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Posts Tagged ‘engine’

1993 Nissan King Cab – Rebuild

January 30th, 2010 1 comment

** Note, any questions about my rebuild?  Go to my about page to find my email address, and send me a message **

 

My truck has a really bad exhaust manifold leak.  I have 2 broken bolts at the rear of the manifold, and it’s loud, and causing the engine not to run very good and gas mileage is suffering.  I need something semi reliable this summer to tow around my tent trailer, so  I thought I would spend the time and fix it right.

DAY 1

We pretty much dissembled the whole motor today.  The top plenum, lower intake manifold, accessories, crank pulley, timing belt, left and right cylinder heads.  We took the heads off with the exhaust manifolds attached, AND the downpipes attached.  The connector between the manifold, and the downpipe was rusted so badly, there’s no way we were going to get at the bolts, so we just cut the exhaust pipe under the car, and took it out in one piece.  When we put it back together, we’ll weld it back up.

Next is to take the exhaust manifolds off the heads, and drill out the broken exhaust manifold studs, and replace. 


From Truck Rebuild
From Truck Rebuild
From Truck Rebuild
From Truck Rebuild
From Truck Rebuild

 
Day 2

Today we worked on the heads, and since they are sitting on the workbench, we were able to move them around, and had lots of room to work.  We used some heat, and got the manifolds off the heads, and all the studs out of the head.  Interesting to note, the studs seemed to have already been replaced with new ones.  Looks like someone has done this job once before on this truck, and he must not have refaced the manifolds, and caused the bolts too much stress, and broken a second time. 
 
We also took the downpipes off the manifolds, and cleaned up that connection a bit as well.
 
We took the cam sprockets off, and pulled the seals (as one was leaking), and also trimmed up the metal plate behind the sprockets, which holds the timing alignment dot.
 
We noticed that both manifolds are slightly warped, so we’ll bring those to a machine shop and get them refaced. 
 
Tomorrow we will probably start trying to get the 2 studs out, which are broken off inside the head.  I think we will try a reverse drill bit first, and some head, and if that doesn’t work, we’ll start drilling.
 


From Truck Rebuild
From Truck Rebuild

 
DAY 3
Today we decided to drill out the 2 broken studs that were stuck inside the head.  But since the studs seemed to be new , we used an ‘easy out’, and easily screwed the studs out.  That was about it today.
 
We are going to order all the parts necessary, and start putting things back together Friday, Sat, and Sun.  Those will be major days, as it seems a little overwhelming all the parts stacked up on the workbench that have to go back on.  :)
 
DAY 4
Well, no work today.  But we did order all the parts for putting the motor back together.  Here’s the parts list:
  • Head gaskets
  • Exhaust manifold gaskets
  • Downpipe gaskets
  • Intake manifold gasket set
  • Waterpump w/ gasket
  • Cam seals
  • Timing belt w/ tensioner, w/ spring
  • All new radiator hoses, and lower intake manifold 90 degree hose
  • All new accessory belts
  • O2 sensor
  • Oil Filter
  • New catalytic converter

 

The parts
come in tomorrow, so this weekend we’ll get it all back together hopefully.  I’ll update my post as the days come and pass

 
DAY 5

After all the parts came in, we put them all on the motor. Everything went on perfect, with no troubles. We put on the new timing belt, and made sure everything was timed up. After everything was on, we started it up, and it started first try! I took the truck in to get the exhaust all welded back on. The truck runs awesome now! I Love it again!

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