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ENGINE MECHANICAL SECTION EM

1. EM 24 EM 20 TIMING CHAIN Installation Cont d 10 Apply a continuous bead of liquid gasket to mating surface of Gi front cover 2 e Use Genuine Liquid Gasket or equivalent lt Front 7 e Attaching should be done within 5 minutes after coating MA cover LG 11 Install front cover EC Cylinder CY nder head Align edges e Lift front cover at an angle and install it to mounting posi gasket tion so that front cover will come in contact with both cyl E inder head gasket lower surface and cylinder block front anis surface at the same time Perens i e Be careful not to damage cylinder head gasket CL Front cover MT 1 Parallel amet Cylinder block PBICO563E AT w 4 Bolt No Tightening torque N m kg m in lb POLUM gt l l mm in TE a 45 1 77 6 9 9 5 0 70 0 97 61 84 b 16 0 63 PD FA RA e Make sure three O rings are present and new ones e Be careful not to damage oil seal when installing front _ cover BR ST RS BT 12 Install front cover bolts at cylinder head front side HA BL SE IDX N EM 21 TIMING CHAIN Installation Cont d ay 13 Install oil pump drive spacer ae 14 Install water pump and water_pump pulley Refer to Water Pump i n LC section s 15 Install idler pulley and bracket 16 Install oil pan Refer to IEM 12 Installation a 17 Install crankshaft pulley 36 e Tightening procedure a Tighten bolt t
2. Go to SUP 5 Rev 1 ENGINE MECHANICAL ao EMI MODIFICATION NOTICE EG e Engine mounting parts have been modified e Models with three way catalyst have been introduced for the Middle East e 1B48DE engine has been introduced for Europe For information and specifications other than those not PE described here refer to Y61 series Service Manual Supplement V 1st Revision Publication No SM1E MA Y61EG1 e TD42Ti engine has been introduced for Australia For information and specifications other than those not GL described here refer to Y61 series Service Manual Supplement Ill 3rd Revision Publication No SM9E Y61CG3 MT CONTENTS TB45E amp TB45S aie e TS 24 TI ENGINE REMOVAL enne nnns 26 ENGINE REMOVAL eeeenmmmmmRMI 2 CYLINDER BLOCK 27 3m PUSS SY cpress i dpi usd tus ERU SM ASE 28 TB48DE X PREPARATION 3 777 TTi FPA cibis Sery Hit alae i PREPARATION 30 es a OUTER COMPONENT PARTS ee 31 BA OUTER COMPONENT PARTS es 5 TURBOCHARGER 33 POWER VALVE ACTUATOR emm 8 Sergi al and Petala us DU 34 COMPRESSION PRESSURE eese 9 te LM MN BR M ement ar Gopression P 9 IS DOC HOD aceites enteras deterius Ore een rane eee 34 E o pet id edi E d CHARGE AIR COOLER 38 C
3. VALVE OIL SEAL 1 Remove rocker cover 2 Remove camshaft 3 Remove valve spring Refer to Removal EM 31 Publication No SM1E Y61EG1 4 Remove valve oil seal with suitable tool Piston concerned should be set at TDC to prevent valve from falling 5 Apply new engine oil to new valve oil seal and install it with E SST KV10116300 to dimension as shown 0 012 in FRONT OIL SEAL 1 Remove the following parts Engine under cover Radiator and radiator shroud Refer to Radiator in LC section Drive belts and cooling fan Crankshaft pulley and oil pump drive spacer Refer to TIMING CHAIN Remove front oil seal from front cover Be careful not to scratch front cover en 3 Apply new engine oil to new oil seal and install it using a suit able tool e Install new oil seal in the direction as shown in the figure Engine lt a Engine inside outside Oil seal lip Dust seal lip AS SL EM 24 OIL SEAL Replacement Cont d REAR OIL SEAL Gl 1 Separate clutch assembly or automatic_transmission Refer to REMOVAL AND INSTALLATION i or MA 2 Remove flywheel or drive plate 3 Remove bolts fixing from both rear and bottom sides 4 Remove rear oil seal retainer assembly using Seal cutter SST 5 KV10111100 Remove traces of liquid gasket from mating surface of cylinder block and oil pan using scraper Le e Replace oil seal and retainer assembly as a si
4. 2 sensor 2 Bank 2 3 29 4 37 3 Pd l 3 0 3 8 CT 22 27 g s 40 2 50 0 TWC r1 2 Nut 4 1 5 1 30 36 D 0 78 4 8 0 58 manifold i Heated oxygen sensor 2 Bank 1 O 40 2 50 0 4 1 5 1 30 36 TWC cover fls1 65 N 0 52 0 66 46 57 TWC cover 4 5 5 3 33 38 5 1 6 5 Spark plug 0 52 0 66 D 19 6 29 4 46 57 2 0 2 9 15 21 Front engine slinger Q ec b 0 32 3 38 2 3 3 3 8 24 28 Power steering oil pump bracket Se 0 24 5 31 4 2 5 3 2 18 23 A C compressor bracket Always replace after every disassembly kO Ne m kg m in Ib D Nem kg m ft Ib 0 20 6 26 5 2 1 2 7 16 19 SEM018H EM 6 OUTER COMPONENT PARTS Power valve l SEC 140 148 163 164 actuator W 4 0 6 8 Fuel injector and tube assembly I9 3 82 4 51 OD 20 6 26 5 0 39 0 46 2 1 2 7 34 39 0 9 s Solenoid valve 35 60 MA Wg 6 9 7 8 0 71 0 79 61 69 LG 87 112 Intake manifold rear support 9 20 6 26 5 EG 7 6 2 1 2 7 16 19 Intake 9 manifold PE collector j Gasket cover w Pd e I 4 hg 7 0 9 5 Pani CL 0 72 0 96 QU AT S 62 84 SP Accelerator Gasket 1 K 9 MTT S T d 2 e wire bracket DC 3 X a c JU rft M
5. SEC 111 130 185 220 Oil filler cap Rocker cover screw ko 1 2 0 1 Meg USD e Rocker cover T Hocker cover gasket e3 Adjusting screw Hocker arm lock nut 5 20 25 2 0 2 5 14 18 Rocker shaft bracket bolt 5 20 25 2 0 2 5 14 18 Rocker shaft lock bolt kO 10 13 1 0 1 3 87 113 E al 3 Wave washer Valve oil seal e3 n Rocker shaft bracket A Spring seat Spring Q9 vave ote B Spring retainer 3 G B Valve spring Injection nozzle Injection nozzle holder holder No 1 Pa 7 I No 2 No 6 Valve guide oe 0 54 64 o 5 6 5 5 5 6 5 40 47 40 A7 SS l RO Nozzle washer 3 S d 5 i 0 N Top 5 Ps NS E nozzle gasket e3 war od ve Nozzle support Nozzle gasket e3 Nozzle washer 5 Top JZ P di ea nozzle gasket e3 N E di Front Nozzle support Nozzle gasket e3 EM 39 BK TA um udin Valve M Combustion Jy Exhaust valve E Intake valve Adee Glow nut Wy 1 5 2 0 0 16 0 20 1 5 2 0 11 14 l Cylinder head bolt E71 D 1st 40 44 4 0 4 5 29 32 2nd 59 63 l 6 0 6 5 44 47 3rd 100 120 degrees clockwise angle tightening Cylinder head Always replace after every disassembly Nem kg m in Ib Nem kg m ft lb Lubricate with engine oil SEM078H MA LG eC GL MT AT I
6. 8 0 110 GL d 6 6 0 260 e 107 4 21 f 14 0 55 MUT g 20 0 79 h 14 0 55 dia NT617 Unit mm in AT Commercial Service Tools TF Tool name Description BD Spark plug wrench Removing and installing spark plug Neo e FA 16 mm Q RA 0 63 in NT047 Valve oil seal drift Installing valve oil seal BR a 25 0 98 dia b 14 4 0 567 dia ST c 11 8 0 465 dia d 10 0 39 e 11 0 43 AS f 9 0 35 NT602 Unit mm in Valve guide drift Removing and installing valve guide BI 2m RA Intake amp Exhaust EL a 10 mm 0 39 in dia NTO1S b 6 5 mm 0 256 in dia SE DX EM 3 PREPARATION Commercial Service Tools Cont d Tool name Description Valve guide reamer Reaming valve guide D or hole for oversize valve guide Intake amp Exhaust d 7 000 mm 0 2756 in dia NT016 d 11 19 mm 0 4406 in dia Valve seat cutter set Finishing valve seat dimensions NT048 Front oil seal drift Installing front oil seal X a a 80 mm 3 15 in dia NT049 b 58 mm 2 28 in dia Piston pin drift Removing and installing piston pin a 22 5 mm 0 886 in dia NT074 b 12 5 mm 0 492 in dia Piston ring expander Removing and installing piston ring NT030 EM 4 OUTER COMPONENT PARTS Gl SEC 140 210 220 221 fl 9 8 12 7 Except for Europe 1 0 1 2 87 112 Heated oxygen sensor wg MA connector clamp _ Rc C LG Exhaust manifold cover Gasket e3 NS EC Tighten in numer
7. After securing bearing cap bolts make sure crankshaft turns smoothly by hand Appiy also 3 Apply a continuous bead of liquid gasket to mating surfaces of liquid gasket rear oil seal retainer both for cylinder block and oil pan sides to bottom e Use Genuine Liquid Gasket or equivalent side a Coat of liquid gasket should be maintained within 2 0 to 3 0 mm 0 079 to 0 118 in dia range b Attach oil seal retainer to cylinder block within 5 minutes Diamster of after coating liquid gasket c Wait at least 30 minutes before refilling engine oil or start 2 0 3 0 mm ing engine 0 079 0 118 in 4 Measure crankshaft end play Crankshaft end play Standard 0 05 0 169 mm 0 0020 0 0067 in Limit 0 3 mm 0 012 in If end play exceeds the limit replace No 6 bearing and measure again If it still exceeds the limit replace crankshaft also 5 Install connecting rod bearings in connecting rods and connect ing rod caps e Confirm that correct bearings are used Refer to Inspection EM 47 Publication No SM1E Y61EG1 e install bearings so that oil hole in connecting rod aligns with oil hole of bearing EM 28 CYLINDER BLOCK Assembly Cont d 6 Install pistons with connecting rods QI 1 Install them into corresponding cylinders with SST e Be careful not to scratch cylinder wall by connecting rod e Arrange so that front mark on piston head faces toward MA front of engine LG EG 2 Instal
8. T model 6 NO S SS Accelerator O 24 5 31 4 St 2 wire bracket AT eyes A T model 2 5 3 2 D 18 23 te 1 245 31 4 Relief plug 2 5 3 2 TE 6 9 7 8 18 23 0 7 0 8 61 69 NI PD FA Upper collector Gasket 1 3 RA D 24 5 31 4 Sidi yas q Intake manifold ea ge Teo racket I9 9 81 12 7 BR 1 0 1 3 87 112 Solenoid valve gt P Iglost 12 7 10 13 87 112 ST p Place cutout to e Engine ornament E upper side a cover bracket P RS a o 7 EN M T model s o J 7 BT o Throttle bod Oo BAN S ZN A is HA Tighten in numerical order 0 ist 8 8 10 8 eL 0 9 1 1 6 5 8 0 2nd 17 7 21 8 1 8 2 2 13 16 S D 19 6 23 5 2 0 2 3 15 17 ie Nem kg m in Ib 1 Tighten in numerical order Loosen in reverse order O N m kg m ft lb iind e3 Always replace after every disassembly Electric throttle control actuator SEM044H EM 7 actuator INi 4 Adjusting screw Washer A POWER VALVE ACTUATOR Pug E ring E 0 4 0 7 kg m 35 60 in Ib MEM266A DISASSEMBLY 1 Remove washer and E ring 2 Remove actuator assembly 3 Disconnect shaft lever from actuator rod ASSEMBLY 1 Connect shaft lever with actuator rod 2 Install actuator assembly with stopper 3 Install washer and E ring e Use anew E ring ADJUSTMENT 1 Apply vacuum pressure of 33 3 to 40 0 kPa 333 to 400 mbar 250 to
9. sprockets EL SE EM 17 TIMING CHAIN Removal Cont d 24 Remove front cover bolts at cylinder head front side N 25 Remove starter motor and set ring gear stopper SST using mounting bolt holes of starter motor KV10105630 INS Sm lt 26 Loosen crankshaft pulley bolt eo esa Mhe 27 Remove crankshaft pulley with a suitable puller Crankshaft pulley x Y 28 Remove water pump pulley and water pump Refer to Water Pump 29 Remove front cover bolts as shown 30 Remove front cover carefully using Seal cutter SST KV10111100 e Be careful not to damage or bend front end of cylinder head gasket e If cylinder head gasket is damaged replace it with a new one 31 Remove timing chain Slack guide JES M Lr 32 Remove oil pump drive spacer 1 Ho eo 33 Remove tension guide and slack guide j Tension guide 34 320 9 L4 Oil sume Remove crankshaft sprocket e D A Crankshaft drive PAG Ake WT Some STA W gt DA Ke SEMO 19H EM 18 ao Crankshaft sprocket TIMING CHAIN Removal Cont d 35 Remove O rings from front cover Inspection Check for cracks and excessive wear at roller links Replace if necessary Installation 1 Install crankshaft sprocket on crankshaft e There is no installation direction 2 Position crankshaft so that No 1 piston is at TDC and key way is at 12 o clock 3 Install timing chain on crankshaft
10. wheel Oil outlet Turbine housing Oil inlet Compressor housing SEM074H OIL TUBES BT Check tubes for clogging HA BL OQ g O aan wes ater IG l IDX EM 35 TURBOCHARGER Inspection Cont d ROTOR SHAFT 1 Check rotor shaft for smooth rotation 2 Check rotor shaft for carbon deposits 3 Measure rotor shaft runout Runout Total indicator reading Standard 0 12 0 17 mm 0 0047 0 0067 in 4 Measure rotor shaft end play End play Standard 0 05 0 10 mm 0 0020 0 0039 in e Do not allow wheels to turn when axial play is being mea sured TURBINE WHEEL Check turbine wheel for the following e Oil e Carbon deposits e Deformed fins e Contact with turbine housing EM 36 NON VA L i ZS Mercury manometer gt J NES i Compressed air Nd Dial T NE m Wastegate valve actuator DEM141 TURBOCHARGER Inspection Cont d COMPRESSOR WHEEL e compressor wheel for the following o e Deformed fins e Contact with compressor housing WASTEGATE VALVE Remove rod pin and check wastegate valve for cracks deformation and smooth movement Check valve seat surface for smoothness WASTEGATE VALVE ACTUATOR Check operation of wastegate valve actuator Do not apply more than 96 0 kPa 960 mbar 720 mmHg 28 35 inHg pressure to actuator diaphragm Wastegate valve actuator stroke pressure 1 5 mm 0 059 in 85 3 90 7 kPa 853 907 mbar 640 680 mmHg
11. 1 1 0 1 1 80 97 5 16 21 1 6 2 1 12 15 M Gasket 23 g i Exhaust manifold cover Thermostat housing Refer to LC section 9 16 21 B 1 6 2 1 12 15 M C x D ms 16 20 1 6 2 1 12 15 2 M10 30 41 Pa Qasket 3 0 4 2 22 30 Water pump amp fan coupling Exhaust Washer 1 manifold E3 7130 34 3 1 3 4 23 25 24 32 2 5 3 2 18 23 EGA tbe 3 30 41 3 1 4 2 22 30 Air conditioner compressor We 7 9 0 7 0 9 61 78 bracket A 9 16 20 ae KR 1 6 2 1 12 15 Q y ses Turbocharger 18 21 Refer to TURBOCHARGER P c E D il e in EM section S Ji mE D 44 54 Alternator adjusting bar 4 5 5 5 7 30 41 Idler E and engine slinger 33 40 3 1 4 2 22 30 Pulley Roller 9 16 20 1 6 2 1 12 15 S w o 30 41 Air conditioner 3 1 4 2 22 30 compressor Refer to HA section 3 30 41 P eue Qu US amp 7 Cylinder 3 1 4 2 22 30 T head sid cc e3 Always replace after every disassembly ko Nem kg m in Ib OD 29 39 0 Nem kg m ft Ib Alternator bracket 3 0 4 0 22 29 Apply recommended sealant Nissan genuine part KP610 00250 or equivalent SEM072H EM 32 TURBOCHARGER SEC 140 144 Gl aie 11 1 0 1 1 80 97 MA Exhaust manifold cover LG 0 1
12. 17 0 108 123 Q Crankshaft Connecting rod Crankshaft 2 ae IE in position sensor TIE o ee dia i Installed on a To 50 65 Transmission Gannacinguss bead ET 0 51 0 66 V b PD onnecting rod bearing A 2 1 2 7 15 20 45 57 Reinforcement plate A T P d Meshed area Main bearing KE Y Ww N o b a M BR Wy We Main bearing V NS X NG cap Y 3 0 3 8 mm Ede c 0 118 0 150 in AS 16 5 17 5 rare e 119 127 ear plate A T ia Meshed area A 5 For installation of connecting rod cap Bu refer to Assembly Models for Europe Drive plate A T Pilot converter A T SU RO Nem kg m in Ib D Nem kg m ft Ib FA Use Genuine Liquid Gasket or equivalent EL FY Lubricate with new engine oil e3 Always replace after every disassembly SE DX SEM043H EM 27 CYLINDER BLOCK Upper main bearing Assembly With oil ao E CRANKSHAFT 1 Set main bearings in their proper positions on cylinder block and main bearing cap e Do not confuse upper and lower sides of main bearings Lower main bearing SEM986B 2 Install crankshaft and main bearing caps and tighten bolts to the specified torque e Prior to tightening bearing cap bolts place bearing cap in its proper position by shifting crankshaft in the axial direc tion e Tighten bearing cap bolts gradually in two or three stages starting with the center bearing and move outward sequen tially e
13. 25 19 26 78 inHg EM 37 MA LG ec re GL MT AT CHARGE AIR COOLER SEC 144 163 640 Charge air cooler O ring e3 Throttle body D 16 21 1 6 2 1 12 15 Mounting e rubber 1 6 2 1 12 15 U 1 3 16 21 5 16 21 1 6 2 1 12 15 1 6 2 1 12 15 Na j 7 1 2 1 6 9 11 Wagon models only Charge air cooler support e3 Always replace after every disassembly 0 N m kg m ft Ib CHECKING CHARGE AIR COOLER Check charge air cooler for mud or clogging If necessary clean charge air cooler as follows 1 pe Os oo Iw Be careful not to bend or damage the charge air cooler fins Hemove charge air cooler Before cleaning securely cover its inlet and outlet with vinyl and wrap them with tape or something to prevent water from getting into the charge air cooler Apply water by hose to the back side of the charge air cooler core vertically downward Apply water again to all charge air cooler core surfaces once per minute Stop washing if any stains no longer flow out from the charge air cooler Blow air into the back side of charge air cooler core vertically downward Use compressed air lower than 490 kPa 5 kg m 71 psi and keep distance more than 30 cm 11 8 in Blow air again into all the charge air cooler core surfaces once per minute until no water sprays out EM 38 CYLINDER HEAD
14. 3 18 1 3 1 9 10 13 EC Oil supply tube To cylinder block PE GL D To EGR cooler Oo AN Exhaust Washer 1 MT manifold Gasket e 3 7130 34 E R tube 0 25 29 013 18 3 1 3 4 23 25 m AY 2 5 3 0 18 21 1 3 1 9 ae a 3 0124 32 TE Air outlet tube we 2 5 3 2 18 23 Turbocharger cover 2 wat FA 0 ko o 11 1 0 1 1 80 97 J RA jas 29 2 5 3 0 18 21 BR Air inlet 0 25 5 35 3 ST tube 2 6 3 6 19 26 A 9 Always replace after Pp a Turbocharger cum T e every disassembly ae ns Gasket 9 Turbocharger we Aas 61 8 D N m kg m ft Ib j support D 4 6 6 3 34 45 ko Nem kg m in Ib 3 13 18 0 13 18 Sr 1 3 1 9 10 13 To cylinder block 1 3 1 9 d N 1 9 10 13 Gasket ga RON HA 2 Hose o gt Cylinder il return head side tube EL SZ 013 18 SE 1 3 1 9 10 13 IDX SEMO73H EM 33 TURBOCHARGER Removal and Installation Turbocharger should not be disassembled Remove the following Air duct and charge air cooler components Heat shield plates Exhaust front tube Refer to FE section Oil tubes Remove turbocharger support Remove turbocharger from exhaust manifold wne o o Inspection Condition 1 Low engine power Probable cause Corrective action Air leak at the connection of compressor housi
15. 300 mmHg 9 84 to 11 81 inHg to the actuator 2 Loosen adjusting screw until it is separated from the lever 3 Screw in adjusting screw until it contacts the shaft lever and then screw it in two turns 45 4 Apply vacuum pressure of 40 0 13 3 kPa 400x133 mbar 300x100 mmHg 11 81 3 94 inHg to the actuator Switch on and off power valve to check more than three times if the valve operates smoothly with no play or looseness EM 8 COMPRESSION PRESSURE Measurement of Compression Pressure 1 e 3 Warm up engine Turn ignition switch OFF Release fuel pressure Refer to procedure without CONSULT II of Fuel Pressure Release in ectio Remove fuel pump fuse until the end of step 9 4 33 e oo Disconnect ignition coil harness connector Remove air intake duct upper collector throttle body or elec tric throttle control actuator ignition coil and all spark plugs Attach a compression tester to No 1 cylinder Crank the engine and record the highest gauge indication Repeat the measurement on each cylinder as shown below Always use a fully charged battery to obtain specified engine revolution Compression pressure kPa bar kg cm psi rpm Standard 1 226 12 26 12 5 178 200 Minimum 1 030 10 30 10 5 149 200 Difference limit between cylinders 98 0 98 1 0 14 200 If cylinder compression in one or more cylinders is low pour a small amount of engine oil into cylinders through the spark plu
16. F RA EL CYLINDER HEAD Removal Remove injection nozzle holder and top nozzle gasket e Use nozzle holder socket SST KV11105700 for No 1 nozzle holder e Use deep socket wrench for No 2 to No 6 nozzle holders Inspection COMBUSTION CHAMBER Identification of combustion chambers Identification mark Outer diameter on combustion chamber D mm in Identification 1 place 36 985 37 011 1 4561 1 4571 mark EM 40 Technical Bulletin CYLINDER BLOCK SEC 110 120 130 135 150 Rear plate Gasket e3 D 16 21 1 6 2 1 12 15 Cylinder block Front plate Cylinder liner Idler gear shaft E 7 13 19 E 1 3 1 9 Hear engine insulator LG Idler gear 0 25 35 gear K Camshaft 9 14 2 6 3 6 19 26 bushing Fry Rear oil seal retainer EG assembly E Gasket e3 Fe Camshaft FY Locating plate E GL ko 3 9 6 9 0 40 0 70 35 61 Piston ring E Snap ring e3 D Camshaft Piston pin A gear Piston a Rie Ss Connecting rod AT es Flywheel 1 6 2 1 Snap ring e3 2 12 15 Connecting rod bushing El A Lubricate with engine oil Apply recommended sealant 7 9 EL Nissan genuine part 0 7 0 9 61 78 KP610 00250 or equivalent 1 Do not damage the sensor edges S 2 Keep in correct order Connection rod bearin 4 us Connecting rod4 TF E
17. YLINDER HEAD 99 REMOVAl ccccceeccccccccececseeeeeeeeecencceceeeceeseseeeeeeeenttaees 10 ST aiio E ne EI E T A A 40 BFS PUN esae E 12 Inspection 40 TIMING CHAIN eeeeennnnmmmmmRRIIIIII 15 CYLINDER BLOCK 41 ae See d ROT 15 Renal 16 licere e T T 42 alsssseeeeeneeeneennnnnnnnnnnnnttnrnnnennnnnnnnnnnnnnnnnnnnnnnnns SERVICE DATA AND SPECIFICATIONS SDS 43 MEDOC UO EEE EEEE 19 5 Inspection and Adjustment eeees 43 BI Iis tall all Incosenuuauter cem PEU Ee tet Equo zU pue DU UU Dus ecto 19 24 HA EL SE IDX EM 1 ENGINE REMOVAL Except for the Middle East 0 77 98 7 9 10 0 57 72 Jure uds 21 eie y o oz ic pa Spe ag 7 9 10 0 57 72 O Nem kg m ft Ib For the Middle East 0 77 98 7 9 10 0 57 72 9 77 98 7 9 10 0 57 72 D 22 28 2 2 2 9 16 21 5 51 0 64 7 5 2 6 5 38 47 5D 51 0 64 7 5 2 6 5 38 47 O Nem kg m ft Ib EM 2 PREPARATION Special Service Tools Gl TOR RUE Description MA Tool name KV10111100 Removing steel oil pan and timing chain case Seal cutter LG NT046 KV101056S0 Preventing crankshaft from rotating EG Ring gear stopper 1 KV10105630 Adapter Ple 2 KV10105610 a 3 0 12 Plate b 6 4 0 252 c 2
18. ameter is within specifications Refer to EM 145 PISTON TO CYLINDER BORE CLEAR 0 ANCE in Service Manual Publication No SM7E 1Y61G1 e Using piston press piston ring to cylinder mid point and mea sure end gap Unit mm in ASRA Standard Standard Measuring point With cylinder With cylinder Limit liner for factory liner for service 0 25 0 45 0 35 0 60 Ree 0 0098 0 0177 0 0138 0 0236 0 50 0 65 0 60 0 80 1 5 0 ROMER 0 0197 0 0256 0 0236 0 0315 eo i 0 25 0 50 0 35 0 65 Oil ring 0 0098 0 0197 0 0138 0 0256 EM 42 SERVICE DATA AND SPECIFICATIONS SDS Inspection and Adjustment Valve seat PISTON RING Unit mm in Side clearance Top 2nd Oil Ring gap With cylinder liner for factory SEM146H Top Intake E 44 550 44 560 2nd Outer diameter D 1 7539 1 7543 37 9 38 1 Oil rail ring Inner diameter D Diameter of seat D Cylinder head valve seat diameter Valve seat face angle p 1 492 1 500 42 5 1 673 44 500 44 515 1 7520 1 7526 89 90 With cylinder liner for service Top 2nd Oil ring EM 43 0 05 0 07 0 0020 0 0028 0 04 0 08 0 0016 0 0031 0 02 0 06 0 0008 0 0024 0 25 0 45 0 0098 0 0177 0 50 0 65 0 0197 0 0256 0 25 0 50 0 0098 0 0197 0 35 0 60 0 0138 0 0236 0 60 0 80 0 0236 0 0315 0 35 0 65 0 0138 0 0256 U
19. e figure Wait at least 30 minutes before refilling engine oil Connect left side of the tie rod end Refer to STEERING LINKAGE in ST section Install in reverse order of removal for remaining steps paying attention to the following After refilling engine oil check engine oil level Start engine and check that there is no leakage of engine oil c poo EM 14 TIMING CHAIN Components Gl 130 ko 9 8 12 7 SEC 120 130 135 0 4 Er iD MA ko 9 8 12 7 1 0 1 2 97 112 ho 6 c 9 8 12 7 1 0 1 2 87 112 LG EG 20 6 26 5 LR esis II 108 118 2e PE 11 0 12 0 80 87 a le 9 8 12 7 e gt Gasket a GL 1 0 1 2 87 112 Rey Ne 0 WT MD Orn AT 0 12 7 18 6 1 3 1 8 10 13 Top face TIF I9 8 43 10 8 vAn PD 0 86 1 10 75 95 DA yA A FA t RA D 24 5 31 4 pe 2 5 3 2 18 23 BR Z 4 a RO Nem kg m in Ib SN 0 03 10 8 O Nem kg m ft Ib ST ae 0 86 1 10 75 95 Use Genuine Liquid Gasket or equivalent 7 i E Lubricate with new engine oil RS efer to Installation in e Always replace after every disassembly TIMING CHAIN BT RA TA semoe2H EL l l 6 Timing chain tension guide 11 Dowel pin 1 Chain tensioner 7 Timing chain 12 Front oil seal 2 Camshaft sprocket Intake 8 Crankshaft sprocket 13 Crankshaft pulley SE 3 Camshaft spr
20. g holes and retest compression If adding oil helps the compression piston rings may be worn or damaged If so replace piston rings after check ing piston If pressure stays low a valve may be sticking or seating improperly Inspect and repair valve and valve seat Refer to SDS If valve or valve seat is damaged excessively replace them If compression in any two adjacent cylinders is low and if adding oil does not help the compression there is leakage past the gasket surface If so replace cylinder head gas ket 10 Install removed parts in reverse order of removal EM 9 Gl MA Lug LG EC PE GL MT AT TF PD PA RA ST AS BY RA EL SE SEC 110 150 Wy 8 43 10 8 0 86 1 10 75 95 0 20 6 26 5 Steel oil pan 2 1 2 7 16 19 Drain plug 0 29 4 39 2 3 0 3 9 22 28 qq a kO Nem kg m in Ib OJ N m kg m ft Ib Use Genuine Liquid Gasket or equivalent OIL PAN Baffle plate Oil pan side ify ay pd e3 Oil strainer Reinforcement 0 20 6 26 5 Wg 8 43 10 8 2 1 2 7 16 19 0 86 1 1 75 95 Removal 1 2 3 O Remove engine undercover Drain engine oil Remove steel oil pan bolts Loosen steel oil pan bolts in reverse order EM 10 OIL PAN Removal Cont d 4 Remove steel oil pan QI a Insert seal cutter SST between aluminum oil pan and steel oil pan e Be careful no
21. gasket is 3 5 to 4 5 mm 0 138 to 0 177 in in diameter e Attaching should be done within 5 minutes after coating apo Engine front EM 12 OIL PAN Installation Cont d d Install aluminum oil pan QI Apply liquid gasket to the shank of the bolts marked with x Use Genuine Liquid Gasket or equivalent Tightening should be done within 5 minutes after coating MA Tighten bolts in numerical order Tightening torque 8 43 10 8 N m 0 86 1 1 kg m 75 95 in Ib Others 20 6 26 5 N m 2 1 2 7 kg m 16 19 Engine front ft Ib LG Tighten in numerical order Loosen in reverse order 3 Install the transmission bolts Refer to Service Manual NISSAN EG 61 SUPPLEMENT V 1st Revision Publication No SM1E i pea FE GL MT AY 4 Install steel oil pan a Use a scraper to remove all traces of old liquid gasket from mating surfaces TF e Also remove traces of old liquid gasket from mating surface of aluminum oil pan PD PA RA py Inner b Apply a continuous bead of liquid gasket to mating surface of side aluminum oil pan e Use Genuine Liquid Gasket or equivalent BR e Be sure liquid gasket is 3 5 to 4 5 mm 0 138 to 0 177 in in diameter e Attaching should be done within 5 minutes after coating SI AS Inner side SEM159F BT RA EL SE EMOO0252D EM 13 OIL PAN Installation Cont d c Install steel oil pan Tighten in numerical order as shown in th
22. ical order Loosen in reverse order PE Exhaust i 7 0 9 5 manifold e 0 72 0 96 GL 62 84 C Nut O 78 4 8 0 58 MT Heated oxygen sensor 1 Spark plug Bank 1 and Bank 2 l C 9 19 6 29 4 ic td e a Cs L iic ed 36 AT 2 0 2 9 15 21 SS SK icc G C A REN TE 4 4 9 Zo Models with three way catalyst D 28 4 32 4 3 e 2 9 3 3 21 23 Rd Models without PD three way catalyst 0 78 4 8 0 58 PA Front engine slinger j RA it i S e BR 0 32 3 38 2 3 3 3 8 24 28 ST Power steering oil pump bracket gt RS Se 0 24 5 31 4 Br 2 5 3 2 18 23 Idler pulley BT D 20 6 26 5 A 2 1 2 7 16 19 S i HA e3 Always replace after A C compressor 49 61 8 every disassembly bracket 3 5 0 6 3 37 45 EL Nem kg m in Ib 0 Nem kg m ft lb E DX SEM822GB EM 5 OUTER COMPONENT PARTS For Europe Tighten in numerical order manifold sensor connector 6 Loosen in reverse order clamp SEC 140 210 220 221 Gasket 9 ExHaust dienisdoxvdeh ko 5 1 6 5 Nut cover 0 78 4 8 0 58 Heated S sente pon oxygen l P 28 4 32 4 yd sensor 1 MED EO 2 9 33 cb Bank 1 21 23 gt lt r 0 40 2 50 0 4 1 5 1 40 2 50 0 H 36 7 44 1 52 4 1 5 1 30 36 gl 4 5 5 3 Nut D 78 4 33 38 8 0 58 Heated oxygen
23. l connecting rod bearing caps Tighten connecting rod bearing cap nuts to the specified torque Connecting rod bearing nut BE 1 Tighten to 38 to 40 N m 3 9 to 4 1 kg m 28 to 30 ft Ib 2 Tighten to 67 to 71 N m CL 6 8 to 7 2 kg m 49 to 52 ft lb or if you have an angle wrench tighten bolts to 40 to 45 degrees clockwise MT Angle tightening is preferable AT 7 Measure connecting rod side clearance Connecting rod side clearance Standard TP 0 20 0 35 mm 0 0079 0 0138 in Limit 0 40 mm 0 0157 in PD If clearance exceeds the limit replace connecting rod and or crank shaft PA RA 8 Install flywheel M T or drive plate A T as shown in the fig Flywheel assembly M T an ure aR Drive plate A T SS Pilot converter ay Crankshaft RS Reinforcement plate Don t disassemble a P M T model only SEMO65H BY RA EL SE EM 29 Special tool or commercial equivalent Tool number Description Tool name KV11105700 Nozzle holder socket ZZA1127D PREPARATION SPECIAL SERVICE TOOLS EM 30 Tightening or loosening injection nozzle holder OUTER COMPONENT PARTS SEC 135 140 185 186 213 Gl MA 14 20 To E 7 a pm DEM D 21 26 2 1 2 7 16 19 14 Oil filter Refer to MA section To charge ko 8 82 11 76 air cooler _a Oil cooler LG 0 9 1 1 2 Air intake tube 78 104 4 Co A EG To g
24. ng and suc i Correct the connection tion hose inlet tube or inlet and intake manifold Exhaust gas leak at the connection of turbine housing and l i Correct the connection or replace gasket exhaust manifold connecting tube or exhaust outlet Wastegate valve is stuck in open position Stuck or worn journal or bearing Broken shaft Replace turbocharger assembly Sludge on back of turbine wheel Broken turbine wheel Condition 2 Excessively high engine power Probable cause Corrective action Disconnected or cracked rubber hose of by pass valve actuator Correct or replace rubber hose Wastegate valve is stuck in closed position Replace turbocharger assembly Actuator diaphragm is broken EM 34 TURBOCHARGER Inspection Cont d Gl Condition 3 Excessively high oil consumption or exhaust shows pale blue smoke MA Probable cause Corrective action Oil leak at the connection of lubricating oil passage Correct the connection rg Oil leak at oil seal of turbine K udo LC Oil leak at oil seal of compressor Replace turbocharger assembly EC Worn journal or bearing GL MT AT Perform the following checks If NG replace turbocharger unit Wastegate valve Check for leaks Check for leaks actuator Check for leaks Check for leaks Check for leaks t Center NY l Wastegate Housing valve Compressor wheel Check for leaks Check for leaks Turbine
25. ngine Timing gear case E 2 78 83 bearing cap revolution Mating surface to timing 8 0 8 5 58 SS 57 167 186 sensor gear case and front plate Oil jet g 17 19 PD 123 137 Front oil seal 3 7 29 39 3 0 4 0 22 29 Pilot bushing i ke 5 6 8 4 Crankshaft gear KE ETRORSBaN FA 0 57 0 85 Main bearing FY 50 74 Crankshaft damper E D eiaakenatepulley Thrust bearing 1 RA Main bearing cap FY KY 167 171 BR 17 0 17 5 123 126 eA ST Cone Oil pan gasket D 373 402 T m 38 41 275 296 Oil pan Irade RS Always replace after every BT disassembly O Nem kg m ft Ib 3 E T 1 6 2 1 12 15 RO Nem kg m in Ib 7 29 39 HA A 3 0 4 0 22 29 SEMO80H EM 41 CYLINDER BLOCK Inspection PISTON RING SIDE CLEARANCE e Using feeler gauge measure clearance between piston ring and piston ring groove Thickness j Unit mm in Standard Limit Top ring 0 05 0 07 0 0020 0 0028 0 50 0 0197 Second ring 0 04 0 08 0 0016 0 0031 0 30 0 0118 Oil ring 0 02 0 06 0 0008 0 0024 0 15 0 0059 e Align top ring and external surface of piston Measure lower side clearance of top ring with top ring pressed onto upper side of ring groove e If side clearance exceeds the limit replace piston ring e Check clearance again If side clearance still exceeds the limit replace piston PISTON RING END GAP Piston y Feeler gauge e Check that cylinder bore di
26. ngle unit 6 Apply a continuous bead of liquid gasket to mating surfaces of EG rear oil seal retainer both for cylinder block and oil pan sides e Use Genuine Liquid Gasket or equivalent EE a Coatof liquid gasket should be maintained within 2 0 to 3 0 2 0 3 0 mm mm 0 079 to 0 118 in and 3 5 to 4 5 mm 0 138 0 177 in 0 079 0 118 in dia range CL b Attach oil seal retainer to cylinder block within 5 minutes after coating c Wait at least 30 minutes before refilling engine oil or start MT Bottom side 3 5 4 5 mm ing engine 0 138 0 177 in SEM064H AT TF PA RA ST AS BY RA EL SE EM 25 ENGINE REMOVAL 0 77 98 7 9 10 0 57 72 0 51 0 64 7 5 2 6 5 38 47 7 9 10 0 57 72 0 22 28 2 2 2 9 16 21 9 51 0 64 7 5 2 6 5 38 47 0 22 28 0 Nem kg m ft Ib CAUTION e Before removing engine assembly and transmission assembly be sure to remove crankshaft position sensor on models for Europe e Be careful not to drop or damage crankshaft position sen sor EM 26 CYLINDER BLOCK SEC 110 120 130 MA BY O 147 167 15 0 17 0 108 123 EG Reinforcement Flywheel M T plate M T EE Pilot converter M T Rear plate M T GL O Piston rings MT Piston pin E pc NP ring e Rear oil seal retainer AY I Piston EK e T2 147 167 Q i 15 0
27. nit mm in Limit 0 50 0 0197 0 30 0 0118 0 15 0 0059 1 5 0 059 Gl MA LG Ee GL MT AT TF RA EL SE
28. o 54 0 to 63 8 N m 5 5 to 6 5 kg m 39 8 to 47 0 ft lb b Turn bolt 120 to 125 degrees clockwise using marks provided on bolt flange Turning for one mark equals 120 degrees 18 Remove ring gear stopper 19 Install starter motor 20 Install cylinder head front cover CITRE BERGIE E e Apply liquid gasket to cylinder head front cover e Use Genuine Liquid Gasket or equivalent 2 0 3 0 mm 0 079 0 118 in dia 21 Install camshaft position sensor with new O ring Camshatt position sensor SOT Yi eon m oe Oylinder h head 22 Before installing rocker cover apply a continuous bead of liq E n M LE N uid gasket to mating surface of cylinder head E S e Use Genuine Liquid Gasket or equivalent EN NOME BO ON Ro A MB S c D SR al front cover EM 22 TIMING CHAIN Installation Cont d 23 Install rocker cover with new rocker cover gasket and tighten Gl bolts in numerical order as shown in the figure 24 Install ignition coils 25 Install alternator and alternator bracket MA 26 Install power steering oil pump and power steering oil pump bracket 27 Install fan coupling with fan 28 Drive belts For adjusting drive belt deflection refer to Checking Drive Belts in MA section ig Meh I DURTGHESNOUMBR 29 Reinstall parts in reverse order of removal GL MT AT TF BT RA EL SE EM 23 OIL SEAL Replacement Suitable tool f A
29. ocket Exhaust 9 Oil pump drive spacer 14 Cylinder head front cover 4 O ring 10 Front cover 15 Camshaft position sensor 5 Timing chain slack guide 16 Chain guide IDX EM 15 TIMING CHAIN Components Cont d CAUTION e After removing timing chain do not turn and camshaft separately or valves will strike piston heads e When installing chain tensioner oil seats or other sliding parts lubricate contacting surfaces with new engine oil e Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprocket and crankshaft pulley e When removing front cover remove camshaft position sensor then remove timing chain from engine e Be careful not to damage sensor edges Removal 1 Release fuel pressure Refer to Fuel Pressure Release in EC section Remove engine undercover Drain engine oil Drain engine coolant from radiator Be careful not to spill engine coolant on drive belts Remove radiator and radiator shroud Refer to Radiator in Remove the following belts A C compressor drive belt Power steering oil pump drive belt Alternator drive belt Remove fan coupling with fan Remove power steering oil pump and power steering oil pump bracket 9 Remove A C compressor idler pulley 10 Remove alternator and alternator bracket 11 Remove oil pans Refer to Removal 12 Remove air duct from intake manifold collector o eeeo o AWN ims f 13 Remove vacuum hoses f
30. round es Air intake housing i Hose HE Intake manifold 12 15 1 2 1 5 9 11 o E e CL 29 34 Gasket Gasket M 3 0 3 5 22 _ e TS Gasket e3 P MUT Gasket O S di di AT Vacuum pump a A Pd 5 44 54 4 5 5 5 33 40 O ring 9 Oil tube a TE Injection pump mM a Engine slinger Refer to EC section Injection tube TES a a ee T 3 13 19 poses CY 3 PD 1 3 2 0 NN 10 14 30 39 0 40 gt YS ae PA 22 2 B 8 C y Injection nozzle holder ic TA fie ROR Gasket D YZ 5 5 6 5 40 p P AN Croce Co RA Nozzle washer 79 Py Nozzle gasket Q P a At z SS a ae Spill Top nozzle gasket e3 p d POP Si tube oo bo p BR ae Nozzle support lt A Gasket m T AA Ma Ly Bracket CS rA P di S Z ST y wer yd a T g3 Injection pump Qs drive gear S 13 19 1 3 2 0 10 14 RS j 59 69 js 6 0 7 0 43 51 i d O ring 3 BI 0 25 35 Dust cover p a 2 5 3 6 18 26 D 16 21 E 1 6 2 1 12 15 Engine revolution sensor 1 HA Always replace after every disassembly OC e ys rep y y 2 5 3 6 18 26 ke Nem kg m in Ib EL 5 6 8 4 O Nem kg m ft Ib 0 57 0 85 50 74 Apply recommended sealant Nissan genuine part KP610 00250 or equivalent SE 1 Do not damage the sensor edges IDX SEM071H EM 31 OUTER COMPONENT PARTS SEC 135 140 144 210 230 ko 9 1
31. sprocket e Support chain with a suitable tool to keep the mating mark aligned EM 19 MA LG eG GL MT AT TF TIMING CHAIN Installation Cont d U 4 Install timing chain slack guide and timing chain tension guide LIS 7 Tension guide 5 Install camshaft sprocket e Set timing chain by aligning mating marks with those of camshaft sprockets Mating mark e F cec Mating mark ey M uror XP e 2 oy c N CL 7 A 2 SY el 3 Q o CA s 7 9 v N S P 7 EN S DA o od AGNI amshaft sprocket Camshaft sprocket INT AIL SS I MEM221A 6 Install camshaft sprocket bolts and tighten them to specified torque holding camshaft at hexagonal area e Apply new engine oil to bolt threads and seat surface 7 Install chain tensioner e Before installing chain tensioner insert a suitable pin into pin hole of chain tensioner to keep plunger compressed e After installing chain tensioner remove the pin to release lunger Chain tensioner 3 p g M l l 21 NP ee 8 Install timing chain guide to camshaft bracket N V vat BYR KARE ANA 9 4 MO NSORSN WEE Stopper pin Le e Or Pass SASS 9 Replace front oil seal with new one and remove all traces of liquid gasket from mating surface using a scraper e Also remove traces of liquid gasket from mating surface of cyl inder block e For front oil seal replacement refer to FRONT OIL SEAL
32. t to damage aluminum mating surface MA e Do not insert screwdriver or oil pan flange will be deformed LG b Slide seal cutter by tapping on the side of the tool with a ham lt N mer 100 gt M EE a Yn KV10111 jv 5 5 Remove steel oil pan OLX NO SK By MS 6 Disconnect left side of the tie rod end Refer to STEERING LINKAGE in 5 section 7 Remove transmission bolts EM 11 OIL PAN Removal Cont d 8 Remove aluminum oil pan bolts enguie vom e Loosen aluminum oil pan bolts in reverse order Tighten in numerical order Loosen in reverse order 9 Remove aluminum oil pan using seal cutter SST e Be careful not to damage aluminum mating surface e Do not insert screwdriver or oil pan flange will be deformed 10 Remove oil strainer x Roe PN Installation 1 Install oil strainer 2 Install aluminum oil pan a Use a scraper to remove all traces of old liquid gasket from mating surfaces e Also remove traces of old liquid gasket from mating surface of cylinder block front cover and steel oil pan e Remove old liquid gasket from the bolt hole and thread m b Apply a continuous bead of liquid gasket to mating surface of aluminum oil pan e Use Genuine Liquid Gasket or equivalent Inner side SEM159F c Apply liquid gasket to inner sealing surface as shown in figure e Be sure liquid
33. uel hoses and so on i 14 Remove ignition coils 15 Remove rocker cover bolts in numerical order as shown in the figure EM 16 TIMING CHAIN Removal Cont d 16 Set No 1 piston at TDC on its compression stroke QI Crim poner 9 Timing mark Z Q oz M oa E FS mo Crankshaft pulley Le MEM207A Mating mark amp amp A Ir Ses Soe N T4 E aS um OTROS RN NN RW i QN ANS GL INT N VA EXHI Q MIT m RH camshaft LH camshaft gt sprocket A Sis YA ANY wEM208A e Rotate crankshaft until mating mark on camshaft sprocket is set at position indicated in figure sprocket AT 17 Remove camshaft position sensor N 5 9 e Do not allow any magnetic materials to contact the cam 6 s shaft position sensor TE i e Be careful not to drop or damage sensor 18 Remove cylinder head front cover using Seal cutter SST KV10111100 PD Cylinder head front cover 7 4 FA e Camshaft position sensors MES x MEM209AA BA 19 Remove timing chain guide from camshaft bracket 20 Attach a suitable stopper pin to chain tensioner to hold plunger at its compressed position BR 21 Remove chain tensioner Chain tensioner S em a b Si TON T go A S ee KES AS ee d O t SASS aT 22 Loosen camshaft sprocket bolts holding camshaft at hexagonal area A e Apply paint to timing chain and camshaft sprockets for alignment during installation 23 Remove camshaft

ENGINE MECHANICAL SECTION EM

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