NISSAN PRIMERA 1999 Electronic Repair Manual

ENGINE MECHANICAL
SECTION
EM
CONTENTS
PRECAUTIONS...............................................................5
Parts Requiring Angular Tightening .............................5
Liquid Gasket Application Procedure ..........................5
PREPARATION................................................................6
Special Service Tools ..................................................6
Commercial Service Tools .........................................10
QG
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING................................................... 11
NVH Troubleshooting - Engine Noise ....................... 11
OUTER COMPONENT PARTS.....................................13
Removal and Installation ...........................................13
MEASUREMENT OF COMPRESSION PRESSURE....16
OIL PAN.........................................................................17
Components...............................................................17
Removal .....................................................................17
Installation ..................................................................18
TIMING CHAIN..............................................................19
Components...............................................................19
Removal .....................................................................20
Inspection...................................................................24
Installation ..................................................................24
OIL SEAL.......................................................................29
Replacement ..............................................................29
VALVE OIL SEAL.....................................................29
FRONT OIL SEAL....................................................29
REAR OIL SEAL......................................................30
CYLINDER HEAD..........................................................31
Components...............................................................31
Removal .....................................................................32
Disassembly...............................................................34
Inspection...................................................................34
CYLINDER HEAD DISTORTION...............................34
CAMSHAFT VISUAL CHECK....................................34
CAMSHAFT RUNOUT..............................................35
CAMSHAFT CAM HEIGHT.......................................35
CAMSHAFT JOURNAL CLEARANCE........................35
CAMSHAFT END PLAY............................................36
CAMSHAFT SPROCKET RUNOUT...........................36
VALVE GUIDE CLEARANCE....................................36
VALVE GUIDE REPLACEMENT................................37
VALVE SEATS.........................................................38
REPLACING VALVE SEAT FOR SERVICE PARTS.....38
VALVE DIMENSIONS...............................................39
VALVE SPRING.......................................................39
VALVE LIFTER AND VALVE SHIM.............................40
Valve Clearance.........................................................40
CHECKING.............................................................40
ADJUSTING............................................................41
Assembly ...................................................................43
Installation ..................................................................43
ENGINE REMOVAL.......................................................48
Removal and Installation ...........................................48
REMOVAL...............................................................49
INSTALLATION........................................................51
CYLINDER BLOCK.......................................................52
Components...............................................................52
Removal and Installation ...........................................53
Disassembly...............................................................53
PISTON AND CRANKSHAFT....................................53
Inspection...................................................................54
PISTON AND PISTON PIN CLEARANCE...................54
PISTON RING SIDE CLEARANCE............................54
PISTON RING END GAP..........................................54
CONNECTING ROD BEND AND TORSION...............55
CYLINDER BLOCK DISTORTION AND WEAR...........55
PISTON-TO-BORE CLEARANCE..............................56
CRANKSHAFT.........................................................57
BEARING CLEARANCE...........................................57
CONNECTING ROD BUSHING CLEARANCE
(Small end)
..............................................................59
REPLACEMENT OF CONNECTING ROD
BUSHING (Small end)
..............................................60
FLYWHEEL/DRIVE PLATE RUNOUT.........................60
EM

Assembly ...................................................................60
PISTON..................................................................60
CRANKSHAFT.........................................................61
SR20DE
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING........................................64
NVH Troubleshooting - Engine Noise .......................65
OUTER COMPONENT PARTS.....................................66
COMPRESSION PRESSURE........................................69
Measurement of Compression Pressure ...................69
OIL PAN.........................................................................70
Removal .....................................................................70
Installation ..................................................................73
TIMING CHAIN..............................................................75
Components...............................................................75
Removal .....................................................................76
Inspection...................................................................79
Installation ..................................................................79
OIL SEAL REPLACEMENT..........................................84
VALVE OIL SEAL.....................................................84
FRONT OIL SEAL....................................................84
REAR OIL SEAL......................................................85
CYLINDER HEAD..........................................................86
Components...............................................................86
Removal .....................................................................87
Disassembly...............................................................89
Inspection...................................................................91
CYLINDER HEAD DISTORTION...............................91
CAMSHAFT VISUAL CHECK....................................91
CAMSHAFT RUNOUT..............................................92
CAMSHAFT CAM HEIGHT.......................................92
CAMSHAFT JOURNAL CLEARANCE........................92
CAMSHAFT END PLAY............................................93
CAMSHAFT SPROCKET RUNOUT...........................93
VALVE GUIDE CLEARANCE....................................93
VALVE GUIDE REPLACEMENT................................94
VALVE SEATS.........................................................95
REPLACING VALVE SEAT FOR SERVICE PARTS.....95
VALVE DIMENSIONS...............................................95
VALVE SPRING.......................................................96
HYDRAULIC LASH ADJUSTER................................96
ROCKER ARM, SHIM AND ROCKER ARM GUIDE.....97
Assembly ...................................................................97
Installation ..................................................................99
ENGINE REMOVAL.....................................................106
Components.............................................................106
Removal ...................................................................107
Installation ................................................................108
CYLINDER BLOCK.....................................................109
Components.............................................................109
Disassembly............................................................. 110
PISTON AND CRANKSHAFT.................................. 110Inspection................................................................. 110
PISTON AND PISTON PIN CLEARANCE................. 110
PISTON RING SIDE CLEARANCE.......................... 111
PISTON RING END GAP........................................ 111
CONNECTING ROD BEND AND TORSION............. 111
CYLINDER BLOCK DISTORTION AND WEAR......... 112
PISTON-TO-BORE CLEARANCE............................ 112
CRANKSHAFT....................................................... 113
BEARING CLEARANCE......................................... 114
CONNECTING ROD BUSHING CLEARANCE
(Small end)
............................................................ 116
REPLACEMENT OF CONNECTING ROD
BUSHING (Small end)
............................................ 117
REPLACEMENT OF PILOT BUSHING (M/T) OR
PILOT CONVERTER (CVT)
.................................... 117
FLYWHEEL/DRIVE PLATE RUNOUT....................... 117
Assembly ................................................................. 117
PISTON................................................................ 117
CRANKSHAFT....................................................... 118
CD20T
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING.....................................121
NVH Troubleshooting Chart - Engine Noise ...........122
OUTER COMPONENT PARTS...................................123
COMPRESSION PRESSURE......................................126
OIL PAN.......................................................................129
Removal ...................................................................129
Installation ................................................................129
TIMING BELT...............................................................131
Camshaft Timing Belt ..............................................131
REMOVAL.............................................................131
Inspection.................................................................133
Installation ................................................................134
Injection Pump Timing Belt ......................................135
REMOVAL.............................................................135
INSTALLATION......................................................136
OIL SEAL REPLACEMENT........................................138
VALVE OIL SEAL...................................................138
CAMSHAFT AND CRANKSHAFT OIL SEAL
INSTALLING DIRECTION AND MANNER
................138
CAMSHAFT OIL SEALS.........................................138
CRANKSHAFT FRONT OIL SEAL...........................139
CRANKSHAFT REAR OIL SEAL.............................139
CYLINDER HEAD........................................................140
Components.............................................................140
Removal ...................................................................141
Disassembly.............................................................141
Inspection.................................................................142
CYLINDER HEAD DISTORTION.............................142
VALVE GUIDE CLEARANCE..................................142
VALVE GUIDE REPLACEMENT..............................142
VALVE SEATS.......................................................143
VALVE SEAT REPLACEMENT................................143
CONTENTS(Cont'd)
EM-2

VALVE DIMENSIONS.............................................144
VALVE SPRING SQUARENESS..............................145
VALVE SPRING PRESSURE LOAD........................145
VALVE LIFTER......................................................145
COMBUSTION CHAMBER REPLACEMENT............146
CAMSHAFT VISUAL CHECK..................................147
CAMSHAFT END PLAY..........................................147
CAMSHAFT RUNOUT............................................147
CAMSHAFT CAM HEIGHT.....................................147
CAMSHAFT JOURNAL CLEARANCE......................147
Valve clearance .......................................................148
Checking ..................................................................148
Adjusting ..................................................................149
Assembly .................................................................151
Installation ................................................................151
TURBOCHARGER.......................................................156
Removal ...................................................................156
Disassembly.............................................................157
Inspection.................................................................158
OIL AND WATER TUBES........................................158
ROTOR SHAFT.....................................................158
TURBINE WHEEL..................................................159
COMPRESSOR WHEEL.........................................159
WASTEGATE VALVE..............................................160
WASTEGATE VALVE ACTUATOR...........................160
Assembly .................................................................160
Installation ................................................................160
ENGINE REMOVAL.....................................................162
CYLINDER BLOCK.....................................................166
Components.............................................................166
Preparation ..............................................................167
Disassembly.............................................................167
PISTON AND CRANKSHAFT..................................167
Inspection.................................................................168
PISTON AND PISTON PIN CLEARANCE.................168
PISTON RING SIDE CLEARANCE..........................168
PISTON RING END GAP........................................169
MAIN BEARING CLEARANCE................................169
CONNECTING ROD BEARING CLEARANCE (Big
end)
......................................................................170
CONNECTING ROD AND PISTON PIN
CLEARANCE (Small end)
.......................................171
CONNECTING ROD BEND AND TORSION.............172
CRANKSHAFT.......................................................172
CYLINDER BLOCK DISTORTION...........................173
CYLINDER BORE..................................................173
PISTON-TO-BORE CLEARANCE............................174
Assembly .................................................................175
PISTON................................................................175
CRANKSHAFT.......................................................175
PISTON WITH CONNECTING ROD........................176
FLYWHEEL RUNOUT.............................................177QG
SERVICE DATA AND SPECIFICATIONS (SDS)........178
General Specifications .............................................178
Compression Pressure ............................................178
Cylinder Head ..........................................................178
Valve ........................................................................179
VA LV E...................................................................179
VALVE SPRING.....................................................179
VALVE LIFTER......................................................179
VALVE CLEARANCE..............................................179
VALVE GUIDE.......................................................180
AVAILABLE SHIMS................................................180
VA LV E S E AT.........................................................182
VALVE SEAT RESURFACE LIMIT...........................183
Camshaft and Camshaft Bearing ............................183
Cylinder Block ..........................................................184
Piston, Piston Ring and Piston Pin .........................185
PISTON................................................................185
PISTON RING.......................................................185
PISTON PIN..........................................................185
Connecting Rod .......................................................186
Crankshaft................................................................186
Main Bearing............................................................186
STANDARD...........................................................186
UNDERSIZE..........................................................186
Connecting Rod Bearing .........................................187
STANDARD SIZE...................................................187
UNDERSIZE..........................................................187
Bearing Clearance ...................................................187
Miscellaneous Components.....................................187
SR20DE
SERVICE DATA AND SPECIFICATIONS (SDS)........188
General Specifications .............................................188
Inspection and Adjustment ......................................188
COMPRESSION PRESSURE.................................188
CYLINDER HEAD..................................................188
VA LV E...................................................................189
CAMSHAFT AND CAMSHAFT BEARING.................192
CYLINDER BLOCK................................................192
PISTON, PISTON RING AND PISTON PIN..............193
CONNECTING ROD...............................................193
CRANKSHAFT.......................................................194
AVAILABLE MAIN BEARING...................................194
AVAILABLE CONNECTING ROD BEARING.............195
MISCELLANEOUS COMPONENTS.........................195
CD20T
SERVICE DATA AND SPECIFICATIONS (SDS)........196
General Specifications .............................................196
Inspection and Adjustment ......................................196
COMPRESSION PRESSURE.................................196
CYLINDER HEAD..................................................196
CONTENTS(Cont'd)
EM-3

CAMSHAFT AND CAMSHAFT BEARING.................196
VA LV E...................................................................197
VALVE LIFTER......................................................198
AVAILABLE SHIMS................................................198
VALVE CLEARANCE..............................................198
CYLINDER BLOCK................................................199
PISTON, PISTON RING AND PISTON PIN..............199
CONNECTING ROD...............................................200
CRANKSHAFT.......................................................200
AVAILABLE MAIN BEARINGS.................................200
TURBOCHARGER.................................................201
MISCELLANEOUS COMPONENTS.........................201
CONTENTS(Cont'd)
EM-4

Parts Requiring Angular Tightening
ISome important engine parts are tightened using an angular-
tightening method rather than a torque setting method.
IIf these parts are tightened using a torque setting method,
dispersal of the tightening force (axial bolt force) will be two or
three times that of the dispersal produced by using the correct
angular-tightening method.
IAlthough the torque setting values (described in this manual)
are equivalent to those used when bolts and nuts are tightened
with an angular-tightening method, they should be used for
reference only.
ITo assure the satisfactory maintenance of the engine, bolts
and nuts must be tightened using an angular-tightening
method.
IBefore tightening the bolts and nuts, ensure that the thread
and seating surfaces are clean and then coated with engine oil.
IThe bolts and nuts which require the angular-tightening
method are as follows:
(1) Cylinder head bolts ..... SR, CD, QG
(2) Main bearing cap bolts ..... SR
(3) Connecting rod cap nuts ..... SR, QG
Liquid Gasket Application Procedure
a. Before applying liquid gasket, use a scraper to remove
all traces of old liquid gasket from mating surface and
groove, and then completely clean any oil stains from
these areas.
b. Apply a continuous bead of liquid gasket to mating sur-
faces. (Use Genuine Liquid Gasket or equivalent.)
IBe sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197
in) wide for SR engine and 3.5 to 4.5 mm (0.138 to
0.177 in) wide for QG and CD engine (for oil pan).
IBe sure liquid gasket is 2.0 to 3.0 mm (0.079 to
0.118 in) wide (in areas except oil pan).
c. Apply liquid gasket to inner surface around hole perim-
eter area.
(Assembly should be done within 5 minutes after coat-
ing.)
d. Wait at least 30 minutes before refilling with engine oil
and engine coolant.
SEM164FInner
side
GrooveBolt hole
AEM080 Inner side
Groove
PRECAUTIONS
Parts Requiring Angular Tightening
EM-5

Special Service Tools
Tool number
Tool nameDescriptionEngine
application
SR CD QG
ST0501S000
Engine stand
assembly
p1ST05011000
Engine stand
p2ST05012000
Base
NT042
When overhauling engine
XXX
KV10106500
Engine stand shaft
NT028
When overhauling engine
XÐX
KV10115300
Engine sub-attach-
ment
NT008
When overhauling engine
XÐÐ
Engine attachment
assembly
p1KV10106500
Engine attach-
ment
p2KV10113300
Sub-attach-
ment
NT029
When overhauling engine
ÐÐ X
p1KV10108101
Engine attach-
ment
p2KV10102500
Engine stand
shaft
NT366
When overhauling engine
ÐXÐ
ST10120000
Cylinder head bolt
wrench
NT583
Loosening and tightening cylinder
head bolt
XÐX
a: 13 (0.51) dia.
b: 12 (0.47)
c: 10 (0.39)
Unit: mm (in)
PREPARATION
Special Service Tools
EM-6

Tool number
Tool nameDescriptionEngine
application
SR CD QG
KV10116200
Valve spring
compressor
p1KV10115900
Attachment
NT022
Disassembling and assembling
valve mechanism
XÐX
KV101092S0
Valve spring
compressor
p1KV10109210
Compressor
p2KV10109220
Adapter
NT021
Disassembling and assembling
valve mechanism
ÐXÐ
KV10115600
Valve oil seal drift
NT603Side A
Side B
Installing valve oil seal
X
(Side
B)ÐX
(Side
A)
Side A Side B
a: 20 (0.79) 20 (0.79)
b: 13 (0.51) 14.2 (0.559)
c: 10.3 (0.406) 11 (0.43)
d: 8 (0.31) 8 (0.31)
e: 10.7 (0.421) 10.7 (0.421)
f: 5 (0.20) 5 (0.20)
Unit: mm (in)
KV10107902
Valve oil seal
puller
p1KV10116100
Valve oil seal
puller adapter
NT605
Removing valve oil seal
XXX
KV10115700
Dial gauge stand
NT012
Adjusting shims
ÐÐ X
KV101151S0
Lifter stopper set
p1KV10115110
Camshaft
pliers
p2KV10115120
Lifter stopper
NT041
Changing shims
ÐX X
EM03470000
Piston ring com-
pressor
NT044
Installing piston assembly into cyl-
inder bore
XXX
PREPARATION
Special Service Tools (Cont'd)
EM-7

Tool number
Tool nameDescriptionEngine
application
SR CD QG
KV10107400
Piston pin press
stand
p1KV10107310
Center shaft
p2ST13040020
Stand
p3ST13040030
Spring
p4KV10107320
Cap
p5ST13040050
DriftNT013
Disassembling and
assembling piston pin
XÐX
KV10109300*
Pulley holder
NT628
Removing and installing camshaft
sprocket
ÐXÐ
a: 68 mm (2.68 in)
b: 8 mm (0.31 in) dia.
ED19600000*
Compression
gauge set
NT626
Measuring compression pressure
ÐXÐ
KV11100300
Nozzle holder
socket
No. 2-4 injection
nozzle holder
socket
NT563
Loosening and tightening injector
nozzle
ÐXÐ
KV119E0030
No. 1 injection
nozzle holder
socket
NT648
Loosening and tightening injector
nozzle
ÐXÐ
KV101111 0 0
Seal cutter
NT046
Removing oil pan
XXX
*: Special tool or commercial equivalent
PREPARATION
Special Service Tools (Cont'd)
EM-8

Tool number
Tool nameDescriptionEngine
application
SR CD QG
WS39930000
Tube presser
NT052
Pressing the tube of liquid gasket
XXX
KV10112100
Angle wrench
NT014
Tightening bolts for bearing cap,
cylinder head, etc.
XXX
ST16610001*
Pilot bushing puller
NT045
Removing pilot bushing
XXÐ
KV11102900*
Pulley puller
NT647
Removing injection pump pulley
ÐXÐ
KV101056S0*
Ring gear stopper
p1KV10105630
Adapter
p2KV10105620
Adapter
p3KV10105610
Plate assem-
bly
NT617
Preventing crankshaft from rotating
ÐX X
a: 3 (0.12)
b: 6.4 (0.252)
c: 2.8 (0.110)
d: 6.6 (0.260)
e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
h: 14 (0.55) dia.
Unit: mm (in)
*: Special tool or commercial equivalent
PREPARATION
Special Service Tools (Cont'd)
EM-9

Commercial Service Tools
Tool name DescriptionEngine
application
SR CD QG
Spark plug wrench
NT047
16 mm
(0.63 in)Removing and installing spark
plug
XÐX
Valve seat cutter set
NT048
Finishing valve seat dimensions
XXX
Piston ring expander
NT030
Removing and installing piston
ring
XXX
Valve guide drift
NT015
Removing and installing valve
guide
XÐX
SR Intake & Exhaust
a = 9.5 mm (0.374 in) dia.
b = 5.0 mm (0.197 in) dia.
QG Intake & Exhaust
a = 9.5 mm (0.374 in) dia.
b = 5.5 mm (0.217 in) dia.
Valve guide reamer
NT016
Reaming valve guidep1
or hole for oversize valve guide
p2
XÐXSR Intake & Exhaust
d1= 6.0 mm (0.236 in) dia.
d2= 10.175 mm (0.4006 in) dia.
QG Intake & Exhaust
d
1= 5.5 mm (0.217 in) dia.
d2= 9.685 mm (0.3813 in) dia.
Front oil seal drift
NT049
Installing front oil seal
XÐX
a = 75 mm (2.95 in) dia.
b = 45 mm (1.77 in) dia.
Rear oil seal drift
NT049
Installing rear oil seal
XÐX
a = 110 mm (4.33 in) dia.
b = 80 mm (3.15 in) dia.
PREPARATION
Commercial Service Tools
EM-10