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evorock Profile
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Date Registered: 12-2010
Location: Rockingham,Perth WA
TOTAL POSTS: 146
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T30 ti 02 5spd engine removal,stripdown and reassembly - Lots of pics -


Gday all.
Well I sucessfully rebuilt the head of my X 2002 T30 and is running okay.(Refer to DIY)
Before I did this I had an engine whine which I thought was a belt tensioner and when replaced went away.
The high pitched,engine bearing sound has now returned and im pretty sure its the timing chain guide rails that have worn and chain is rubbing against the exposed rivets that hold the guide shoe on. This will only lead to disaster soon enough. (It could be a Crank bearing too tho,dunno yet)

Well I want to keep this car as It has too much of my hard work in it.
I think id like to pull the engine out and rebuild the block with new front cover,bearings,pistons and replace all the timing chain components.

The compression is getting a bit low and almost seems pointless just to fix the chain issue.
There are engine rebuild kits on ebay which seem to be okay quality without going overboard with NASA spec parts for 10000rpm Xtrail.
The kit im looking at contains all bearings,pumps,pistons,rings,gaskets,head bolts and new timing/balancer chains and tensioners etc.
They want $530 and $200 for shipping. Seems okay?????? anyone?

My biggest question is.
Has anyone removed their engine and whats the best way to do it. ie: remove with gearbox attached or seperate it first?
Ill take it from top with a crane but is there any tricks that may help me doing this.

I think ill open my own Xtrail fix it shop if all this goes well.lol.

Oh and I think I might treat the engine to a little higher compression and Hp output bits. Mmmm. exhaust, lighten crank pulleys, 20thou oversize pistons and rings, intake.

Ill do another write-up on the build too,might be a few weeks away tho.

Last edited by evorock, 1/Oct/2011, 11:14 pm


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2002 T30 Xtrail Ti , White 5Sp
Full engine rebuild, Single Mass flywheel upgrade,
Scott, Rockingham, Perth WA
29/Aug/2011, 11:02 pm Link to this post Send Email PM   Send Private Message Blog
 
Robbo0001 Profile
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Date Registered: 07-2008
Location: Brisvegas, Australia
TOTAL POSTS: 1063
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Re: Engine removal and rebuild T30 - DIY


quote:

There are engine rebuild kits on ebay which seem to be okay quality without going overboard with NASA spec parts for 10000rpm Xtrail.


Great line emoticon

I think most of the QR25DE gear available from the States, either via EBay or Amazon are of a good enough quality to be reliable. That price seems pretty fair, provided other quotes are obtained.
If I ever pulled the engine it would be out the engine bay, remove radiator and condensor etc, pull off the grilles and bumper. I cant guarantee it would fit, but with the bonnet removed I dont see why it wouldnt.

 The sentra forums are a great place for info, as you know, so a little bit of research will help. The Jim Wolf balance shaft removal kit may be an option, if you are ripping the engine out and apart.

I haven't seen an "unorthodox" pulleys for a while online (same diametre as OEM, just lighter material) however the smaller diametre underdrive pulleys are still available.

Look forward to anoter write up...dont envy your task though



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Dave
99 GU Patrol 2.8TD
Ex-2002 T30 TI Xtrail
30/Aug/2011, 6:16 am Link to this post Send Email PM   Send Private Message
 
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Date Registered: 02-2004
Location: SUTHERLAND, SYDNEY
TOTAL POSTS: 29094
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Re:


Scott,

Time to consider that GT engine for the exy now and am sure you will be able to find it from NewZealand as they have a huge market for grey imports there emoticon

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30/Aug/2011, 8:54 am Link to this post Send Private Message MSN Blog
 
evorock Profile
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Date Registered: 12-2010
Location: Rockingham,Perth WA
TOTAL POSTS: 146
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Re:


Yeah, here we go again. oh well, I enjoy this kind of stuff but ill still moan all day about it...lol.
The Gt Sr20VET um... OMG... OMG. Im in fricken love, that engine is awesome and they car would pull harder than teenager. I called around and could not track one down in Aus but could get one from New Z or Japan. The engine is actually quite expensive around $4000 but the looks of it. Front cut would be the way to go as youd need something to stop the damn thing too.
The engine only comes in Auto which was a bit of a shame, but i would be dead keen on doing this conversion but the costs would actually be huge.

I bought the Balance Shaft removal kit of Jim Wolf in US, seems like some cheap HP.
The engine rebuild kit is around $700 bucks all up and has some decent bearings and a front cover in it.
Im going to pull the engine with Gearbox attached.
I dont think ill get the crank pulley and as mentioned they are smaller and would have to get another belt again. I just dont think the engine would benefit from it too much as our 4wd gearboxes zap alot of power.
Im still um and ahring about the exhaust headers and again I think to get any decent Hp gains that the whole system would need to be upgraded.

speak to ya all soon.
Oh yeah. ' You tube' SR20VET GT Xtrail and itll send shivers down ur spine and possibly holes in your pockets.

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2002 T30 Xtrail Ti , White 5Sp
Full engine rebuild, Single Mass flywheel upgrade,
Scott, Rockingham, Perth WA
31/Aug/2011, 9:05 pm Link to this post Send Email PM   Send Private Message Blog
 
evorock Profile
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Date Registered: 12-2010
Location: Rockingham,Perth WA
TOTAL POSTS: 146
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Re: Engine removal and rebuild T30 - DIY


Hi all, well I’ve been quite busy lately.
I set out to find myself an engine crane and stand for a reasonable price over here in WA.
After much searching I found an awesome shop called hare and Forbes machinery house here in Belmont, I got the hydraulic crane for $240 and the stand for $60. I also thought I’d get a decent trolley jack and compressor to make life a bit easier.

I got home and set the garage up for the endless parts that hopefully will soon be scattered around the workshop.

I dropped all the oils and begun jacking the car up and removing the wheels.
I started this on Fri arvo and worked late into the night. I struggled with the passenger side axle nut as I think Swartzeneger did it up. After much swearing and stripping of the nut I decided just to pull the whole shaft from the Gearbox (which means I had to completely disassemble the strut and housings). Still not sure how I’ll get that off now.

I set to work taking apart all the easy stuff like the Air intake, exhaust manifolds,alternator,air conditioning pump, fuel rail,sparks,radiator,bonnet and lots of various sensors which I labelled carefully,

The next morning the Tail shaft and the Intake manifold was removed as I couldn’t reach the bolts and some sensors behind it (the power steering pump bolts are in rediculous spots)

I decided to leave the Gearbox on the engine as it seemed that there was plenty of room for removal after taking everything around it apart.

Here are a few pics.
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2002 T30 Xtrail Ti , White 5Sp
Full engine rebuild, Single Mass flywheel upgrade,
Scott, Rockingham, Perth WA
21/Sep/2011, 10:29 pm Link to this post Send Email PM   Send Private Message Blog
 
cooch t31 Profile
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Date Registered: 06-2008
Location: Blue Mountains, NSW
TOTAL POSTS: 5966
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Re:


Been busy Scott.
I like the pic of the pizza and a bottle of what the F*#k do I do know, lol.

To get the hub nut off, try applying a bit of heat with a gas torch and then try with a socket and a length of pipe over the handle. You'll probably have to wait until its all back in to try this though.
If that fails there's always the last resort, cut it off with a small dremel grinder and then get yourself a new nut.
Vise grips work well on stripped nuts as well.

I don't know how your doing all of this in a standard double garage with 2 cars in it.

Last edited by cooch t31, 22/Sep/2011, 5:52 am


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Tony X-891c

HERE is my D22 Navara
HERE is my old 2008 T31, ST Series1

22/Sep/2011, 5:40 am Link to this post Send Private Message
 
evorock Profile
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Date Registered: 12-2010
Location: Rockingham,Perth WA
TOTAL POSTS: 146
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Re: Engine removal and rebuild T30 - DIY


Hahah. Busy much? ooh yeah! Anythings possible with pizza and scotch.

It is a double garage but it has a decent sized alcove in it. But it is quite cramped. Ive had to be very strict with my tool management and get creative with where everything will be put. I was really worried that the Engine Crane wouldnt roll back far enough before it hit the wall to move it away from the car. Thank that Nissan god it did...just...
I work on ships sometimes and the amount of space in some spots is real tight.
One day ill but myself a big shed and have a decent layout with an overhead beam hoist..

Thats good advice with the axle nut. I pretty much tried everything besides a torch. Ive ruined any chance of salvage now I think. dremel time.... Another casulty of war was that I got fed up with and was heavy fisted on was the outer tie rod end. I have a seperator tool but was too small so ended up using a fork type splitter and BFH. um yeah,this ruins the boot pretty much instantly. meh ill get a new one.... im sure there will be more random broken bits to that list.lol.

Ill keep updating soon. Lots more pics to come.

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2002 T30 Xtrail Ti , White 5Sp
Full engine rebuild, Single Mass flywheel upgrade,
Scott, Rockingham, Perth WA
22/Sep/2011, 11:11 pm Link to this post Send Email PM   Send Private Message Blog
 
Robbo0001 Profile
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Date Registered: 07-2008
Location: Brisvegas, Australia
TOTAL POSTS: 1063
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Re: Engine removal and rebuild T30 - DIY


Another option for the hub nut is a large ballpeen hammer and a cold chisel. Cut a nice groove into the lip of the nut and smash it around the shaft. Gotta get a new one anyway, right? emoticon Safety glasses obviously.
The nuts are inrternally tapered and are meant to be a "one use" item anyway, apparently.


Dunno how you can work like that, mate....being cramped up drives me nuts. I end up with my shite spread everywhere. Love the tool "build up" though....you can never have enough emoticon

Did you reclaim any refrigerant or are you leaviing the system intact?
"Makers Mark'...top drop, definately keep you lubricated

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Dave
99 GU Patrol 2.8TD
Ex-2002 T30 TI Xtrail
23/Sep/2011, 5:36 am Link to this post Send Email PM   Send Private Message
 
evorock Profile
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Date Registered: 12-2010
Location: Rockingham,Perth WA
TOTAL POSTS: 146
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Re: Engine removal and rebuild T30 - DIY


Hey guys. Sorry havent got back to this for a while.
Sorry Robbo too, it is possible to remove the AC without having to reclaim which is a bonus. Just have to suspend the Pump with a rope, I left the condensor in as well and just covered with the side of a cardboard box.

Okay, so ive got the engine out and seperated the gearbox.
The Flywheel and clutch mechanism is removed and the engine has been slowly stripped down part by part, ill prob just let most of the pictures do the talking here as there is a lot to talk about with each step. Please give me a call or Pm if you would like to know any indepth stuff if you are thinking of tackling too.
At the time of writing this I have the Block and head in a machine shop having the Cylinders bored oversize, Crank grinded,polished and balanced. Hopefully theyll come come back all nice and shiny after a swim in an acid bath. I wanted to Soda Blast all my parts but couldnt find any shops that could do it. Besides the Block and head I have had to strip,clean and polish all the parts myself which takes alot of time and effort.
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Im sorry to the people with Slow connections,like me! for all this stuff to load.

Oh Yeah, curiosity killed the cat and i couldnt help myself than to have a sticky in the Gearbox..
When the finally figured out how to seperate the case, two small ball bearings fell out and rolled out on the floor. My heart actually skipped 239 times faster than usual. afetr late night trawling of Geearbox rebuilds I figured out that they are called detent balls and are housed in the case with a spring and bolt to make sure I think that the shift fork stays in place. this is apparently what you hear when you change gears and that tick sound is heard. Funnily enough and couldnt believe I even called them but NISSAN had no idea.lol. No more chances left now nissan,thankyou for xtrails but you should just sell em and not try to fix em!

Right, more pics.
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Image Shift Mechanism
Image Throw out Bearing/Thrust bearing(whatever floats ya) and arm
Image Shiny now. Clutch is still in pretty good nick too.
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Image This is the Balancer unit on the engine. Im going to retain it to save the cost of removing it and it is hard to say if itll have a negative imapact, especially on a rebuilt engine.
Image Front cover components, theres actually quite a bit of components in this thing. These were absoloutely filthy too and I have spent hours cleaning up.
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Image - Cause I could and wanted to polish something. OCD was in full swing too, emoticon

Will post more when i get the Block back and ill show how it all goes back all nice and shiny and hope I dont screw it up. emoticon

Have a great weekend, ill be sleeping in my garage. emoticon

---
2002 T30 Xtrail Ti , White 5Sp
Full engine rebuild, Single Mass flywheel upgrade,
Scott, Rockingham, Perth WA
1/Oct/2011, 11:10 pm Link to this post Send Email PM   Send Private Message Blog
 
evorock Profile
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Date Registered: 12-2010
Location: Rockingham,Perth WA
TOTAL POSTS: 146
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Re: T30 ti 02 5spd engine removal,stripdown and reassembly - Lots of pics -


Hi trail fans.
Just an update to what’s happening with this build.
The engine block and crank train are still in the shop and i was starting to get a little frustrated the time it’s taking (2 and half weeks). I rang the shop today and they explained that their flat out and they’ll have it done on Tuesday, cool, all good.

These guys are very good and have won second best in Australia from an American judging Company for their machine work and quality so I don’t care really how long it takes.
I spoke to the foreman and his knowledge was mind boggling on the job at hand. He explained that my pistons suffered massive failure and went into the specifics of the metalology(see i can’t even spell that word!!lol) and he basically demanded that he put oversized specific pistons and rings and certain hardened components, tolerances will be this and ring gap that.... I sort of went 'um err bah, okay cool order em and do what you want.'
Expecting this to cost my next months pay check, he gave me a quote for all the work and it was nothing like I thought it would be and I silently ecstatic.

He did say that my head was clean, decked and ready to go so I just picked that up today and will assemble it over the weekend.

He showed me my Crank that had grinded and polished for the new undersize bearings. The number one journal was really out of spec and that explains the massive failure of my no1 bearings and the gaping score lines and wiping. (Pretty confident that this is the source of my engine whine)
He mentioned that everything had a yellow tinge under the microscope and that an engine additive (you know the ones!!) has been used (guilty emoticon !!) and has built up a crappy layer of bearing hating sludge which ruined everything over time.. The advice was to never use that s***!!!. Point taken...

He spoke about the block and he had concerns that a simple hone wouldn’t suffice and rarely will apparently. He said that any Block with some sort compression issues or oil burning problems should always be bored out and new pistons added. This is because the cylinder walls have sort of absorbed contaminants and burnt oil over time and glazed them like a cheap Christmas cherry. Mmmm Cherries..... (10 weeks to Christmas by the way peoples!!)

Everything else looked okay and I’m looking forward to chatting with him again when the blocks been bored oversize and the pistons and bearing are shipped from the Eastern states. This is going to be one tight xtrail engine when done. Run tens down the quarter for sure..lol...

On a side note. I finally managed to get all the new seals and plugs for the Gearbox from Nissan at Trade price (because they kept ordering the wrong stuff) and the full engine gasket kit with head bolts arrived from the US. ($150.00)
I’ve also ordered a rebuild kit for the Injectors from Mr Injector on US EBay as i damaged two Pintle Caps on removal. $34.00 US for a rebuild kit versus $300 each for new ones versus $380 for local shop to rebuild (which is easy by the way as the instructions are on the net)

Have a great weekend all.. AND

           IMsmallO...... AND THE BIG OPINION OF AN ENGINE BUILDER THAT WON SECOND OVERALL IN AUSTRALIA FOR BEING AWESOME AT ENGINE STUFF, DONT USE ENGINE OIL ADDITIVES.......


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2002 T30 Xtrail Ti , White 5Sp
Full engine rebuild, Single Mass flywheel upgrade,
Scott, Rockingham, Perth WA
14/Oct/2011, 7:54 pm Link to this post Send Email PM   Send Private Message Blog
 


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