drain bolt NISSAN PRIMERA 1999 Electronic Owner's Manual

WARNING:
IPosition 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;
Otherwise, you may burn yourself and/or fire may break
out in fuel line.
IBefore disconnecting fuel hose, release fuel pressure
from fuel line.
Refer to ªReleasing Fuel Pressureº in EC section.
IBe sure to hoist engine and transaxle in a safe manner.
IFor engines not equipped with engine slingers, attach
slingers and bolts described in PARTS CATALOG.
CAUTION:
IWhen lifting engine, be sure to clear surrounding parts.
Use special care for accelerator cable, brake lines and
brake master cylinder.
IIn hoisting the engine, always use engine slingers in a
safe manner.
IWhen removing drive shaft, be careful not to damage
grease seal of transaxle.
Removal
1. Remove engine under cover and hood.
2. Drain coolant from both cylinder block, and radiator.
3. Drain engine oil.
4. Remove vacuum hoses, fuel hoses, wires, harness and con-
nectors.
5. Remove exhaust tubes, ball joints and drive shafts.
6. Remove radiator and fans.
7. Remove drive belts.
8. Remove alternator, compressor and power steering oil pump
from engine.
9. Set a suitable transmission jack under transaxle. Hoist engine
with engine slinger.
10. Remove center member.
SEM092D Center member
Transmission jack
ENGINE REMOVALSR20DE
Components (Cont'd)
EM-107

Removal
1. Drain coolant and disconnect front exhaust pipe from manifold.
2. Remove water hoses, air duct and intake manifold.
3. Remove heat shield and exhaust manifold.
4. Remove rocker cover and injection tubes.
5. Remove both timing belts.
Set No. 1 cylinder at TDC on its compression stroke. Refer to
ªTIMING BELTº (EM-134).
After timing belts have been removed, do not rotate crankshaft
and/or camshaft separately as valves will hit piston heads.
6. Remove cylinder head bolts in numerical order as shown in the
figure.
Disassembly
1. Remove front camshaft sprocket plate, front and rear sprock-
ets using special service tool or a suitable tool, and front back
cover.
2. Remove camshaft brackets in order from outside to inside.
ILoosen camshaft bracket nuts in two or three stages.
3. Remove camshaft and oil seals.
4. Remove valve lifters.
For valve lifter
IAttach tags to valve lifters for identification.
5. Remove valve component parts using special service tool or a
suitable tool.
IKeep each valve and its components together and mark
them so they can be reassembled in their original posi-
tions.
6. Remove valve oil seals using special tool.
SEM373D Drain plug
(cylinder block)
SEM682D
SEM864
SEM716B
SEM745BA
CYLINDER HEADCD20T
Removal
EM-141

Removal
1. Disconnect radiator lower hose and drain coolant.
2. Drain coolant from cylinder block.
3. Remove engine under cover.
4. Remove front exhaust tube.
5. Remove air inlet hose from turbocharger unit.
6. Remove connector bolts of turbocharger oil feed tube and
hoses for turbocharger water feed and return tubes.
7. Remove EGR tube.
8. Remove exhaust manifold cover.
9. Remove insulator.
10. Remove turbocharger oil return hose from oil pan.
11. Remove exhaust manifold fixing nuts and bolts.
NEM204
.Turbocharger water
return tube
.Turbocharger water
feed tube
.Turbocharger oil
feed tube
NEM202 Exhaust
manifold
coverAir inlet
hose EGR
tube
Insulator
.NEM203
.Turbocharger
oil return hose
.Oil pan
NEM205 Loosen in numerical order
p1p2
p3p4
TURBOCHARGERCD20T
Removal
EM-156

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

DESCRIPTION
General
The variable compressor is basically a swash plate type that changes piston stroke in response to the
required cooling capacity.
The tilt of the swash plate allows the piston's stroke to change so that refrigerant discharge can be continu-
ously changed from 6 to 125 cm
3(0.366 to 7.63 cu in).
KHA103 ShaftSealJournal pin
Swash plate
Rear Head
Discharge
valve plate
Control valve
Cylinder
Piston Oil drain bolt
Swash plate
tilting angle
changesLong stroke
(Large amount of refrigerant discharge)
Short stroke
(Small amount of refrigerant
discharge)
Drive lug
Journal pin
Discharge
controlDischarge
capacity
cm
3(cu in)/rev.Pistonstroke
length
mm (in)
Minimum 6 (0.366) 1.2(0.039)
Maximum 125 (7.63) 25.9 (1.02)
DESCRIPTION
CSV613 Variable Displacement Compressor
(Cont'd)
HA-15

Water Pump
REMOVAL AND INSTALLATIONNCLC0018
CAUTION:

When removing water pump assembly, be careful not to
get coolant on drive belt.

Water pump cannot be disassembled and should be
replaced as a unit.

After installing water pump, and check for leaks using
radiator cap tester.
1. Drain coolant from radiator and cylinder block.
Refer to MA section (“Changing Engine Coolant”,“ENGINE
MAINTENANCE”).
2. Remove cylinder head front mounting bracket.
3. Remove drive belts and idler pulley.
4. Loosen water pump pulley bolts.
5. Remove water pump pulley.
6. Remove water pump bolts.
7. Remove water pump with gasket.
8. Reinstall parts in reverse order of removal.
SEM858F
17 - 24 (1.7 - 2.4, 12 - 17)
Water pump
6.3 - 8.3 (0.64 - 0.85, 55.6 - 73.8)
Do not re-use
:N·m (kg-m, in-lb)
:N·m (kg-m, ft-lb)Water pump pulley
17 - 24 (1.7 - 2.4, 12 - 17)
GasketSEC. 210
SEM869F Drain plug
SEM859F Water pump
ENGINE COOLING SYSTEMQG
Water Pump
LC-10

Thermostat
REMOVAL AND INSTALLATION
1. Drain engine coolant.
2. Remove lower radiator hose.
3. Remove water inlet, then take out thermostat.
4. Before installing thermostat, remove all traces of liquid gasket
from mating surface of each part using a scraper.
5. Apply liquid gasket to water outlet, thermostat housing and
water inlet.
6. Install thermostat with jiggle valve uppermost.

After installation, run engine for a few minutes, and check
for leaks.
SLC564AA
SEC. 210-211Water outlet
16 - 21 (1.6 - 2.1, 12 - 15)
From oil cooler
From heater unit
16 - 21 (1.6 - 2.1, 12 - 15)
Up
Thermostat
Thermostat housing
Water inlet
16 - 21 (1.6 - 2.1, 12 - 15)
2.5±0.5
(0.098±0.020)
dia.2.5 (0.098)
3.5 (0.138)
Bolt hole
2.5±0.5 (0.098±0.020) dia.
2.5±0.5
(0.098±0.020) dia.Bolt hole
2.5±0.5 (0.098±0.020) dia.
2.5±0.5
(0.098±0.020) dia.
Unit: mm (in)
:N·m (kg-m, ft-lb)
SLC097 Air bleederUpper
Jiggle valve
ENGINE COOLING SYSTEMCD20T
Thermostat
LC-34

11. Supprt engine by placing a jack under oil pan.
CAUTION:
Do not place jack under oil pan drain plug.
12. Remove rear and LH mounts.
13. Raise jack for access to lower housing bolts. Remove bolts.
Lower jack.
SMT657B
.F31A and F32A
NMT092
.F70A
SMT658B Center
member
Front
REMOVAL AND INSTALLATION
Removal (Cont'd)
MT-11

NCMT0009
Transaxle CaseNCMT0009S011. Remove reverse switch, PNP switch, drain plug, and filler plug
from transaxle case.
2. Remove snap rings from reverse idler shaft.
3. Remove side cover and rear cover from case.
4. Remove O-ring and mainshaft bearing adjusting shim.
5. Remove reverse idler gear shaft.
a. Attach bolt (M6) to thread of reverse idler gear shaft end.
b. Pull out the attached bolt, and remove reverse idler gear shaft
from case.
6. Remove reverse idler gear, thrust washer, and bearing from
case.
7. Remove snap ring of mainshaft bearing from case.
8. Remove check plugs, springs, and check balls from case.
SMT648D Reverse switch
PNP switch
Drain plug Filler plug
SMT644D Snap ring
Rear cover
Side cover
SMT645D Bolt (M6)
SMT646D Flat-head screwdriver
Mainshaft rear bearing snap ring
SMT647D Check plug
DISASSEMBLYRS5F70A
Transaxle Case
MT-52

11. Install transaxle case onto clutch housing, and tighten mount-
ing bolts with specified torque.
Tightening torque:
Refer to MT-48.
12. Apply Three Bond TB1215, Loctite Part No. 51813 or equiva-
lent to threads of reverse switch, PNP switch, and drain plug,
and install them. (Fill the case with oil before installation of filler
plug.)
13. Install speedometer pinion assembly.
CAUTION:
Do not reuse O-ring.
14. Install check springs and check balls. Apply sealant to the
thread on the check plug, and install it.
15. Calculate thickness of adjusting shim using the following pro-
cedure to satisfy specification of end play for mainshaft rear
bearing.
End play: 0 - 0.06 mm (0 - 0.0024 in)
Dimension ªPº = (P1 þ P2) + End play
P : Thickness of adjusting shim
P1: Distance between transaxle case end face
and mainshaft rear bearing
P2: Distance between adjusting shim end face of
rear cover and transaxle mounting face
Available mainshaft rear bearing adjusting shims:
Refer to SDS, MT-92.
SMT649D Clutch housing
Transaxle case
SMT648D Reverse switch
PNP switch
Filler plug Drain plug
SMT749D Check balls
Check springs
Check plugs
16-22
(1.6 -2.2,
12 -16)
N´m (kg-m, ft-lb)
SMT746D Rear cover
Mainshaft rear bearing
adjusting shim
Mainshaft rear
bearing
Dimension ªPº
ASSEMBLYRS5F70A
Transaxle Case (Cont'd)
MT-83