Nissan Primera P12. Manual — part 414
EM-2
INSTALLATION . . . . . . . . . . . . . 36
INSPECTION AFTER INSTALLATION . . . . 36
Disassembly and Assembly . . . . . . . . . 37
DISASSEMBLY . . . . . . . . . . . . ... 37
ASSEMBLY . . . . . . . . . . . . . . . 37
INJECTION TUBE AND FUEL INJECTOR . . . .. 39
Removal and Installation . . . . . . . . . . 39
REMOVAL . . . . . . . . . . . . . . ... 39
INSTALLATION . . . . . . . . . . . . . 40
INSPECTION AFTER INSTALLATION . . . . 41
FUEL PUMP . . . . . . . . . . . . . . . .. 42
Removal and Installation . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . ... 42
INSPECTION AFTER REMOVAL . . . . . . 47
INSTALLATION . . . . . . . . . . . . . 47
ROCKER COVER . . . . . . . . . . . . . . 52
Removal and Installation . . . . . . . . . . 52
REMOVAL . . . . . . . . . . . . . . ... 52
INSTALLATION . . . . . . . . . . . . . 53
INSPECTION AFTER INSTALLATION . . . . 53
CAMSHAFT . . . . . . . . . . . . . . . ... 54
Removal and Installation . . . . . . . . . . 54
REMOVAL . . . . . . . . . . . . . . ... 54
INSPECTION AFTER REMOVAL . . . . . . 55
INSTALLATION . . . . . . . . . . . . . 58
Valve Clearance . . . . . . . . . . . . . .. 59
INSPECTION . . . . . . . . . . . . . ... 59
ADJUSTMENTS . . . . . . . . . . . . .. 60
SECONDARY TIMING CHAIN . . . . . . . . .. 63
Removal and Installation . . . . . . . . . . 63
REMOVAL . . . . . . . . . . . . . . ... 63
INSPECTION AFTER REMOVAL . . . . . . 65
INSTALLATION . . . . . . . . . . . . . 66
PRIMARY TIMING CHAIN . . . . . . . . . . 68
Removal and Installation . . . . . . . . . . 68
REMOVAL . . . . . . . . . . . . . . ... 70
INSPECTION AFTER REMOVAL . . . . . . 72
INSTALLATION . . . . . . . . . . . . . 73
CYLINDER HEAD . . . . . . . . . . . . . . 78
On-Vehicle Service . . . . . . . . . . . . . 78
CHECKING COMPRESSION PRESSURE . . . 78
Removal and Installation . . . . . . . . . . 79
REMOVAL . . . . . . . . . . . . . . ... 79
INSPECTION AFTER REMOVAL . . . . . . 80
INSTALLATION . . . . . . . . . . . . . 80
Disassembly and Assembly . . . . . . . . . 83
DISASSEMBLY . . . . . . . . . . . . ... 83
ASSEMBLY . . . . . . . . . . . . . . . 84
INSPECTION AFTER DISASSEMBLY . . . . 84
ENGINE ASSEMBLY . . . . . . . . . . . . 89
Removal and Installation . . . . . . . . . . 89
REMOVAL . . . . . . . . . . . . . . ... 89
INSTALLATION . . . . . . . . . . . . . 91
INSPECTION AFTER INSTALLATION . . . . 91
CYLINDER BLOCK . . . . . . . . . . . . ... 93
Disassembly and Assembly . . . . . . . . . 93
DISASSEMBLY . . . . . . . . . . . . ... 94
ASSEMBLY . . . . . . . . . . . . . . . 98
How to Select Piston and Bearing . . . . . . 102
DESCRIPTION . . . . . . . . . . . . ..102
HOW TO SELECT PISTON . . . . . . . ...102
HOW TO SELECT CONNECTING ROD BEAR-
ING . . . . . . . . . . . . . . . . . .103
HOW TO SELECT MAIN BEARING . . . . ..104
Inspection After Disassembly . . . . . . . . 105
CRANKSHAFT SIDE CLEARANCE . . . . ..105
CONNECTING ROD SIDE CLEARANCE . . .106
PISTON TO PISTON PIN CLEARANCE . . ...106
PISTON RING SIDE CLEARANCE . . . . ...106
PISTON RING END GAP . . . . . . . . ..107
CONNECTING ROD BEND AND TORSION . .107
CONNECTING ROD BIG END INNER DIAME-
TER . . . . . . . . . . . . . . . . . 108
CONNECTING ROD BUSHING OIL CLEAR-
ANCE (SMALL END) . . . . . . . . . . .108
CYLINDER BLOCK TOP SURFACE DISTOR-
TION . . . . . . . . . . . . . . . . ..109
MAIN BEARING HOUSING INNER DIAMETER.109
PISTON TO CYLINDER BORE CLEARANCE ..109
CRANKSHAFT JOURNAL OUTER DIAMETER. 110
CRANKSHAFT PIN OUTER DIAMETER . . .. 110
CRANKSHAFT OUT-OF-ROUND AND TAPER. 111
CRANKSHAFT RUNOUT . . . . . . . . .. 111
CONNECTING ROD BEARING OIL CLEAR-
ANCE . . . . . . . . . . . . . . . . . 111
MAIN BEARING OIL CLEARANCE . . . . ... 112
MAIN BEARING CRUSH HEIGHT . . . . . 112
MAIN BEARING CAP BOLT DEFORMATION ... 112
CONNECTING ROD BOLT DEFORMATION . 113
OIL JET . . . . . . . . . . . . . . . .. 113
OIL JET RELIEF VALVE . . . . . . . . . 113
MOVEMENT AMOUNT OF FLYWHEEL . . ... 113
SERVICE DATA AND SPECIFICATIONS (SDS) . 115
Standard and Limit . . . . . . . . . . . . 115
GENERAL SPECIFICATIONS . . . . . . ... 115
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD . . . . . . . . . . . . . . . . . 115
DRIVE BELTS . . . . . . . . . . . . . 115
CYLINDER HEAD . . . . . . . . . . . .. 116
VALVE . . . . . . . . . . . . . . . . 116
CAMSHAFT AND CAMSHAFT BEARING . . .120
CYLINDER BLOCK . . . . . . . . . . . 120
PISTON, PISTON RING AND PISTON PIN . ..121
CONNECTNG ROD . . . . . . . . . . ...122
CRANKSHAFT . . . . . . . . . . . . ...122
AVAILABLE MAIN BEARING . . . . . . . .123
AVAILABLE CONNECTING ROD BEARING . .123
MISCELLANEOUS COMPONENTS . . . . ..123
Tightening Torque . . . . . . . . . . . . .124
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Precautions for Assembly and Installation . . ... 126
Parts Requiring Angular Tightening . . . . . . 126
Precautions For Liquid Gasket . . . . . . . . 127
REMOVAL OF LIQUID GASKET . . . . . .. 127
LIQUID GASKET APPLICATION PROCEDURE. 127
Cleanness & Safety . . . . . . . . . . . .. 127
CLEANLINESS INSTRUCTIONS WHICH MUST
BE FOLLOWED WHEN WORKING ON THE
HIGH-PRESSURE DIRECT INJECTION SYS-
TEM . . . . . . . . . . . . . . . . ... 127
SOURCES OF CONTAMINATION . . . . . 128
PRECAUTIONS TO BE FOLLOWED BEFORE
ANY WORK IS CARRIED OUT ON THE INJEC-
TION SYSTEM . . . . . . . . . . . . .. 128
PRECAUTIONS TO BE FOLLOWED BEFORE
OPENING THE FUEL CIRCUIT . . . . . . 128
PRECAUTIONS TO BE FOLLOWED DURING
THE OPERATION . . . . . . . . . . . . 128
INSTRUCTIONS FOR INSTALLING THE
PLUGS . . . . . . . . . . . . . . . .. 129
POST-REPAIR CHECK . . . . . . . . . . 129
INSPECTION FOR NOISE, VIBRATION AND
HARSHNESS (NVH) TROUBLESHOOTEING . 130
PREPARATION . . . . . . . . . . . . . ... 131
Special Service Tools . . . . . . . . . . ... 131
Commercial Service Tools . . . . . . . . . 136
IDENTIFICATION INFORMATION . . . . . . .. 138
Engine Identification . . . . . . . . . . . . 138
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING . . . . . . . . . . . 139
NVH Troubleshooting —Engine Noise . . . . . 139
Use the Chart Below to Help You Find the Cause
of the Symptom. . . . . . . . . . . . . ... 140
ENGINE ROOM COVER . . . . . . . . . . 141
Removal and Installation . . . . . . . . . .. 141
REMOVAL . . . . . . . . . . . . . . . 141
INSTALLATION . . . . . . . . . . . . . 141
DRIVE BELTS . . . . . . . . . . . . . . . 142
REMOVAL . . . . . . . . . . . . . . . 142
INSTALLATION . . . . . . . . . . . . . 142
AIR CLEANER AND AIR DUCT . . . . . . . . 143
Removal and Installation . . . . . . . . . .. 143
REMOVAL . . . . . . . . . . . . . . . 143
INSTALLATION . . . . . . . . . . . . . 143
Changing Air Cleaner Filter . . . . . . . . .. 144
REMOVAL . . . . . . . . . . . . . . . 144
INSTALLATION . . . . . . . . . . . . . 144
CHARGE AIR COOLER . . . . . . . . . . . 145
Removal and Installation . . . . . . . . . .. 145
INTAKE MANIFOLD, EXHAUST MANIFOLD,
TURBO CHARGER, CATALYST . . . . . . . 146
Removal and Installation . . . . . . . . . .. 146
REMOVAL . . . . . . . . . . . . . . . 146
INSTALLATION . . . . . . . . . . . . . 147
INSPECTION AFTER INSTALLATION . . . .. 147
Disassembly and Assembly . . . . . . . . .. 148
DISASSEMBLY . . . . . . . . . . . . . 148
INSPECTION AFTER DISASSEMBLY . . . .. 148
ASSEMBLY . . . . . . . . . . . . . ... 149
OIL PAN . . . . . . . . . . . . . . . . .. 150
Removal and Installation . . . . . . . . . .. 150
REMOVAL . . . . . . . . . . . . . . . 150
INSPECTION AFTER REMOVAL . . . . . . 152
INSTALLATION . . . . . . . . . . . . . 152
INSPECTION AFTER INSTALLATION . . . .. 152
GLOW PLUG . . . . . . . . . . . . . . .. 153
Removal and Installation . . . . . . . . . .. 153
REMOVAL . . . . . . . . . . . . . . . 153
INSTALLATION . . . . . . . . . . . . . 153
VACUUM PUMP . . . . . . . . . . . . . .. 154
Removal and Installation . . . . . . . . . .. 154
REMOVAL . . . . . . . . . . . . . . . 154
INSTALLATION . . . . . . . . . . . . . 154
ROCKER COVER . . . . . . . . . . . . ... 155
Removal and Installation . . . . . . . . . .. 155
REMOVAL . . . . . . . . . . . . . . . 155
INSTALLATION . . . . . . . . . . . . . 156
TIMING BELT . . . . . . . . . . . . . . .. 157
Removal and Installation . . . . . . . . . .. 157
REMOVAL . . . . . . . . . . . . . . . 157
INSTALLATION . . . . . . . . . . . . . 160
CYLINDER HEAD . . . . . . . . . . . . ... 161
Removal and Installation . . . . . . . . . .. 161
REMOVAL . . . . . . . . . . . . . . . 161
INSTALLATION . . . . . . . . . . . . . 162
Disassembly and Assembly . . . . . . . . .. 163
ENGINE ASSEMBLY . . . . . . . . . . . .. 164
Removal and Installation . . . . . . . . . .. 164
REMOVAL . . . . . . . . . . . . . . . 164
INSTALLATION . . . . . . . . . . . . . 166
INSPECTION AFTER INSTALLATION . . . .. 166
OVERHAUL . . . . . . . . . . . . . . . 167
Tightening Torque . . . . . . . . . . . . . 167
UPPER ENGINE . . . . . . . . . . . ... 167
LOWER ENGINE . . . . . . . . . . . .. 167
Standard Replacement . . . . . . . . . . . 168
PREPARING USED ENGINE . . . . . . . 168
Disassembly of Upper Engine . . . . . . . .. 169
DISASSEMBLY . . . . . . . . . . . . . 169
TIMING ADJUSTMENT . . . . . . . . . . 169
CYLINDER HEAD . . . . . . . . . . . . 171
Cleaning . . . . . . . . . . . . . . . ... 175
Inspection After Disassembly . . . . . . . ... 175
Assembly . . . . . . . . . . . . . . . .. 176
EM-4
DIASSEMBLY . . . . . . . . . . . . . 183
PISTON PIN . . . . . . . . . . . . . .. 189
Assembly of Lower Engine . . . . . . . . ... 189
CONNECTING ROD BEARING . . . . . . 189
CONNECTING ROD AND PISTON . . . . ... 191
PISTON RINGS . . . . . . . . . . . . . 192
OIL JET . . . . . . . . . . . . . . . . 192
REMOVAL AND INSTALLATION OF OIL JET .. 192
CLEAN THE LOWER ENGINE . . . . . . . 196
OIL RETURN PIPE . . . . . . . . . . . 196
MAIN BEARING . . . . . . . . . . . . 198
CRANKSHAFT . . . . . . . . . . . . .. 199
PISTON . . . . . . . . . . . . . . . . 201
INSPECTION OF PISTON PROTRUSION . ... 202
INSTALLATION OF LOWER ENGINE . . . ... 203
CRANKSHAFT GASKETS . . . . . . . . 205
INSTALLATION OF THE CRANKSHAFT SEAL
GASKET . . . . . . . . . . . . . . . 205
INSTALLATION OF FLYWHEEL . . . . . ... 210
Assembly of Upper Engine . . . . . . . . ... 213
INSTALLATION OF CYLINDER HEAD . . . . 213
TIMING ADJUSTMENT . . . . . . . . . . 213
DRIVE BELT . . . . . . . . . . . . . .. 218
INSTALLATION OF UPPER ENGINE . . . ... 218
BASIC INSPECTION . . . . . . . . . . . ... 220
Cylinder Head . . . . . . . . . . . . . ... 220
CYLINDER HEAD TIGHTENING PROCEDURE. 220
THICKNESS OF THE CYLINDER HEAD GAS-
KET . . . . . . . . . . . . . . . . . 220
INSPECTION OF THE PISTON PROTRUTION. 220
HEIGHT OF CYLINDER HEAD . . . . . . . 221
VALVE . . . . . . . . . . . . . . . . 221
VALVE SEAT . . . . . . . . . . . . . ..221
VALVE GUIDE . . . . . . . . . . . . ...222
VALVE SPRING . . . . . . . . . . . . .223
PISTON . . . . . . . . . . . . . . . ..223
INSPECTION OF VALVE CLEARANCE . . . 223
CAMSHAFT . . . . . . . . . . . . . ...224
Piston . . . . . . . . . . . . . . . . . 224
PISTON MARKING . . . . . . . . . . . 225
TABLE OF PISTON PIN HEIGHT . . . . . ..225
MEASURING THE PISTON DIAMETER . . ...225
PISTON RING . . . . . . . . . . . . . 225
PISTON RING END GAP . . . . . . . . ..225
PISTON PIN . . . . . . . . . . . . . ...226
Connecting Rod . . . . . . . . . . . . . 226
Crankshaft . . . . . . . . . . . . . . . .227
SPECIFICATIONS . . . . . . . . . . . .227
MAIN BEARING . . . . . . . . . . . . .227
CONNECTING ROD BEARING . . . . . . .228
Cylinder Block . . . . . . . . . . . . . ...229
PRERARING THE ENGINE TO BE SET ON THE
STAND . . . . . . . . . . . . . . . ...229
CONVENTIONAL CYLINDER BLOCK WITH A
SMALL MATING FACE . . . . . . . . . ..230
NEW CYLINDER BLOCK WITH A LARGE MAT-
ING FACE . . . . . . . . . . . . . . ..230
Parts To Be Replaced After Removal . . . . ...230
Installation of Thread Insert . . . . . . . . ..231
PRECAUTIONS
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PRECAUTIONS
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Precautions for Drain Coolant
EBS00SN4
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Drain coolant when engine is cooled.
Precautions for Disconnecting Fuel Piping
EBS00SN5
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Before starting work, make sure no fire or spark producing items are in the work area.
●
Release fuel pressure before disassembly.
●
After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly
EBS00SN6
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When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
●
Exercise maximum care to avoid damage to mating or sliding surfaces.
●
Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
●
Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
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When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precautions for Inspection, Repair and Replacement
EBS00SN7
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Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way,
and replace if necessary.
Precautions for Assembly and Installation
EBS00SN8
●
Use torque wrench to tighten bolts or nuts.
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When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.
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Replace with new gasket, packing, oil seal or O-ring.
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Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
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Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
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Release air within route after draining coolant.
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After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems
for leakage.
Parts Requiring Angular Tightening
EBS00SN9
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Use an angle wrench for the final tightening of the following engine parts:
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Cylinder head bolts
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Main bearing cap bolts
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Connecting rod cap nuts
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Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular
tightening)
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Do not use a torque value for final tightening.
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The torque value for these parts are for a preliminary step.
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Ensure thread and seat surfaces are clean and coated with engine oil.
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