engine NISSAN TIIDA 2007 Service Repair Manual

EM-304
< REMOVAL AND INSTALLATION >[K9K]
ENGINE ASSEMBLY
1. Install engine slingers (1) into front right of cylinder head and
engine slinger (2) into rear left of cylinder head.
2. Remove upper torque rod.
3. Use a manual lift table caddy (commercial service tool) or equiv-
alently rigid tool such as a jack or trestle. Securely support bot-
tom of engine and transaxle.
CAUTION:
Put a piece of wood or something similar at the supporting
surface to secure a stable condition.
4. Remove RH and LH engine mounting bolts.
5. Remove engine and transaxle assembly from vehicle downward
by carefully operating supporting tools.
CAUTION:
 During the operation, make sure that no part interferes with body side.
 Before and during this lifting, always check if any harnesses are left connected.
 During the removal operation, always be careful to prevent vehicle from falling off the lift due to
changes in the center of gravity.
 If necessary, support vehicle by setting a jack or equivalent tool at the rear.
Separation Work
CAUTION:
During the operation, secure the engine by placing a piece of wood under the engine oil pan and tran-
saxle and lift the engine using a suitable tool.
1. Remove starter motor.
2. Separate engine and transaxle.
3. Lift the engine with a suitable tool and separate the engine from the transaxle assembly. Refer to EM-302,
"Exploded View".
INSTALLATION
Installation is in the reverse order of removal.
 Do not allow oil to get on mounting insulator. Be careful not to damage mounting insulator.
 When installation directions are specified, install parts according to the direction marks on them referring to
exploded views.
 Make sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.
InspectionINFOID:0000000001381506
INSPECTION AFTER INSTALLATION
 Before starting engine check the levels of coolant, lubricants and oils. Fill to the specified level.
 Before starting engine, bleed air from fuel piping. Refer to EM-287, "
Removal and Installation".
 Run engine to check for unusual noise and vibration.
 Warm up engine thoroughly to make sure there is no leakage of coolant, lubricants, oil, fuel and exhaust
gas.
 Bleed air from passages in pipes and tubes of applicable lines.
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ENGINE STAND SETTING
EM-305
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DISASSEMBLY AND ASSEMBLY
ENGINE STAND SETTING
SettingINFOID:0000000001381507
Before the engine is mounted on the engine sub-attachment, the engine's electrical harness must be removed
and the engine oil drained.
1. Remove the generator.
2. Remove the multifunction support.
3. Remove the coolant inlet pipe on the water pump.
4. Place the rods (A), (X), (Y) on the cylinder block.
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EM-306
< DISASSEMBLY AND ASSEMBLY >[K9K]
CYLINDER HEAD
CYLINDER HEAD
Exploded ViewINFOID:0000000001381508
Removal and InstallationINFOID:0000000001381509
REMOVAL
1. Remove the following parts.
 Air inlet tube: Refer to EM-272, "
Removal and Installation".
 Rocker cover: Refer to EM-289, "
Removal and Installation".
 Injection tube and fuel injector: Refer to EM-281, "
Removal and Installation".
 High pressure supply pump: Refer to EM-287, "
Removal and Installation".
 Exhaust manifold: Refer to EM-277, "
Removal and Installation".
 Timing belt: Refer to EM-291, "
Removal and Installation".
 Camshaft: Refer to EM-298, "
Removal and Installation".
2. Remove cylinder head bolts in reverse order as shown and
remove cylinder head.
3. Remove cylinder head gasket.
1. Valve lifter 2. Valve collet 3. Valve spring retainer
4. Valve spring 5. Cylinder head bolt 6. Cylinder head
7. Cylinder head gasket 8. Engine slinger 9. Valve
A. 25.0 N·m (2.6 kg-m, 18ft-lb) and 255 degrees
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CYLINDER HEAD
EM-307
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INSTALLATION
1. Position the pistons at mid-stroke.
2. Install new cylinder head gasket using the centering dowels of the cylinder block.
NOTE:
The gasket faces (cylinder head and rocker cover) must be clean, dry and free from grease (in par-
ticular, remove finger marks).
3. Install cylinder head and tighten cylinder head bolts in the
numerical order as shown.
4. Turn all bolts 255 degrees clockwise (angle tightening) in the
numerical order as shown.
CAUTION:
Check and confirm the tightening angle by using the angle
wrench [SST: KV10112100 ( — )] or protractor. Avoid judg-
ment by visual inspection without the tool.
5. Install in the reverse order of removal after this step.
Disassembly and AssemblyINFOID:0000000001381510
DISASSEMBLY
1. Place the cylinder head on cylinder head stand [KV113B0200
(Mot. 1573) (commercial service tool) or equivalent tool].
CAUTION:
Pay strict attention to the rules regarding cleanliness. Refer
to EM-253, "
Precaution for Diesel Equipment".
2. Remove high pressure supply pump and related parts. Refer to EM-281, "
Removal and Installation".
3. Remove the injectors and glow plugs. Refer to EM-281, "
Removal and Installation" and EM-279,
"Removal and Installation".
4. Remove the vacuum pump and water outlet and thermostat assembly. Refer to EM-280, "
Removal and
Installation" and CO-68, "Removal and Installation".
5. Remove the front engine slinger, EGR assembly, air inlet pipe and exhaust manifold. Refer to EM-272,
"Removal and Installation" and EM-277, "Removal and Installation".
6. Remove the camshaft sprocket. Refer to EM-291, "
Removal and Installation".
7. Remove the camshaft brackets. Refer to EM-298, "
Removal and Installation".
8. Remove the tappets, noting their position.: 25.0 N·m (2.6 kg-m, 18 ft-lb)
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EM-310
< DISASSEMBLY AND ASSEMBLY >[K9K]
CYLINDER HEAD
7. Place the guide tube plus push rod assembly on the valve stem
seal.
8. Push the valve stem seal down by tapping the top of the sleeve
with the palm of your hand until the guide tube touches the cylin-
der head.
9. Repeat these operations for all the valves.
10. Install the valve springs and upper cups using valve spring com-
pressor.
11. Install the keys using tweezers.
12. Install in the reverse order of removal after this step.
CleaningINFOID:0000000001381511
 It is very important not to scratch the gasket faces of any aluminium components.
 Use suitable tool to dissolve any part of the seal which remains stuck to the metal surface.
 Apply the dissolving product to the part to be cleaned, wait approximately 10 minutes, then remove it using a
wooden spatula.
 Wear gloves while carrying out this operation.
 Do not allow this dissolving product to drip on to the paintwork.
Great care should be taken when performing this operation, to prevent foreign objects from entering
the pipes taking oil under pressure to the camshafts (pipes in both the cylinder head and its cover)
and the oil return pipes.
Failure to follow these instructions could lead to the blocking of the oilways, resulting in rapid and
serious damage to the engine.
InspectionINFOID:0000000001381512
INSPECTION AFTER REMOVAL
Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checked. Refer to EM-330, "
Inspec-
tion".
1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.
CAUTION:
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CYLINDER HEAD
EM-311
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Use utmost care not to allow gasket debris to enter passages for engine oil or water.
2. At each of several locations on bottom surface of cylinder head, measure the distortion in six directions
using straightedge and feeler gauge.
 If it exceeds the limit, replace cylinder head.
Cylinder Head Height
Measure the height of cylinder head (H).
Valve protrusion
Check the valve protrusion using dial gauge stand set [KV113B0040
(Mot. 251-01) (commercial service tool) or equivalent tool] and dial
gauge stand set [KV113B0050 (Mot. 252-01) (commercial service
tool) or equivalent tool] as shown.
INSPECTION AFTER DISASSEMBLY
Va l v e
Measure the valves as follows.
 Stem diameter (d)
 Face angle (α)
 Head diameter (D)
 Valve length (L)
 Valve margin (T)Limit : Refer to EM-335, "
CylinderHead".
Standard : Refer to EM-335, "
CylinderHead".
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Standard : −0.07 to 0.07 mm (−0.0028 to 0.0028 in)
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Intake : Refer to EM-335, "CylinderHead"
Exhaust : Refer to EM-335, "CylinderHead"
Intake : Refer to EM-335, "CylinderHead"
Exhaust : Refer to EM-335, "CylinderHead"
Intake : Refer to EM-335, "CylinderHead"
Exhaust : Refer to EM-335, "CylinderHead"
Intake : Refer to EM-335, "CylinderHead"
Exhaust : Refer to EM-335, "CylinderHead"
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EM-318
< DISASSEMBLY AND ASSEMBLY >[K9K]
CYLINDER BLOCK
19. Screw sliding hammer [SST: KV113B0020 (Emb. 880)] onto oil
jet remover [SST: KV113B0120 (Mot. 1485-01)] and remove the
oil jet.
20. To remove the piston pin, remove the snap ring using a screwdriver, then release the pin.
Removing the Piston Pins
NOTE:
It is imperative to mark the connecting rod to match it to its piston, because the piston height classes
in the same engine may be different (see Technical Specifications section).
ASSEMBLY
1. The oil jets must be installed using oil jet remover plate [SST: KV113B0170 (Mot. 1494)].
2. Install oil jets for NO. 1 and NO. 3 cylinders with the following procedure.
a. Install plate (A) of oil jet remover plate [SST: KV113B0170 (Mot. 1494)] onto the cylinder block (as shown)
without tightening the two bolts (C).
b. Position the guide rod (B) in the plate (A) and the end of the guide rod in the hole of the oil jet to center the
plate (A).
c. Tighten the two bolts (C).
d. Remove the guide rod.
e. Install the push rod instead of the guide rod, then insert the oil jet
into the push rod.
NOTE:
Check that the oil jet is correctly oriented with the end of
the jet (D) directed towards the center of the cylinder.
f. With a hammer, tap the push rod until the shoulder (E) of the
push rod comes into contact with the plate (A).
3. Install oil jets for NO. 1 and NO.4 cylinders with the following procedure.
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EM-322
< DISASSEMBLY AND ASSEMBLY >[K9K]
CYLINDER BLOCK
e. Position bearing insert [SST: KV113B0160 (Mot. 1493-01)] on
the bearing cap.
f. Install the main bearing in bearing insert [SST: KV113B0160
(Mot. 1493-01)], then press at (A) until the main bearing is
touching at (B) with bearing insert.
g. Lubricate the main bearing with engine oil.
h. Install the crankshaft.
i. Install the lateral shims on bearing No. 3, putting the grooves on
the crankshaft side.
j. Degrease the gasket faces (of the cylinder block and bearing
No. 1). They should be clean, dry and free from grease (in par-
ticular, remove finger marks).
k. Lay two beads of liquid sealant with a width of 4 mm (0.16 in) on
bearing No. 1 of the cylinder block.
l. Install the main bearing caps on bearing cap No. 1 (these are
numbered from 1 - 5 and these numbers should be positioned
opposite the water pump). Then tighten the bolts to a torque of
25 N·m (2.6 kg-m, 18 ft-lb) plus an angle tightening of 47
degrees.
m. Turn all bolts 47 degrees clockwise (angle tightening).
CAUTION:
Check and confirm the tightening angle by using the angle
wrench [SST: KV10112100 ( — )] or protractor. Avoid judg-
ment by visual inspection without the tool.
n. Check the lateral play. Refer to EM-330, "
Inspection".
9. Install connecting rod bearing with the following procedure.
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: 25.0 N·m (2.6 kg-m, 18 ft-lb)
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CYLINDER BLOCK
EM-325
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k. Install the connecting rod bearing (H) on the bearing support,
then push it in the direction of the arrow (as shown).
l. Bring the connecting rod bearing support up against the base of
the connecting rod cap.
m. Remove the connecting rod bearing support and repeat the
operation for the remaining connecting rod caps.
10. Assemble connecting rod and piston with the following procedure.
a. The pistons have a mark engraved on their heads indicating the engine rear side.
 Oil the piston pin.
 Check that the piston pins rotate correctly in the new piston and in the matching connecting rod.
b. Point the mark (A) engraved on the top of the piston upwards
and the flat (B) of the big end downwards as shown.
c. Position the opening (C) of the snap rings opposite the removal
and fitting channel (D).
d. Install snap ring.
 Rings set to their original adjustment must be free within their
channels.
 Ensure the snap rings are fitted the correct way, with the word
TOP pointing upwards.
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EM-326
< DISASSEMBLY AND ASSEMBLY >[K9K]
CYLINDER BLOCK
e. Ensure the break in each piston ring is correctly oriented as
shown.
f. Apply new engine oil to the pistons.
g. Install the connecting rod/piston assemblies into the cylinder
block using the ring, being careful to fit them the right way round
(mark towards the flywheel).
h. Install the connecting rods onto the oiled crankshaft pins of the
crankshaft.
i. Install the connecting rod caps, ensuring they are correctly
matched.
j. Tighten the connecting rod cap bolts.
k. Turn all bolts 45 degrees clockwise (angle tightening).
CAUTION:
Check and confirm the tightening angle by using the angle wrench [SST: KV10112100 ( — )] or pro-
tractor. Avoid judgment by visual inspection without the tool.
l. Inspect that the big end lateral play. Refer to EM-330, "
Inspection".
11. Install the oil pump sprocket and chain.
12. Tighten oil pump mounting bolts.
13. Install water pump, Refer to CO-66, "
Removal and Installation".
NOTE:
The gasket faces (cylinder block, crankshaft cover and water
pump) must be clean, dry and free from grease (in particular,
remove finger marks).
14. Install crankshaft cover oil seal with a new one.
15. Install the crankshaft cover in the numerical order as shown.
16. Apply two beads (B) of liquid gasket, with a diameter of 5 mm
(0.20 in).
Apply two points (C) of liquid gasket, with a diameter of 5 mm
(0.20 in) at the intersection of the crankshaft cover and the cylin-
der block.
 Use Genuine Liquid Gasket or equivalent.: 20.0 N·m (2.0 kg-m, 15 ft-lb)
: 25.0 N·m (2.6 kg-m, 18 ft-lb)
: 11.0 N·m (1.1 kg-m, 8 ft-lb)
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