engine NISSAN PATROL 2000 Electronic Repair Manual

INSPECTION
1. Remove the vacuum hose. Connect the vacuum gauge
through the 3-way connector. Otherwise, remove the welch
valve of the vacuum pipe and attach the vacuum gauge
directly. (The illustration shows the second method.)
+Remove an appropriate part to measure the vacuum pump
load pressure directly and install the vacuum gauge. Refer to
the figure.
2. Start the engine, and measure the load pressure with the
engine idling.
Vacuum pressure:
Standard
þ93.3 to þ101.3 kPa (þ933 to þ1,013 mbar, þ700 to
þ760 mmHg, þ27.56 to þ29.92 inHg)
3. If outside the standard value, make sure that there is no
intake of air within the circuit and measure again.
4. Replace the vacuum pump if still outside the standard value.
INSTALLATION
+Install in the reverse order of removal.
SEM322G
VACUUM PUMPZD
Removal and Installation (Cont'd)
EM-1026

Removal and Installation
CAUTION:
As the internal mechanism of the idler gear must first of all,
and always, be set by a bolt when removing the timing chain
before removing the fuel injection pump and timing gear,
follow the procedures on EM-1039, ªRemoval of timing
chain after setting idler gearº, ªElectronic controlled fuel
injection pumpº.
+This chapter will deal with the summary of removing the tim-
ing chain before removing the camshaft and cylinder head.
Removal
1. Remove the following parts.
+Engine cover
+Intercooler
+Air inlet pipe
+Throttle body
+Rocker cover
+Spill tube
+Coolant (Drain)
+Radiator upper hose
+Water outlet
+Radiator shroud
+Cooling fan
+Auxilary belt
FEM003
TIMING CHAINZD
EM-1027

6. Remove the timing chain slack guide.
7. Remove the timing chain with cam sprocket.
+Loosen the cam sprocket holding bolt by fixing the hexago-
nal portion of the intake manifold side camshaft with a
spanner, etc.
+If the spill tube is not removed, fix the hexagonal portion of
the exhaust manifold side camshaft.
CAUTION:
Do not loosen the holding bolt by using the tension of the
chain.
8. Remove the timing chain tension guide.
Installation
1. Install the timing chain tension guide.
2. Install the cam sprocket and the timing chain together.
+Install by aligning the sprocket and timing chain match
marks.
+Tighten the cam sprocket holding bolt by fixing the hexago-
nal portion of the camshaft.
CAUTION:
Do not tighten in the holding bolt using the tension of the
chain.
3. Install the timing chain slack guide.
CAUTION:
When the holding bolt is tightened to the specified torque,
there is a gap between the guide and bolt. Do not over-
tighten.
4. Install the chain tensioner.
1) With the chain tensioner in the position shown in the figure
(with the plunger on the outer side), temporarily tighten the
holding bolt.
2) Press the plunger into the tensioner body while pressing on
the clips which prevent the plunger from returning.
3) Install the upper side holding bolt while holding the plunger
down with your finger and rotating it 180 degrees.
4) Tighten the holding bolt to the specified torque.
5. Install the chain cover.
1) Before installing chain cover, remove all traces of liquid gas-
ket from mating surface using a scraper.
2) Apply a continuous bead of liquid gasket to chain cover.
+Use Genuine Liquid Gasket or equivalent.
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 chain cover to gear case within 5 minutes after
coating.
c. Wait at least 30 minutes before refilling engine oil or
starting engine.
SEM335G
FEM007
FEM008
FEM009
TIMING CHAINZD
Removal (Cont'd)
EM-1029

Removal and Installation
+This engine will have a different valve arrangement from
normal DOHC 4-valve type engines. As both camshafts on
this engine have intake and exhaust cams, in this chapter
they are named as follows:
Camshaft (Right side): Intake manifold side camshaft
Camshaft (Left side): Exhaust manifold side camshaft
+The same parts are used for the right and left sides.
+Refer to the figure for intake and exhaust valve arrangement.
(The camshafts have, alternately, either an intake valve or an
exhaust valve.)
Removal
1. Set the No. 1 cylinder at TDC, then remove the chain case,
timing chain and other parts in connection. Refer to ªTIMING
CHAINº, EM-1027.
2. Remove the cam gear.
+Loosen the cam gear installation bolt by fixing the hexago-
nal portion of the camshaft.
+The idler gear cannot be removed at this point as the gear
case is in the way. (The cylinder head can be removed as a
single unit.)
SEM350G
FEM010
FEM011
CAMSHAFTZD
EM-1031

3. Remove injection tube and injection nozzle assembly. Refer
to EC section, ªInjection Tube and Injection Nozzleº in
ªBASIC SERVICE PROCEDUREº.
4. Remove the camshaft.
+Place distinguishing marks on the right and left sides with
paint.
+Loosen and remove the installation bolt in reverse order
shown in the figure.
5. Remove the adjusting shim and valve lifter.
+Remove by taking notice of the installation position, and
place outside engine in order to prevent confusion.
Inspection
VISUAL CHECK OF CAMSHAFT
+Check the camshaft for one sided wear or scratches.
+Replace the camshaft if there are abnormalities.
CAMSHAFT RUNOUT
+Prepare V-block on a flat surface and secure camshaft jour-
nals No. 1 and No. 5.
+Set the dial gauge vertically on journal No. 3.
+Rotate camshaft in one direction by hand, then read needle
movement on dial indicator.
Camshaft bend value is 1/2 of needle movement.
Limit: 0.02 mm (0.0008 in)
HEIGHT OF CAM NOSE
Measure by using a micrometer.
Standard:
Intake
40.488 0.02 mm (1.5940 0.0008 in)
Exhaust
40.850 0.02 mm (1.6083 0.0008 in)
CAMSHAFT OIL CLEARANCE
Measure by using a micrometer.
Cam journal outer diameter:
Standard
29.931 - 29.955 mm (1.1784 - 1.1793 in) dia.
FEM012
FEM013
FEM014
FEM015
CAMSHAFTZD
Removal (Cont'd)
EM-1032

VALVE LIFTER BORE DIAMETER
Measure the bore diameter of the cylinder head valve lifter with
an inside micrometer.
Standard: 34.495 - 34.515 mm (1.3581 - 1.3589 in) dia.
VALVE LIFTER CLEARANCE CALCULATIONS
Clearance = Valve lifter bore diameter þ Valve lifter outer diam-
eter
Standard: 0.030 - 0.065 mm (0.0012 - 0.0026 in)
If it exceeds the standard value, refer to the outer diameter and
bore diameter standard values and replace valve lifter and/or
cylinder head.
Installation
1. Install the valve lifter and adjusting shim.
+Make sure that these are installed in the same position as
before the removal process.
2. Install the camshaft.
+Follow the distinguishing marks that were placed on in the
removal process.
+Face the key in the direction shown in the figure.
3. Install the camshaft bracket.
+Refer to the camshaft bracket upper side journal No. and
install.
+Looking from the exhaust manifold side (left side of engine),
install in the direction that the journal number can be read
correctly.
+Place baffle plate onto upper face of No. 1 camshaft bracket,
and tighten together.
4. Tighten the installation bolts in numerical order in the figure.
1) Tighten to 10 to 14 Nzm (1.0 to 1.5 kg-m, 8 to 10 ft-lb).
+Make sure that the thrust portion of the camshaft is fitted
properly in the head installation side.
2) Tighten to 20 to 23 Nzm (2.0 to 2.4 kg-m, 15 to 17 ft-lb).
FEM019
FEM020
FEM021
FEM012
CAMSHAFTZD
Inspection (Cont'd)
EM-1034

Inspection
+When the camshaft or parts in connection with valves are
removed or replaced, and a fault has occurred (poor starting,
idling, or other faults) due to the misadjustment of the valve
clearance, inspect as follows.
+Inspect and adjust when the engine is cool (at normal tem-
perature).
+Be careful of the intake and exhaust valve arrangement. (The
valve arrangement is different from that in a normal engine.)
(The camshafts have, alternately, either an intake valve or an
exhaust valve.)
1. Remove the following parts.
+Intercooler cover
+Intercooler
+Rocker cover
2. Set the No. 1 cylinder at TDC.
1) Rotate the crankshaft pulley clockwise, and align the TDC
mark of the crankshaft pulley with the timing indicator of the
TDC sensor bracket.
2) Confirm that the cam nose of the No. 1 cylinder and the
knock pin of the cam sprocket is in the position shown in the
figure.
+Rotate the crankshaft pulley again if not in the position shown
in the figure.
3. While referring to the figure, measure the valve clearance in
the circled area of the table below.
Measuring pointNo. 1 No. 2 No. 3 No. 4
INT EXH INT EXH INT EXH INT EXH
When the No. 1
cylinder is in the
TDCjjj j
+The injection order is 1-3-4-2.
+Measure the valve clearance using a JIS high grade feeler
gauge when the engine is cool (at normal temperature).
Standard:
Intake and exhaust
0.35 0.05 mm (0.0138 0.0020 in)
4. Set the No. 4 cylinder at TDC by rotating the crankshaft
clockwise once.
FEM010
SEM342G
FEM024
FEM025
FEM026
VALVE CLEARANCE INSPECTIONS AND ADJUSTMENTSZD
EM-1036

5. While referring to the figure, measure the valve clearance in
the circled area of the table below.
Measuring pointNo. 1 No. 2 No. 3 No. 4
INT EXH INT EXH INT EXH INT EXH
When the No. 4
cylinder is in the
TDCjj jj
6. If the valve clearance is outside the specification, adjust as
follows.
Adjustments
+Remove the adjusting shim for parts which are outside the
specified valve clearance.
1. Remove the spill tube.
2. Extract the engine oil on the upper side of the cylinder head
(for the air gun used in step 7).
3. Rotate the crankshaft to face the cam for adjusting shims that
are to be removed upward.
4. Grip the camshaft with camshaft pliers (SST), the using the
camshaft as a support point, push the adjusting shim down-
ward to compress the valve spring.
CAUTION:
Do not damage the camshaft, cylinder head, or the outer
circumference of the valve lifter.
5. With the valve spring in a compressed state, remove the
camshaft pliers (SST) by securely setting the outer circum-
ference of the valve lifter with the end of the lifter stopper
(SST).
+Hold the lifter stopper by hand until the shim is removed.
CAUTION:
Do not retrieve the camshaft pliers forcefully, as the cam-
shaft will be damaged.
6. Move the rounded hole of the adjusting shim to the front with
a very thin screwdriver.
+When the adjusting shim on the valve lifter will not rotate
smoothly, restart from step 4 with the end of the lifter stop-
per (SST) touching the adjusting shim.
7. Remove the adjusting shim from the valve lifter by blowing
air through the rounded hole of the shim with an air gun.
CAUTION:
To prevent any remaining oil from being blown around, thor-
oughly wipe the area clean and wear protective goggles.
FEM027
FEM028
FEM029
FEM030
VALVE CLEARANCE INSPECTIONS AND ADJUSTMENTSZD
Inspection (Cont'd)
EM-1037

8. Remove the adjusting shim by using a magnetic hand.
9. Measure the thickness of the adjusting shim using a
micrometer.
+Measure near the center of the shim (the part that touches
the cam).
10. Select the new adjusting shim from the following methods.
Calculation method of the adjusting shim thickness:
t=t
1+(C1þC2)
t = Adjusting shim thickness
t
1= Thickness of the removed shim
C
1= Measured valve clearance
C
2= Specified valve clearance
[when the engine is cool (at normal temperature)]
0.35 mm (0.0138 in)
+New adjusting shims have the thickness stamped on the rear
side.
Stamped Shim thickness mm (in)
2.35
2.40
.
.
.
3.052.35 (0.0925)
2.40 (0.0945)
.
.
.
3.05 (0.1201)
+The thickness of the adjusting shim ranges from 2.35 to 3.05
mm (0.0925 to 0.1201 in), where in the space of 0.05 mm
(0.0020 in). There are 15 types of shims available.
11. Fix the selected adjusting shim to the valve lifter.
CAUTION:
Place the stamped side of the adjusting shim to the valve
lifter.
12. Compress the valve spring using the camshaft pliers and
remove the lifter stopper (SST).
13. Rotate the crankshaft 2 to 3 times by hand.
14. Confirm that the valve clearance is within the specification.
FEM031
FEM032
FEM033
VALVE CLEARANCE INSPECTIONS AND ADJUSTMENTSZD
Adjustments (Cont'd)
EM-1038

Removal
1. Remove the following parts.
+Undercover
+Engine oil (Drain)
+Engine coolant (Drain)
+Engine cover
+Intercooler
+Air inlet pipe
+Air cleaner case
+Throttle body
+Swirl and intake air control valve control solenoid valve and
bracket
+Vacuum tank
+Glow plate
+Rocker cover
+Spill tube
+Radiator shrouds (Rear and Lower)
+Cooling fan
+Radiator hose (Upper and Lower)
+Auxiliary belt and auto tensioner.
2. Remove the alternator.
3. Remove the A/C compressor and bracket with piping con-
nected. Move and support it at the LH side of engine bay with
a rope to avoid putting load on piping.
Refer to HA section in Nissan Service Manual (Supplement
I: Publication No. SM0E-Y61AE0E.)
4. Remove the chain cover, timing chain and other parts in
connection.
Before removing timing chain, remove injection pump
sprocket with No.1 cylinder being positioned at TDC. Refer
to the figure.
Refer to ªTIMING CHAINº, EM-1027.
CAUTION:
After removing timing chain, never rotate crankshaft, or the
piston will push the valve up and damage the valve.
+Do not paint the match mark on the timing chain beforehand
as the No. 1 cylinder is set at the TDC during assembly.
5. Remove the TDC sensor.
CAUTION:
+Do not drop or hit the sensor.
+Store in a clean place free of iron filings, etc.
+Do not place near any magnetic equipment.
6. Remove the water pump and its stud bolts.
Refer to ªWATER PUMPº in LC section.
7. Remove the water inlet.
SEM376G
TIMING GEARZD
EM-1040