Engine Mechanical - 3.5L: Removal & Installation Nissan Altima L31

PRECAUTIONS FOR REMOVAL AND DISASSEMBLY

1. When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid forceful or uninstructed operations.
2. Exercise maximum care to avoid damage to mating or sliding surfaces.
3. Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
4. Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly.
5. 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. Power tools may be used where noted in the step.

PRECAUTIONS FOR ASSEMBLY AND INSTALLATION

1. Use torque wrench to tighten bolts or nuts to specification.
2. 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 specified, do exactly as specified.
3. Replace with new gasket, packing, oil seal or O-ring.
4. Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction and blockage.
5. Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well.
6. Release air within route after draining coolant.
7. After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for leakage.

Removal

1. Disconnect the harness connector from the mass air flow sensor.
2. Disconnect the tube clamp at the electric throttle control actuator and at the fresh air intake tube.
3. Remove air cleaner to electric throttle control actuator tube, air cleaner case (upper) with the mass air flow sensor attached.
4. Remove mass air flow sensor from air cleaner case (upper), as necessary. CAUTION: Handle mass air flow sensor with care. Do not shock it. Do not disassemble it. Do not touch its sensor.
5. Remove resonator in the fender, lifting left fender protector, as necessary.

Installation

1. Installation is in the reverse order of removal.

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1. Remove the engine cover with power tool.
2. Release the fuel pressure. Refer to «FUEL PRESSURE RELEASE»(ref-135504-S01957061042002022200000) .
3. Remove air cleaner case lid and mass air flow sensor, and air intake tube as an assembly. Refer to «Removal And Installation»(ref-163530-S39534864752005050200000) .
4. Partially drain the coolant when the engine is cool. Refer to «CHANGING ENGINE COOLANT»(ref-183495-S21164635392005081400000) .
5. Disconnect fuel tube quick connector at vehicle piping side.
6. To remove the quick connector cap, hold the sides of the connector, push in the tabs and pull out the tube. (Figure is for reference only.) NOTE: If the connector and the tube are stuck together, push and pull several times until they start to move. Then disconnect them by pulling. CAUTION: The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary. Do not use any tools to remove the quick connector. Keep the resin tube away from heat. Be especially careful when welding near the tube. Prevent acid liquids such as battery electrolyte, etc. from getting on the resin tube. Do not bend or twist the tube during removal or installation. Do not remove the remaining retainer on the tube When the tube is replaced, also replace the retainer with a new one. To keep the connecting portion clean and to avoid damage and foreign materials entering, cover the ends of the fuel tubes with plastic bags or something similar.
7. Disconnect the power brake booster vacuum hose, the coolant hoses from the electric throttle control actuator, the swirl control vacuum lines, the fuel injectors electrical connectors, and the PCV hose. CAUTION: Cover any engine openings to avoid the entry of any foreign material.
8. Disconnect the electric throttle control actuator electrical connectors.
9. Remove the cowl top grille and the windshield wiper assembly. Refer to «REMOVAL & INSTALLATION»(ref-153096-S04190084822003031400000) .
10. Disconnect the power steering hose bracket.
11. Remove the vacuum tank from the back of the intake manifold collector.
12. Remove the intake manifold collector pipe and electric throttle control actuator by loosening the four bolts in a diagonal pattern. CAUTION: Handle carefully to avoid any shock to the electric throttle control actuator.
13. Loosen the bolts in the order shown, and remove the intake manifold collector with power tool.
14. Remove the fuel rail with the fuel injectors attached, from the intake manifold. Remove the fuel injector O-rings and use new O-rings for installation.
15. Loosen the bolts in the order shown, and remove the intake manifold with power tool.

Scheme 344

1. Using straightedge and feeler gauge, inspect the surface distortion of both the intake manifold and the intake manifold collector. Standard: 0.1 mm (0.004 in)

Installation is in the reverse order of removal. Follow the procedures below for specific tightening sequences and procedures.

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Scheme 347

1. Install intake manifold bolts in two stages in the numerical order as shown. Stage 1: 5 - 10 N.m (0.5 - 1.0 kg-m, 44 - 86 in-lb) Stage 2: 26 - 31 N.m (2.7 - 3.2 kg-m, 20 - 23 ft-lb)
2. Seat the fuel injectors into the intake manifold with new O-rings. Tighten the fuel rail bolts as shown, in two stages: Stage 1: 9.3 - 10.8 N.m (0.95 - 1.1 kg-m, 83 - 95 in-lb) Stage 2: 21 - 26 N.m (2.1 - 2.7 kg-m, 15 - 20 ft-lb)
3. Install the intake manifold collector bolts in the numerical order as shown. Intake manifold collector bolts: 18 - 21 N.m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
4. Tighten the mounting bolts of the intake manifold collector pipe and electric throttle control actuator assembly equally and diagonally to specification. Intake manifold collector pipe bolts: 18 - 21 N.m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)

Note. After installation, it is necessary to re-calibrate the electric throttle control actuator as follows

Scheme 348

1. Perform the "Throttle Valve Closed Position Learning" when harness connector of the electric throttle control actuator is disconnected. Refer to «THROTTLE VALVE CLOSED POSITION LEARNING»(ref-135505-S20463220872002101400000) .
2. Perform the "Idle Air Volume Learning" when the electric throttle control actuator is replaced. Refer to «IDLE AIR VOLUME LEARNING»(ref-135505-S30377112672002101400000) . Install the quick connector as follows: Make sure no foreign substances are deposited in and around the fuel tube and quick connector and that there is no damage. Align the center to insert the quick connector straight onto the fuel tube. Insert the fuel tube until a click is heard. Install the quick connector cap on the quick connector joint. Align the arrow mark on the quick connector cap to the upper side. Install the fuel hose into the hose clamp.

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1. Remove the front wheel and tires with power tool.
2. Remove the engine undercovers with power tool.
3. Remove the inner wheel well splash shields with power tool.
4. Remove the radiator and cooling fan assembly. Refer to «RADIATOR»(ref-183495-S20693689032005081400000) .
5. Remove the front exhaust tube. Refer to «EXHAUST SYSTEM»(ref-183496) .
6. Remove the front suspension member as follows: CAUTION: Before disconnecting, support the front suspension member with a suitable power lift. Use the lift to lower the member to remove it. Disconnect the lower ball joints. Refer to «TRANSVERSE LINK & BALL JOINT»(ref-165758-S13064975352004090300000) . Remove the steering gear mounting bolts. Refer to «REMOVAL AND INSTALLATION»(ref-239975-S34149628912006080400000) . Disconnect the upper sway bar connecting rod. Refer to «STABILIZER BAR»(ref-165758-S42769306462004090300000) . Disconnect the front and rear engine mounts electrical connectors, if equipped. Remove the front and rear engine mount through bolts and nuts using power tool. CAUTION: For vehicles equipped with an automatic transaxle, the front and rear engine mounts are electrically controlled. Disconnect the engine mount electrical connector(s) before removing the through bolt and nut. Disconnect the power steering line bracket. Remove the LH and RH drive axles. Refer to «REMOVAL AND INSTALLATION»(ref-214677-S37977583402006010500000) . Remove the front suspension member mounting nuts and lower the member out of the engine compartment.
7. Remove heated oxygen sensor 1 (front) (bank 1) and heated oxygen sensor 2 (front) (bank 2). Remove harness connector of each heated oxygen sensor, and disconnect the harness from the bracket and middle clamp. Remove both heated oxygen sensors with the Tool. CAUTION: Be careful not to damage heated oxygen sensor. Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; replace with a new sensor.
8. Remove exhaust manifolds and the three way catalyst heat shields with power tool.
9. Remove the three way catalyst (manifold) (bank 1) and three way catalyst (manifold) (bank 2) by loosening the bolts first and then removing the nuts and through bolts.
10. Remove the exhaust manifolds. Loosen the nuts in the numerical order as shown.

Installation is in the reverse order of removal.

1. Install the exhaust manifold nuts in the numerical order as shown.

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1. Remove the front RH wheel and tire with power tool.
2. Disconnect the battery negative terminal.
3. Remove the oil dipstick.
4. Drain the engine coolant. Refer to «CHANGING ENGINE COOLANT»(ref-183495-S21164635392005081400000).
5. Remove the engine undercover using power tool.
6. Remove the RH inner fender splash shield using power tool.
7. Remove the A/C drive belt.
8. Remove the front exhaust tube. Refer to «EXHAUST SYSTEM (VQ35DE)»(ref-183496-S33542195382005081400000).
9. Dismount the A/C compressor with piping attached, and reposition it out of the way securely with wire. CAUTION: Do not pull on or crimp the A/C lines and hoses.
10. Disconnect the coolant lines from the engine oil cooler and plug them to prevent coolant loss.
11. Remove the oil filter and engine oil cooler from the upper oil pan.
12. Remove the oil pressure switch, and the crankshaft position sensor (POS) from the upper oil pan.
13. Remove the front suspension member. (Scheme 350)and (Scheme 351). CAUTION: Before disconnecting, support the front suspension member with a suitable power lift. Use the lift to lower the front suspension member to remove it. Disconnect the lower ball joints Refer to «TRANSVERSE LINK & BALL JOINT»(ref-165758-S13064975352004090300000). Disconnect the power steering line bracket. Disconnect the steering gear mounting bolts. Disconnect the upper sway bar links. Refer to «STABILIZER BAR»(ref-165758-S42769306462004090300000). Remove the LH and RH drive axles. Refer to «REMOVAL AND INSTALLATION»(ref-214677-S37977583402006010500000). Disconnect the front engine mounts electrical connectors, if equipped. Remove the front and rear engine mounts through bolts and nuts using power tool. WARNING: For additional safety, support the engine from above with a suitable hoist. CAUTION: For vehicles equipped with an automatic transaxle, the front and rear engine mounts are electrically controlled. Disconnect the engine mount electrical connector before removing the through bolt. Remove the front suspension member mounting nuts and lower the member out of the engine compartment.
14. Disconnect the heated oxygen sensors and remove the two catalytic convertors from the exhaust manifolds using power tool.
15. Remove the rear plate cover from the upper oil pan.
16. Remove the bottom oil pan. Loosen the bolts in the numerical sequence as shown with power tool. Insert a tool between the lower oil pan and the upper oil pan. Be careful not to damage the mating surface. Do not insert a screwdriver, this will damage the mating surfaces. Slide the tool by tapping its side with a hammer to remove the lower oil pan from the upper oil pan.
17. Remove the four engine-to-transaxle bolts.
18. Remove the upper oil pan. Loosen the bolts in the numerical order as shown, using power tool. Insert an appropriate size tool into the notch of the upper oil pan as shown (1). Pry off the upper oil pan by moving the tool up and down as shown (2).
19. Remove the O-ring seals from the bottom of the cylinder block and oil pump housing, use new O-rings for installation.
20. Remove front cover gasket and rear oil seal retainer gasket.
21. If re-installing the original oil pan, remove the old sealant from the mating surfaces using a scraper. Also remove the old sealant from mating surface of the cylinder block. Remove the old sealant from the bolt holes and threads. CAUTION: Do not scratch or damage the mating surfaces when cleaning off the old sealant.

1. Installation is in the reverse order of removal.

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1. Apply Genuine RTV Silicone Sealant or equivalent, to the front cover gasket and the rear oil seal retainer gasket as shown. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-177331-S04337218152005052600000) .
2. Install the front cover gasket and rear oil seal retainer gasket as shown.
3. Apply a bead of sealant to the cylinder block mating surface of the upper oil pan to a limited portion as shown. Use Genuine RTV Silicone Sealant, or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-177331-S04337218152005052600000) . Be sure the sealant is applied to a limited portion as shown, and the sealant is 4.0 - 5.0 mm (0.157 - 0.197 in) or 4.5 - 5.5 mm (0.177 - 0.217 in) wide. Attaching should be done within 5 minutes after coating.
4. Install new O-rings on the cylinder block and oil pump body.
5. Install the upper oil pan. Tighten bolts in numerical order. Wait at least 30 minutes before refilling the engine with oil.
6. Install the four engine-to-transmission bolts. Refer to «Removal and Installation»(ref-163530-S33260878492005050200000) .
7. Apply a continuous bead of sealant to the lower oil pan. Use Genuine RTV Silicone Sealant, or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-177331-S04337218152005052600000) . Be sure the sealant is 4.5 - 5.5 mm (0.177 - 0.217 in) wide. Attaching should be done within 5 minutes after coating.
8. Install the lower oil pan. Tighten the bolts in the numerical order as shown. Wait at least 30 minutes before refilling the engine with oil.

Scheme 371

1. Remove the engine cover, with power tool.
2. Drain engine coolant. Refer to «CHANGING ENGINE COOLANT»(ref-183495-S21164635392005081400000) .
3. Disconnect the mass air flow sensor electrical connector and remove the air cleaner assembly and air intake tubes. Refer to «Removal and Installation»(ref-163530-S39534864752005050200000) .
4. Remove the windshield wiper arms and motor assembly and the front cowl panel.
5. Remove the intake manifold collector, gasket, and throttle body. Refer to «Removal and Installation»(ref-163530-S37214515072005050200000) ".
6. Remove the six ignition coils.

1. Installation is in the reverse order of removal.

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Scheme 373

1. Remove the engine cover, with power tool.
2. Drain engine coolant. Refer to «V6»(ref-165889-S39468187392004090800000) .
3. Disconnect the mass air flow sensor electrical connector and remove the air cleaner assembly and air intake tubes. Refer to «Removal and Installation»(ref-163530-S39534864752005050200000) .
4. Remove the windshield wiper arms and motor assembly and the front cowl panel.
5. Remove the intake manifold collector, gasket, and throttle body. Refer to «Removal and Installation»(ref-163530-S37214515072005050200000) .
6. Remove the six ignition coils.
7. Remove the six spark plugs with a suitable tool. If replacing the spark plugs use the correct spark plug for maximum performance.

Installation is in the reverse order of removal.

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Scheme 375

1. Remove the engine cover using power tool.
2. Release the fuel pressure. Refer to «FUEL PRESSURE RELEASE»(ref-135504-S01957061042002022200000) .
3. Remove air cleaner case lid and mass air flow sensor, and air intake tube as an assembly. Refer to «Removal and Installation»(ref-163530-S39534864752005050200000) .
4. Partially drain the coolant when the engine is cool. Refer to «CHANGING ENGINE COOLANT»(ref-183495-S21164635392005081400000) .
5. Disconnect fuel tube quick connector at vehicle piping side. Refer to step 5 of REMOVAL.
6. Disconnect the power brake booster vacuum hose, the coolant hoses from the electric throttle control actuator, the swirl control vacuum lines, the fuel injectors electrical connectors, and the PCV hose. CAUTION: Cover any engine openings to avoid the entry of any foreign material.
7. Disconnect the electric throttle control actuator electrical connector and coolant hoses.
8. Remove the cowl top grille and the windshield wiper assembly.
9. Disconnect the power steering hose bracket.
10. Remove the vacuum tank from the back of the intake manifold collector.
11. Remove the intake manifold collector pipe and electric throttle control actuator, by loosening the four bolts in a diagonal pattern. CAUTION: Handle carefully to avoid any shock to the electric throttle control actuator.
12. Loosen the bolts in the order shown, and remove the intake manifold collector using power tool.
13. Remove the fuel rail with the fuel injectors attached, from the intake manifold. Remove the fuel injector O-rings and use new O-rings for installation.

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1. Installation is in the reverse order of removal. Carefully install new O-rings, including the one used with the fuel damper. Lubricate O-rings by lightly coating with new engine oil. Be careful not to damage the O-rings and surfaces for O-ring sealing surfaces. Do not expand or twist O-rings. Discard old clips; replace with new ones. Position clips in grooves on the fuel injectors. Make sure that protrusions of fuel injectors are aligned with cutouts of clips after installation. Align the protrusions of the fuel tube assembly with those of the fuel injectors. After properly inserting the fuel injectors onto the fuel tube assembly, check that the fuel tube protrusions are engaged with those of fuel injectors, and the flanges of the fuel tube assembly are fully engaged with the clips. Tighten fuel tube assembly mounting bolts as shown, in two steps: 1st step: 9.3 - 10.8 N.m (0.95 - 1.1 kg-m, 6.2 - 7.9 ft-lb) 2nd step: 20.6 - 26.5 N.m (2.1 - 2.7 kg-m, 16 - 19 ft-lb) CAUTION: After properly connecting fuel tube assembly to injector and fuel hose, check connection for fuel leakage. Install the intake manifold collector bolts in the numerical order as shown. Intake manifold collector bolts: 18 - 21 N.m (1.8 - 2.2 kg-m, 13 - 15 ft-lb Tighten the mounting bolts of the intake manifold collector pipe and electric throttle control actuator assembly diagonally to specification. Intake manifold collector pipe bolts: 18 - 21 N.m (1.8 - 2.2 kg-m, 13 - 15 ft-lb) After installation, it is necessary to re-calibrate the electric throttle control actuator. Perform "Throttle Control Closed Position Learning" when the harness connector of the electric throttle control actuator is disconnected. Refer to «THROTTLE VALVE CLOSED POSITION LEARNING»(ref-135505-S20463220872002101400000) . Perform "Idle Air Volume Learning" when the electric throttle control actuator is replaced. Refer to «IDLE AIR VOLUME LEARNING»(ref-135505-S30377112672002101400000) . Install the quick connector. Refer to «INSTALLATION»(ref-163530-S35446369442005050200000) .

Valve Guide Replacement

When valve guide is removed, replace with oversized [0.2 mm (0.008 in)] valve guide.

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1. To remove valve guide, heat cylinder head to 110° to 130°C (230° to 266°F) by soaking in heated oil.
2. Drive out the valve guide with a press [under a 20 kN (2.2 US ton) pressure] or hammer and suitable tool.
3. Ream cylinder head valve guide hole. Valve guide hole diameter: 10.175 - 10.196 mm (for service parts), intake (0.4006 - 0.4014 in) and exhaust
4. Heat cylinder head to 110° to 130°C (230° to 266°F) by soaking in heated oil and press new valve guide from camshaft side into the cylinder head to the dimensions as shown. Projection "L": 12.6 - 12.8 mm (0.496 - 0.504 in)
5. Using a valve guide reamer, apply a reamer finish to the valve guide. Intake and exhaust: 6.000 - 6.018 mm finished size (0.2362 - 0.2369 in)

Scheme 383

1. After confirming that the dimensions of valve guides and valves are within specifications, perform this procedure.
2. Apply prussian blue onto contacting surface of valve seat to check the condition of the valve contact on the surface.
3. Check if the contact area band is continuous all around the circumference.
4. If not, grind to adjust valve fitting and check again. If the contacting surface still has N.G conditions even after the re-check, replace valve seat.

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1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess in cylinder head. Set the machine depth stop to ensure this.
2. Ream cylinder head recess for service valve seat. Oversize: 0.5 mm (0.020 in) Intake: 38.500 - 38.516 mm (1.5157 - 1.5164 in) Exhaust: 32.700 - 32.716 mm (1.2874 - 1.2880 in) Be sure to ream in circles concentric to the valve guide center. This will enable valve seat to fit correctly.
3. Heat cylinder head to 110° to 130°C (230° to 266°F) by soaking in heated oil.
4. Press fit valve seat until it seats on the bottom.
5. Cut or grind valve seat using suitable tool to the specified dimensions. Refer to «VALVE»(ref-163530-S40687404322005050200000) .
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition. Seat face angle "alpha": 45° 15' - 45° 45' degrees/minutes Contacting width "W" for intake: 1.09 - 1.31 mm (0.0429 - 0.0516 in) Contacting width "W" for exhaust: 1.29 - 1.51 mm (0.0508 - 0.0594 in)
8. Use a depth gauge to measure the distance between the mounting surface of the cylinder head spring seat and the valve stem end. If the distance is shorter than specified, repeat step 5 to adjust it. If it is longer, replace the valve seat with a new one. Valve seat resurface limit "L" intake: 41.07 - 41.67 mm (1.6169 - 1.6405 in) Valve seat resurface limit "L" exhaust: 41.00 - 41.60 mm (1.6142 - 1.6378 in)

Installation is in the reverse order of removal.

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