engine NISSAN TEANA 2003 Service Manual

EX-2
EXHAUST SYSTEM

EXHAUST SYSTEMPFP:20100
Checking Exhaust SystemBBS005AK
Check exhaust pipes, muffler and mounting for improper attachment,
leaks, cracks, damage or deterioration.

If necessary, repair or replace damaged parts.
Removal and InstallationBBS005AL
WARNING:
Be careful not to cut your hand on heat insulator edge.
CAUTION:

Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat
resistance, corrosion resistance, and shape.

Perform the operation with the exhaust system fully cooled down because the system will be hot
just after engine stops.
QR20DE
SMA211A
PBIC4688E
1. Gasket 2. Exhaust front tube 3. Spring
4. Seal bearing 5. Stud bolt 6. Exhaust front tube mounting rubber

EX-4
EXHAUST SYSTEM


When installing heat insulator avoid large gaps or interference between heat insulator and each
exhaust pipe.

Remove deposits from the sealing surface of each connection. Connect them securely to avoid
gas leakage.

Temporarily tighten mounting nuts and bolts on the exhaust manifold side, and mounting bolts
and nuts on the vehicle side. Check each part for unusual interference, and then tighten them to
the specified torque.

When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/
left directions.
Seal Bearing (QR20DE)
1. Securely insert seal bearing into exhaust manifold and three
way catalyst assembly side in the direction as shown in the fig-
ure.
CAUTION:
Be careful not to damage seal bearing surface when install-
ing.
2. With spring large diameter side facing to exhaust front tube
flange, tighten mounting nut.
3. Make sure that stud bolt does not interfere with flange of
exhaust front tube.
INSPECTION AFTER INSTALLATION

Make sure that clearance between tail tube and rear bumper is even.

With engine running, check exhaust tube joints for gas leakage and unusual noises.

Make sure that mounting brackets and mounting rubbers are installed properly and free from undue
stress. Improper installation could result in excessive noise and vibration.
PBIC2432E

FRONT DRIVE SHAFT
FAX-9
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FA X

11. Remove circular clip from shaft.
12. Remove boot from shaft.
13. Clean the old grease on joint sub-assembly with paper towels.
14. Apply the appropriate amount of grease (NISSAN genuine
grease or equivalent) inside joint sub-assembly serration hole
until grease begins to ooze from ball groove and serration hole.
After inserting grease, use a shop cloth to wipe off old grease
that has oozed out.
15. Wrap serration on shaft with tape to protect boot from damage.
Install new boot and boot bands to shaft.
NOTE:
Do not reuse boot bands and boot.
16. Remove the tape wrapped around the serration on shaft.
17. Position circular clip on groove at shaft edge. Align both counter
axles of shaft edge and joint sub-assembly. Then, assemble
shaft with circular clip onto joint sub-assembly.
NOTE:

Do not reuse circular clip.

Drive joint inserter (suitable tool) is recommended when
installing circular clip.
18. Install joint sub-assembly to shaft using plastic hammer.
CAUTION:
Confirm that joint sub-assembly is correctly engaged while
rotating drive shaft.
19. Apply the balance of the specified amount of grease (NISSAN
genuine grease or equivalent) into boot inside from large diame-
ter side of boot.
SDIA2489E
SDIA2775E
SDIA2490E
Engine model Grease amount
QR20DE
88 – 108 g (3.10 – 3.80 oz)
VQ23DE
VQ35DE 115 – 125 g (4.06 – 4.41 oz)
SDIA2372E

FAX-10
FRONT DRIVE SHAFT

20. Install boot securely into grooves (indicated by *marks) shown in
the figure.
CAUTION:
If there is grease on boot mounting surfaces (indicated by *
marks) of shaft and housing, boot may come off. Remove
all grease from surfaces.
21. Make sure boot installation length “L” is the length indicated
below. Insert flat-bladed screwdriver or similar tool into smaller
side of boot. bleed air from boot to prevent boot deformation.
CAUTION:

Boot may break if boot installation length is less then standard value.

Take care not to touch the tip of screwdriver to inside of boot.
22. Secure the large and small ends of boot with new boot bands
using boot band crimping tool [SST: KV40107300] as shown in
the figure.
NOTE:

Do not reuse boot bands.

Secure boot band so that dimension “M” meets the specifica-
tion as shown.
23. Secure joint sub-assembly and shaft, and then make sure that
they are in the correct position when rotating boot. Install them
with new boot band when boot installation positions become
incorrect.
24. Confirm that circular clip on transaxle side is fully engaged.
25. Insert drive shaft to wheel hub and bearing assembly, and then
temporarily tighten hub lock nut.
26. Install nuts and bolts of steering knuckle and strut. Refer to FSU-7, "
Components" , “FRONT SUSPEN-
SION ASSEMBLY” for tightening torque.
27. Install disc rotor. Refer to FAX-5, "
Removal and Installation" .
28. Install torque member fixing bolts to steering knuckle. Refer to BR-26, "
FRONT DISC BRAKE" .
29. Install wheel sensor to steering knuckle. Refer to BRC-33, "
WHEEL SENSORS" .
30. Tighten lock nut to the specified torque. Refer to FA X - 11 , "
COMPONENT"
31. Install cotter pin.
NOTE:
Do not reuse cotter pin.
32. Install tires to vehicle.Engine model Boot installation length L
QR20DE
141.7 – 143.7 mm (5.58 – 5.66 in)
VQ23DE
VQ35DE 155.3 – 161.3 mm (6.11 – 6.35 in)
SDIA1760E
RAC1133D
Dimension “M” : 2.0 – 3.0 mm (0.079 – 0.118 in)
DSF0047D

FL-1
FUEL SYSTEM
B ENGINE
CONTENTS
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SECTION FL
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FL

FUEL SYSTEM
PREPARATION ........................................................... 2
Commercial Service Tools ........................................ 2
FUEL SYSTEM ........................................................... 3
Checking Fuel Lines ................................................. 3
General Precautions ................................................ 3
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND
FUEL PUMP ASSEMBLY ........................................... 4
Removal and Installation .......................................... 4
REMOVAL ............................................................. 4
INSTALLATION ..................................................... 7
INSPECTION AFTER INSTALLATION ................. 7FUEL TANK ................................................................ 8
Removal and Installation .......................................... 8
REMOVAL ............................................................. 8
INSTALLATION ..................................................... 9
INSPECTION AFTER INSTALLATION .................. 9
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 11
Standard and Limit .................................................. 11

FUEL SYSTEM
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FUEL SYSTEMPFP:17503
Checking Fuel LinesBBS005AE
Inspect fuel lines, fuel filler cap and fuel tank for improper attach-
ment, leaks, cracks, damage, loose connections, chafing or deterio-
ration.
If necessary, repair or replace damaged parts.
General PrecautionsBBS005AF
WARNING:
When replacing fuel line parts, be sure to observe the following.

Put a “CAUTION: FLAMMABLE” sign in the workshop.

Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.

Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.

Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in
safe area.
CAUTION:

Use gasoline required by the regulations for octane number. Refer to GI-6, "Precautions for Fuel" .

Before removing fuel line parts, perform the following procedures:
–Release fuel pressure from the fuel lines. Refer to EC-49, "FUEL PRESSURE RELEASE"
(QR20DE), or EC-392, "FUEL PRESSURE RELEASE" (VQ23DE and VQ35DE).
–Disconnect the battery cable from negative terminal.

Always replace clamps with new ones.

Do not kink or twist tubes when they are being installed.

Perform work on level place.

Do not tighten hose clamps excessively to avoid damaging hoses.

After connecting fuel tube quick connectors, make sure
quick connectors are secure.
Ensure that connector and resin tube do not contact any
adjacent parts.

After installing tubes, make sure there is no fuel leakage at
connections in the following steps.
–Apply fuel pressure to fuel lines with turning ignition switch
“ON” (with engine stopped). Then check for fuel leaks at
connections.
–Start engine and rev it up and check for fuel leaks at con-
nections.

Use only a genuine NISSAN fuel filler cap as a replacement.
If an incorrect fuel filler cap is used, the “MIL” may come
on.

For servicing “Evaporative Emission System” parts, refer to
EC-27, "
EVAPORATIVE EMISSION SYSTEM" (QR20DE), or
EC-366, "
EVAPORATIVE EMISSION SYSTEM" (VQ23DE
and VQ35DE).
SMA803A
SBIA0504E

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
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INSTALLATION
Note the following, and install in the reverse order of removal.
Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly
1. Install seal packing to fuel tank without any twist.
2. Align “B” with “A” as shown in the figure. Install fuel level sensor
unit, fuel filter and fuel pump assembly to fuel tank.
CAUTION:
Do not bend float arm during installing.
3. Tighten lock ring with lock ring wrench (commercial service tool).
CAUTION:
Install lock ring horizontally.
Quick Connector
Connect quick connector of fuel feed hose as follows:
1. Check the connection for damage or any foreign materials.
2. Align the connector with the tube, then insert the connector straight into the tube until a click sound is
heard.
3. After connecting, make sure that the connection is secure by following method.

Visually confirm that the two tabs are connected to the connector.

Pull the tube and the connector to make sure they are
securely connected.
Inspection Hole Cover
1. Install inspection hole cover with front mark (arrow) facing front of vehicle.
2. Lock clips by turning counter-clockwise.
INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.
1. Turn ignition switch “ON” (with engine stopped), then check connections for leaks by applying fuel pres-
sure to fuel piping.
2. Start engine and rev it up and make sure there are no fuel leaks at the fuel system connections.
A : Arrow mark (Fuel tank side)
B : Positioning mark
C : Fuel tank
: Vehicle front
PBIC4584J
PBIC1653E

FUEL TANK
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7. Disconnect fuel filler hose and vent hose at the position shown
in the figure.
8. Disconnect EVAP hose at EVAP canister side.
9. Support the lower part of fuel tank with transmission jack.
CAUTION:

Support right and left part of flat bottom plate with pass-
ing board.

Because the height of right and left bottom plate is differ-
ent, horizontally support them with wood plate and things
like that.

Support the position that fuel tank mounting bands do
not engage.
10. Remove fuel tank mounting bands.
11. Supporting with hands, descend transmission jack carefully, and remove fuel tank.
CAUTION:

Make sure that all connection points have been disconnected.

Confirm there is no interference with vehicle.
12. Remove fuel filler tube, if necessary.
INSTALLATION
Note to the following, and install in the reverse order of removal.

Surely clamp fuel hoses and insert hose to the length below.

Be sure hose clamp is not placed on swelled area of fuel tube.

Tighten fuel hose clamp so that the distance between its lugs becomes to the following.

Before fixing fuel tank, temporarily install fuel filler tube.
CAUTION:
Use genuine fuel filler tube mounting bolts or equivalent. Make sure to tighten them to the speci-
fied torque.

To connect quick connector, refer to FL-7, "Quick Connector" .
INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.
1. Turn ignition switch “ON” (with engine stopped), and check connections for leakage by applying fuel pres-
sure to fuel piping.
2. Start engine and rev it up and make sure there are no fuel leaks at the fuel system tube and hose connec-
tions.
PBIC2528E
PBIC2529E
Fuel filler hose : 35 mm (1.38 in)
The other hoses : 25 mm (0.98 in)
Fuel tank side : 5 - 9 mm (0.20 - 0.35 in)
Fuel filler tube side : 7 - 11 mm (0.28 - 0.43 in)

FSU-2
PRECAUTIONS

PRECAUTIONSPFP:00001
CautionBES0003G

When installing rubber bushings, final tightening must be performed under unladen conditions with tires
on ground. Oil will shorten the life of rubber bushings. Be sure to wipe off any spilled oil.
–Unladen conditions mean that fuel, engine coolant and lubricant are full. A spare tire, a jack, hand tools
and mats are in designated positions.

After servicing suspension parts, be sure to check wheel alignment.

Self-lock nut are not reusable. Always use new ones when installing. Since new self-lock nuts are pre-
oiled, tighten as they are.

FRONT SUSPENSION ASSEMBLY
FSU-5
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FSU

FRONT SUSPENSION ASSEMBLYPFP:54010
On-Vehicle Inspection BES0003K
Make sure that the mounting conditions (looseness, back lash) of each component and component status
(wear, damage) are normal.
INSPECTION OF TRANSVERSE LINK BALL JOINT END PLAY
1. Set front wheels in a straight-ahead position. Do not depress brake pedal.
2. Measure axial end play by placing an iron pry bar or a similar item between suspension arm and strut
assembly and prying up and down.
CAUTION:
Be careful not to damage ball joint boot. Do not damage the installation position by applying
excessive force.
STRUT INSPECTION
Check for oil leakage, damage, and breakage of installation positions.
Wheel Alignment InspectionBES0003L
DESCRIPTION
Measure wheel alignment under unladen conditions.
NOTE:
“Unladen” conditions mean that fuel, engine coolant, and lubricant are full. A spare tire, a jack, hand tools and
mats are in designated positions.
PRELIMINARY CHECK
1. Check Tires for improper air pressure and wear.
2. Check Road wheels for runout. Refer to WT-3, "
ROAD WHEEL" .
3. Check Wheel bearing axial end play. Refer to FAX-5, "
WHEEL BEARING INSPECTION" .
4. Check Transverse link ball joint axial end play. Refer to FSU-14, "
INSPECTION AFTER REMOVAL" .
5. Check Strut operation.
6. Check Each mounting point of axle and suspension for looseness and deformation.
7. Check Each link, rod, and member for cracks, deformation and other damage.
8. Check Vehicle height (posture).
INSPECTION OF CAMBER, CASTER AND KINGPIN INCLINATION ANGLES.

Camber, caster, kingpin inclination angles cannot be adjusted.

Before inspection, mount wheels onto turning radius gauge. Mount rear wheels onto a stand that has
same height so vehicle will remain horizontal.
Using a CCK Gauge
Install CCK gauge attachment [SST:KV991040S0] with the following procedure on wheel, then measure wheel
alignment.
1. Remove three wheel nuts, and install the guide bolts to hub
bolts.
2. Screw adapter into the plate until it contacts the plate tightly.
3. Screw center plate into the plate.
4. Insert plate on guide bolt. Put spring in, and then evenly screw
both guide bolt nuts. When fastening guide bolt nuts, do not
completely compress the spring.Axial end play : 0 mm (0 in)
SEIA0240E