NISSAN PRIMERA 1999 Electronic Repair Manual

2. Installation is the reverse order of removal.
IInstall oil tubes and water tubes in the following order, aligning
the mating marks.
a. Oil feed tube
b. Water return tube
c. Water feed tube
d. Oil return tube
NEM207 Turbocharger
water return
tube
Turbocharger
oil feed tube Turbo-
charger
water
feed tube
Turbocharger
oil return tube
TURBOCHARGERCD20T
Installation (Cont'd)
EM-161

NEM226
43-55
(4.4 - 5.6,
32 - 41)
Rear engine
mounting
43 - 55 (4.4 - 5.6, 32 - 41)
64 - 74 (6.5 - 7.5, 47 - 54)
64-74
(6.5 - 7.5,
47 - 54)
49 - 59 (5.0 - 6.0, 36 - 44)43 - 55 (4.4 - 5.6, 32 - 41)
62 - 78 (6.3 - 8.0, 46 - 58)
Front mounting
bracket
49 - 59 (5.0 - 6.0, 36 - 44)
77 - 98 (7.9 - 100, 57 - 72)
49-59
(5.0 - 6.0,
36 - 44)Insulator
77 - 98 (7.9 - 100, 57 - 72)
43-55
(4.4 - 5.6,
32 - 41)
: N´m (kg-m, ft-lb)
SEC. 112
ENGINE REMOVALCD20T
EM-162

WARNING:
ISituate vehicle on a flat and solid surface.
IPlace chocks at front and back of rear wheels.
IDo not remove engine until exhaust system has com-
pletely cooled down.
IFor safety during subsequent steps, the tension of wires
should be slackened against the engine.
IBefore removing front axle from transaxle, place safety
stands under designated front supporting points. Refer to
GI section for lifting points and towing.
IBe sure to hoist engine and transaxle in a safe manner.
IFor engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG
or Eurofast.
CAUTION:
IWhen lifting engine, be careful not to strike adjacent parts,
especially accelerator wire casing, brake lines, and brake
master cylinder.
IAlways use engine slingers when hoisting the engine.
IWhen removing drive shaft, be careful not to damage tran-
saxle oil seal.
1. Remove engine undercovers and splash covers.
2. Remove front exhaust tube.
3. Disconnect lower water hose from radiator and drain coolant.
4. Drain transaxle oil.
5. Remove power steering mounting bolt. (See left.)
6. Drain coolant from cylinder head.
7. Disconnect water hoses and electrical wiring from radiator and
remove radiator.
8. Disconnect fuel tubes and vacuum tubes.
9. Release power steering belt adjusting nut and remove power
steering pump from engine.
Bind pump properly to the vehicle.
10. Remove A/C compressor.
11. Disconnect or remove electrical wiring where necessary.
12. Release clutch lever cable.
13. Release tachometer cable from transaxle housing.
14. Remove front wheels.
15. Remove brake caliper mounting bolts and bind caliper properly
to vehicle LH & RH.
.SEM531D
SEM532D
ENGINE REMOVALCD20T
EM-163

16. Disconnect tie rod ball joints and lower ball joints (LH & RH).
17. Remove stabilizer.
18. Remove drive shafts from transaxle.
1) RH: Split drive shaft center thrust bearing.
2) RH & LH: Remove hub mounting bolts and remove drive shaft
carefully from transaxle.
19. Mount suitable slingers to cylinder head. Use a suitable hoist
to release the force on the engine mountings.
20. Remove upper mounting (Right side).
21. Release transaxle shift linkages.
22. Release left engine mounting.
SEM534D
SEM535D
SEM536D
ENGINE REMOVALCD20T
EM-164

23. Remove center member fixing bolts from chassis.
24. Remove engine with transaxle as shown.
SEM538D
.SEM247D
ENGINE REMOVALCD20T
EM-165

Components
p1Piston ring
p2Piston
p3Piston pin
p4Connecting rod bearing
p5Connecting rod
p6Main bearing cap
p7Rear plate
p8Flywheel
p9Rear oil seal
p10Rear oil seal retainer
p11Gusset
p12Cylinder block
p13Main bearing
p14Crankshaft
p15Main bearing
p16Gusset
p17Drain plug
p18Pilot bushing
p19Plate
p20Oil jet
NEM376 54-74
(5.5 - 7.5,
40 - 54)
83-93
(8.5 - 9.5,
61 - 69)
69 - 78 (7.0 - 8.0, 51 - 58)
8.4 - 11.0 (0.86 - 1.12, 74.35 - 97.36)
30 - 40 (3.1 - 4.1, 22 - 30)
Refer to
ªAssemblyº
: Do not re-use.
: N´m (kg-m, in-lb)
îî
: N´m (kg-m, ft-lb)
î
: Lubricate with new engine oil.
SEC. 110×120
30 - 40 (3.1 - 4.1, 22 - 30)
30 - 40 (3.1 - 4.1, 266 - 354)
30-40
(3.1 - 4.1, 22 - 30)
16 - 21 (1.6 - 2.1, 12 - 15)
16 - 21 (1.6 - 2.1, 12 - 15)
CYLINDER BLOCKCD20T
Components
EM-166

Preparation
IDrill a hole into the attachment (KV10108101).
Disassembly
PISTON AND CRANKSHAFT
1. Place engine on a work stand.
2. Drain coolant and oil.
3. Remove timing belt.
4. Remove water pump.
5. Remove oil pan and oil pump.
6. Remove cylinder head.
7. Remove pistons with connecting rods.
When disassembling piston and connecting rod, heat piston
to 60 to 70ÉC (140 to 158ÉF) or use piston pin press stand at
room temperature.
8. Remove main bearing cap and crankshaft.
Place the bearings and caps in their proper order.
Upper bearings (cylinder block side) have oil groove.
9. Remove piston rings with a tool.
SEM707D
SEM895
SEM360D Piston with connecting rod
Heater
SEM359F Engine front
Loosen in numerical order
SEM291
CYLINDER BLOCKCD20T
Preparation
EM-167

Inspection
PISTON AND PISTON PIN CLEARANCE
1. Measure outer diameter of piston pin and inner diameter of
piston pin hole.
2. Calculate piston to piston pin clearance.
Pin diameter:
27.994 - 28.000 mm (1.1021 - 1.1024 in)
Pin hole diameter:
27.991 - 27.999 mm (1.1020 - 1.1023 in)
Clearance:
þ0.004 to 0 mm (þ0.0002 to 0 in)
(Interference fit)
Service parts are available as a set of piston and piston pin.
PISTON RING SIDE CLEARANCE
Side clearance:
Unit: mm (in)
Standard Limit
Top ring0.020 - 0.040
(0.0008 - 0.0016)0.10 (0.0039)
2nd ring0.050 - 0.085
(0.0020 - 0.0033)0.10 (0.0039)
Oil ring0.030 - 0.070
(0.0012 - 0.0028)0.10 (0.0039)
If out of specification, replace piston and/or piston ring assembly.
SEM024AA NG
OK Feeler
gauge
Feeler gauge
Ring
CYLINDER BLOCKCD20T
Inspection
EM-168

PISTON RING END GAP
End gap:
Unit: mm (in)
Standard Limit
Top ringBore grade 1, 2, 3
0.22 - 0.32 (0.0087 - 0.0126)
Bore grade 4, 5
0.12 - 0.22 (0.0047 - 0.0087)1.0 (0.039)
2nd ring 0.38 - 0.53 (0.0150 - 0.0209) 0.7 (0.028)
Oil ring 0.30 - 0.55 (0.0118 - 0.0217) 0.6 (0.024)
IIf out of specification, replace piston ring. If gap exceeds maxi-
mum limit with new ring, rebore cylinder and use oversize pis-
ton and piston rings.
Refer to SDS (EM-199).
IWhen replacing the piston, check the cylinder block surface for
scratches or evidence of seizure. If scratches or evidence of
seizure is found, hone or replace the cylinder block.
MAIN BEARING CLEARANCE
1. Install main bearings to cylinder block and main bearing cap.
2. Install main bearing cap with bearing to cylinder block.
Tighten all bolts in two or three stages.
: 69 - 78 N´m (7.0 - 8.0 kg-m, 51 - 58 ft-lb)
3. Measure inside diameter ªAº of main journal.
4. Measure outside diameter ªDmº of main journal of crankshaft.
Journal diameter:
Refer to SDS (EM-199).
5. Calculate main bearing clearance.
Main bearing clearance = A þ Dm
Standard:
0.039 - 0.065 mm (0.0015 - 0.0026 in)
IIf it exceeds the limit, replace the bearing.
SEM599A Piston
Press-fit
RingFeeler
gauge
Ring
SEM360F
SEM506A
CYLINDER BLOCKCD20T
Inspection (Cont'd)
EM-169

IIf crankshaft main journal is worn or shows any abnormality,
regrind crank journal and use undersized bearings to maintain
the specified oil clearance.
IRefer to SDS for regrinding crankshaft journal diameter
and available service parts (EM-200).
IWhen regrinding crankshaft journal, do not grind fillet-roll.
IIf either bearing, crankshaft or cylinder block is replaced with
a new one, select main bearing according to the following
table. These numbers are punched in either Arabic or Roman
numerals.
Main bearing housing grade number
012
Main bearing grade number
Crankshaft main journal
grade number0012
1123
2234
Identification color:
Grade 0 Yellow
Grade 1 Green
Grade 2 Brown
Grade 3 Black
Grade 4 Blue
For example:
Main journal grade number: 1
Crankshaft journal grade number: 2
Main bearing grade number=1+2=3
Main bearing thickness:
Refer to SDS (EM-200).
CONNECTING ROD BEARING CLEARANCE (Big end)
1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap with bearing to connecting rod.
Apply oil to the threaded portion of bolts and seating surface
of nuts.
: 37 - 45 N´m (3.8 - 4.6 kg-m, 27 - 33 ft-lb)
3. Measure inside diameter ªCº of bearing.
SEM566B Counter weight
Main journal
.Maintain more than 0.13 mm (0.0051 in)
SEM706DA
SEM706A
AEM027 Inside micrometer
CYLINDER BLOCKCD20T
Inspection (Cont'd)
EM-170