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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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Rebuild 2002 T30Ti Cylinder Head


Gday all.
Lately i noticed my Xtrails performance was lower,using alot of coolant,fuel and was hard to start after short trips.
I removed the Spark Plugs and used a borescope to discover that there was coolant on top of No1 and 2 piston. I removed the Radiator Cap and found foam and bubbles. Did a Turkey baster test and found there was oil contamination in the coolant.
I looked at the coolant overflow bottle and was almost empty to the last time I marked it.
Um... err... (Add lots of curse words here!!!!)

Yep.. All the symtons of a leaking head gasket.
Shes done 185000kms so I guess its had a good run, I did use the wrong coolant a few months ago so im guessing this was the cause of the corrosion to compromise the head gasket.

Im going to rebuild this myself after talking to Nissan and they gave me a rediculous figure to fix it, funnily enough the mehanic(I think he was twelve) told me that he had only done a couple before and thought it would be better to get a second hand engine instead. Mmmm.
This was actually the same mechanic that told me that I couldn't replace the throttle Body with a second hand unit as the engine would not accept it and only a very expensive relearn computerised technical NASA procedure would it work..... I proved him wrong very quickly when I drove into the workshop after the changeout.(my old throttle body had a stretched spring somehow and wouldnt start) Nissan wanted to strip the engine. I had a better idea.

Anyhoo. I thought Id post some pics up as im rebuilding it for anyone thats interested in seeing whats in the guts of the engine. Im not a mechanic but I have been around the industry for a while. I can't thank this forum and google enough.

Please enjoy my journey over the next weeks as I get busy with replacing the head and various parts to bring the Xee back to life. Gulp.
Please feel free to comment on the pics or procedures and add advice or just tell me im crazy,please remember im not a mechanic nor an expert but the cost of nissan fixing it compared to me is worth the risk.




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2002 T30 Xtrail Ti , White 5Sp
Full engine rebuild, Single Mass flywheel upgrade,
Scott, Rockingham, Perth WA
24/Jul/2011, 10:52 pm Link to this post Send Email PM   Send Private Message Blog
 
Robbo0001 Profile
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BANNED USER

Date Registered: 07-2008
Location: Brisvegas, Australia
TOTAL POSTS: 1063
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Re: Rebuild 2002 T30Ti Cylinder Head


Mate, I will be reading this emoticon

Sorry about the head, but it will be interesting to watch as you work your way through. Take heaps of pics and post them if if you can, always helps when it comes time to re-assemble stuff as well.

quote:

funnily enough the mehanic(I think he was twelve


.....that made me laugh out loud

cheers

---
Dave
99 GU Patrol 2.8TD
Ex-2002 T30 TI Xtrail
24/Jul/2011, 11:00 pm 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: Rebuild 2002 T30Ti Cylinder Head


Okay.

I Added radiator Cleaner and flushed the entire cooling system with the cars heaters on full with a hose on medium pressure in the top of radiator and bucket under the drain point. You could also remove both thermostats to do this but a bit more mucking around.(remember to let engine cool before doing this or you could stress the aluminium parts into thermal shock and warp stuff)

 To completely rid all the engine block of coolant, there is a bolt on the back of the block on the left hand side where in some models a block heater is attached (next to oil pressure bolt), unbolt this last after the flush and the water that is around the cylinder passages will flow out from the block.
When I let the water out from the block I noticed that there was a fair bit of Aluminium Oxide on the coolant passage walls. Im wondering if this white crystal is the cause of peoples radiators being blocked and not from original casting sand! Just a thought but again I guess plausable.(I disolved it with distilled water and tiny bit of degreaser and flush away through that heater acc bolt hole).

I took to the Intake Manifold and Throttle body with the spray cleaner and slowly sprayed into the housing with engine running and a plastic handled tool to open the butterfly valve a little. Dont spray too much or the engine will stall. You will get a check engine light illuminate, dont stress! its because the intake Box is off and the computer THINKS something is wrong with the intake air. Did this step before the Coolant flush obviously.
(IVE SINCE LEARNT THAT THE BELOW STATEMENT FROM ME IS NOT A 100% CORRECT AND A FULL LEAKDOWN TEST IS THE ONLY WAY TO TEST IF THE CYLINDERS HOLD COMPRESSION)
Do a quick compression test for some before and after numbers. Pour a little bit of engine oil into spark plug hole (Plugs removed) and see if that boosts the compression. If it does it may mean that the pison rings are damaged. Luckily my compression figures stayed constant. Phew!
(EDIT TO THIS BELOW STATEMENT. DONT USE OIL ADDITIVE OR ENGINE CLEANS/FLUSH, SEE T30 ENGINE RE BUILD WITH PICS FOR COMMENTS AND REASONS) THIS STUFF WILL COAT EVERYTHING IN BEARING KILLING PASTE!!
I Flushed the engine and oil as I wanted to get rid of as much contaminated oil and deposits as possible because of the coolant in the oil. some people are totally against this step but Ill be cleaning most internal parts besides the block anyway and checking tolerances. (Some people think this removes vital carbon on engine components that form over time and when removed that leaks and scoring on bearings etc can occur.. Plausable I suppose but it wouldnt if you changed the oil often and flushed often) meh!.. Drain old oil and filter and laugh at how black the oil is.

Sorry these steps are not in obvious order.

Okay cool. after all this is done and youve prayed to the Nissan gods that all will go well, remove the main engine belt by pulling the Belt Tensioner bolt towards front of engine. i loosened alternator and slipped belt off that way!

Now this step is up to you but I have a really annoying engine whine somewhere and need to find out where its coming from. I think it might be from using 15w-40 engine oil(my bad) and the oil pump is whinging about it or its one of the pulleys. Anyways I started the engine with belt off(for about 10 seconds as this belt runs the water pump and everything) and bugger me the whine dissapeared, cause of whine = Belt tensioner.
Dont listen to Nissan when they say you have to replace the whole tensioner..... the pulley is just a bolt and a nut.... get a new pulley($30) and put some threadlocker on the bolts thread. problem solvered.

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Last edited by evorock, 14/Oct/2011, 8:08 pm


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2002 T30 Xtrail Ti , White 5Sp
Full engine rebuild, Single Mass flywheel upgrade,
Scott, Rockingham, Perth WA
25/Jul/2011, 1:00 am 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:


Good on you for having a go Scott.
Really this is the only way anyone can learn.
One word of advice, get yourself a torque wrench as you will need this to re tension the head bolts. Finding out what the torque settings will help too. If you can't source the torque settings, before removing the head bolts, re tighten them to find out what setting is and do this on a couple of the head bolts to get an average torque setting.

Good luck.

---
Tony X-891c

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

25/Jul/2011, 5:02 am Link to this post Send Private Message
 
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Date Registered: 02-2004
Location: SUTHERLAND, SYDNEY
TOTAL POSTS: 29094
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Re: Rebuild 2002 T30Ti Cylinder Head


Hi Scott,

This will be an interesting adventure.

I would invest in a copy of the service manual if I was you. Just to make sure that the steps followed are in order and also to get all those torque settings Tony mentioned.

It is a good idea to also mark the parts, so you don't end up with any excess ones after re-assembly emoticon

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25/Jul/2011, 6:02 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: Rebuild 2002 T30Ti Cylinder Head


Thankyou for the advice guys. i had to buy a larger torque wrench as the manual I managed to find on the net calls for the head bolts to be yielded to +- 94Nm and so on. i had to invest in a good set of Hex sockets and breaker bar to make this easier.
Stay tuned.....

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2002 T30 Xtrail Ti , White 5Sp
Full engine rebuild, Single Mass flywheel upgrade,
Scott, Rockingham, Perth WA
25/Jul/2011, 11:51 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: Rebuild 2002 T30Ti Cylinder Head


Alright.. Ive been working on disassembly of the engine a bit more, Ive just put some pics here as i managed to do a write up with pics but then accidently clicked the 'Back' button and lost it all.. bugger... Add more curse words here..

Next I removed the radiator,Exhaust manifold,intake mainifold,fuel injectors and alternator.
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all of the engine component removed were filty with oil residue and carbon buildup, Im guessing this has an affect on performance. The famous 'Butterfly' intake manifold screws were still there but im not going to remove as I feel comfortable with the 'If its not broke' and they were very tight after many Kms.
The alternator was removed for ease of access to the water pump later on and gives you more room to move the Exhaust back.
The lower half of the Intake manifold is held on by nuts and studs, remove them and slide off the head. i didnt completely remove from engine bay as way too many hoses and cable ties. I just carefully placed it to the side.
Remove the Rocker cover,cam position sensor and thermostat housing.
Now is a good time to locate Top dead center on the crank sprocket and make sure the No1 cam lobes are pointing outwards. I placed a long screwdriver with some tape on it to make doubly sure(just rotate the engine forward via the crank and mark the spot where the piston is at that transition where its stopped travelling up and is about to descend)

To get only this far it has been nearly 5 hours, but going fairly slow.
So far it has been fairly easy to remove components, I have labeled as many things as possible and scribbled quite a few notes. the next bit is cleaning all the parts up and takes alot of perserverance to get done. My cleanliness OCD didnt help me at this stage and have spent hours on some of these parts as you will see in pics to come.
 

---
2002 T30 Xtrail Ti , White 5Sp
Full engine rebuild, Single Mass flywheel upgrade,
Scott, Rockingham, Perth WA
26/Jul/2011, 1:05 am Link to this post Send Email PM   Send Private Message Blog
 
cooch t31 Profile
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X-TRAIL HOLIC
 


Date Registered: 06-2008
Location: Blue Mountains, NSW
TOTAL POSTS: 5966
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Re:


Scott,
taking pictures will help put things back together as well.

---
Tony X-891c

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

26/Jul/2011, 5:52 am Link to this post Send Private Message
 
Atsugnam Profile
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Date Registered: 07-2011
TOTAL POSTS: 3
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Re: Rebuild 2002 T30Ti Cylinder Head


Great to see it all coming apart easily Scott, just some hard earned tips for when doing a head job on a car:

99% of the time, in W.A. Head failure is due to cooking from a cooling system failure, this can be catastrophic, or a slow boil brought about by a partially blocked radiator, failing thermostat or air bleed/leak. Check every aluminum water fitting for corrosion, replace every hose that looks other than beautiful and always, always, always get a radiator cleanout, what's an extra $300 now compared to having to do this all again next summer...

As for the bottom end, one sneaky trick you can do to add life to an older engine such as this is replace the big ends in situ. You can probably get shells by themselves for this engine, and one by one, you can pop the big end , push the piston up a bit and swap out for new shells. Adds a small cost and some time to your job, but the big ends are likely to be the next thing to go after a water oil event, and hey, why not, might get another 185k out of it...

Best of luck, can't wait to see more innards!!
27/Jul/2011, 1:57 am 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: Rebuild 2002 T30Ti Cylinder Head


Damn youve got me thinking now about the Big end caps!Haha. Mmmm, I think that would involve taking that balancer mechanism off the bottom and im not sure for certain but I think that it runs a chain that is attached to the crank? If thats the case the front timing cover would have to come completely off and engine engine supported.
Any chance youve done this as im considering it.

Cheers
 

---
2002 T30 Xtrail Ti , White 5Sp
Full engine rebuild, Single Mass flywheel upgrade,
Scott, Rockingham, Perth WA
27/Jul/2011, 9:30 pm Link to this post Send Email PM   Send Private Message Blog
 


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