages with pipe
cleaners or a suitable brush.
• Check the keyway and threads.
Alignment
• Measure runout on all main journals to make
sure the crank is not bent.
• The difference between measurements on each
journal must not be more than the service limit.
Crankshaft Total Indicated Runout:
Standard (New): 0.015 mm (0.0006 in) max.
Service Limit: 0.03 mm (0.0012 in)
DIAL INDICATOR
Rotate two complete
revolutions.
Support with lathe-
type tool or V-blocks.
Out-of-Round and Taper
• Measure out-of-round at the middle of each rod
and main journal in two places.
• The difference between measurements on each
journal must not be more than the service limit.
Journal Out-of-Round:
Standard (New): 0.004 mm (0.0002 in) max.
Service Limit: 0.006 mm (0.0002 in)
Measure taper
at edges.
Measure out-of-
round at middle.
• Measure taper at edges of each rod and main
journal.
• The difference between measurements on each
journal must not be more than the service limit.
Journal Taper:
Standard (New): 0.005 mm (0.0002 in) max.
Service Limit: 0.010 mm (0.0004 in)

Attachments