Engine Mechanical: Removal & Installation Nissan Maxima A33

Removal

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1. Remove engine undercover.
2. Drain engine oil.
3. Remove steel oil pan bolts.
4. Remove steel oil pan. Insert Tool between aluminum oil pan and steel oil pan. Be careful not to damage aluminum mating surface. Do not insert screwdriver, or oil pan flange will be deformed. Slide Tool by tapping on the side of the Tool with a hammer. Remove steel oil pan.
5. Remove oil strainer.
6. Remove front exhaust tube and its support. Refer to REMOVAL AND INSTALLATION .
7. Set a suitable transmission jack under transaxle and hoist engine with engine slinger.
8. Remove crankshaft position sensor (POS) from oil pan.
9. Remove front and rear engine mounting nuts and bolts.
10. Remove center member.
11. Remove drive belts.
12. Remove air conditioner compressor and bracket. Refer to REMOVAL AND INSTALLATION or REMOVAL AND INSTALLATION .
13. Remove rear cover plate.
14. Remove aluminum oil pan bolts in numerical order.
15. Remove four engine-to-transaxle bolts.
16. Remove aluminum oil pan. Insert an appropriate size tool into the notch of aluminum oil pan as shown in the figure. Be careful not to damage aluminum mating surface. Do not insert screwdriver, or oil pan flange will be deformed. Pry off aluminum oil pan by moving the tool up and down. Remove aluminum oil pan.
17. Remove O-rings from cylinder block and oil pump body.

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1. Install aluminum oil pan. Use a scraper to remove old liquid gasket from mating surfaces. Also remove old liquid gasket from mating surface of cylinder block, front cover and steel oil pan. Remove old liquid gasket from the bolt hole and thread. Apply sealant to front cover gasket and rear oil seal retainer gasket. Apply a continuous bead of liquid gasket to mating surface of aluminum oil pan. Use Genuine RTV silicone sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-183533-S20212108872005081400000) . Apply liquid gasket to inner sealing surface as shown in figure. Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197 in) or 4.5 to 5.5 mm (0.177 to 0.217 in) wide as shown in the figure. Assembly should be done within 5 minutes after coating. Install O-rings, cylinder block and oil pump body. Install aluminum oil pan. Tighten bolts in numerical order. Wait at least 30 minutes before refilling engine oil.
2. Install the four engine-to-transaxle bolts. For tightening torque, refer to INSTALLATION or INSTALLATION .
3. Install rear cover plate.
4. Install air conditioner compressor and bracket. Refer to REMOVAL AND INSTALLATION .
5. Install drive belts.
6. Install center member.
7. Install front and rear engine mounting insulator nuts and bolts.
8. Install crankshaft position sensor (POS) with new rubber seal, and heated oxygen sensor 1 (front) (bank 2) harness clamp. Make sure that crankshaft position sensor (POS) and heated oxygen sensor 1 (front) (bank 2) harness clamp are installed correctly as shown in figure.
9. Install front exhaust tube and its support.
10. Install oil strainer.
11. Install steel oil pan. Use a scraper to remove old liquid gasket from mating surfaces. Also remove old liquid gasket from mating surface of aluminum oil pan. Apply a continuous bead of liquid gasket to mating surface of steel oil pan. Use Genuine RTV silicone sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-183533-S20212108872005081400000) . Be sure liquid gasket is 4.5 to 5.5 mm (0.177 to 0.217 in) wide. Assembly should be done within 5 minutes after coating. Install steel oil pan. Tighten in numerical order shown in the figure. Wait at least 30 minutes before refilling engine oil.

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REPLACEMENT

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1. Remove ornament cover.
2. Remove intake manifold upper collector and intake manifold lower collector.
3. Remove RH and LH ignition coils.
4. Remove RH and LH rocker covers from cylinder head.
5. Remove crankshaft position sensor (POS).
6. Remove oil pan. Refer to «REMOVAL»(ref-159268-S07230537042005081400000) .
7. Remove timing chain. Refer to «REMOVAL»(ref-159268-S41407476942005081400000) .
8. Remove camshaft brackets and camshaft. Refer to «DISASSEMBLY»(ref-159268-S33251716812005081400000) .
9. Remove valve lifters.
10. Remove valve spring with Tool.
11. Reinstall any parts removed in reverse order of removal. Before removing valve spring, fix valve as follows. Piston concerned should be set at TDC to prevent valve from falling. Remove spark plug, then install air hose adapter into spark plug hole and apply air pressure to hold valves in place. Apply a pressure of 490 kPa (5 kg/cm 2 , 71 psi).
12. Remove valve oil seal.
13. Apply engine oil to new valve oil seal and install it with Tool.

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1. Remove the following parts: Engine undercover Front RH wheel and engine side cover Drive belts Crankshaft pulley Be careful not to damage sensor edge.
2. Remove front oil seal using a suitable tool. Be careful not to scratch front cover.
3. Apply engine oil to new oil seal and install it using a suitable tool. Install new oil seal in the direction shown in the figure.

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1. Remove transaxle. Refer to REMOVAL AND INSTALLATION (A/T) or REMOVAL AND INSTALLATION (M/T).
2. Remove flywheel or drive plate.
3. Remove oil pan. Refer to «REMOVAL»(ref-159268-S07230537042005081400000) .
4. Remove rear oil seal retainer.
5. Remove old liquid gasket on mating surface of cylinder block and oil pan using scraper. Remove old liquid gasket from the bolt hole and thread.
6. Apply liquid gasket to rear oil seal retainer. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-183533-S20212108872005081400000) . Assembly should be done within 5 minutes after coating. Wait at least 30 minutes before refilling engine oil and engine coolant.

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1. Remove engine from vehicle. Refer to «REMOVAL AND INSTALLATION»(ref-159268-S15429585682005081400000) .
2. Remove exhaust manifolds.
3. Place engine on a work stand.
4. Remove aluminum oil pan. Refer to «REMOVAL»(ref-159268-S07230537042005081400000) .
5. Remove timing chain. Refer to «REMOVAL»(ref-159268-S41407476942005081400000) .
6. Remove intake manifold in reverse order of installation. Refer to «TIGHTENING PROCEDURES»(ref-159268-S05298752482005081400000) .
7. Remove water outlet.
8. Remove near timing chain case bolts. Loosen in reverse order as shown in the figure.
9. Remove rear timing chain case.
10. Remove O-rings from cylinder head.
11. Remove O-rings from cylinder block.
12. Remove intake valve timing control solenoid valves.
13. Remove intake and exhaust camshafts and camshaft brackets. Equally loosen camshaft bracket bolts in several steps in the numerical order shown in the figure. For reinstallation, be sure to put marks on camshaft bracket before removal.
14. Remove RH and LH camshaft chain tensioners from cylinder head.
15. Remove cylinder head bolts. Cylinder head bolts should be loosened in two or three steps. A warped or cracked cylinder head could result from removing in incorrect order.
16. Remove cylinder head.

Installation

Installation is in the reverse order of removal. Install the electronically-controlled engine mount harness to match the following values. (Models with electronically-controlled engine mounts)

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Length between A and B

1. 170 mm (6.69 in)

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REMOVAL AND INSTALLATION

Note. Flywheel removal may require use of special tool J-46531 (TP55 Torx Plus driver) for M/T flywheel bolts. See ESSENTIAL TOOL: TORX DRIVER FOR FLYWHEEL BOLTS for more information.

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1. Remove engine. Refer to «REMOVAL AND INSTALLATION»(ref-159268-S15429585682005081400000) .
2. Place engine on a work stand.
3. Drain coolant and oil.
4. Remove oil pan. Refer to «REMOVAL»(ref-159268-S07230537042005081400000) .
5. Remove timing chain. Refer to «REMOVAL»(ref-159268-S41407476942005081400000) .
6. Remove cylinder head. Refer to «REMOVAL»(ref-159268-S13459737342005081400000) .
7. Remove pistons with connecting rods. When disassembling piston and connecting rod, remove snap ring first, then heat piston to 60 to 70°C (140 to 158°F).
8. Remove rear oil seal retainer. CAUTION: When piston rings are not replaced, make sure that piston rings are mounted in their original positions. When replacing piston rings, if there is no punchmark, install with either side up.
9. Loosen bolts in numerical order as shown and remove main bearing beam, bearing cap and crankshaft. Before removing bearing beam and bearing cap, measure crankshaft end play. Refer to «CRANKSHAFT»(ref-159268-S25762122862005081400000) . Bolts should be loosened in two or three steps.
10. Remove oil jets.

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1. Measure inner diameter of piston pin hole "dp". Standard diameter "dp": Grade No. 0 21.993 - 21.999 mm (0.8659 - 0.8661 in) Grade No. 1 21.999 - 22.005 mm (0.8661 - 0.8663 in)
2. Measure outer diameter of piston pin "Dp. Standard diameter "Dp": Grade No. 0 21.989 - 21.995 mm (0.8657 - 0.8659 in) Grade No. 1 21.995 - 22.001 mm (0.8659 - 0.8662 in)
3. Calculate interference fit of piston pin to piston. Dp - dp = 0.002 - 0.006 mm (0.0001 - 0.0002 in)

If it exceeds the above value, replace piston assembly with pin.

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Side clearance

1. Top ring 0.045 - 0.080 mm (0.0018 - 0.0031 in)
2. 2nd ring 0.030 - 0.070 mm (0.0012 - 0.0028 in)
3. Oil ring 0.065 - 0.135 mm (0.0026 - 0.0053 in)

Max. limit of side clearance

1. Top ring 0.11 mm (0.0043 in)
2. 2nd ring 0.1 mm (0.004 in)

If out of specification, replace piston ring. If clearance exceeds maximum limit with new ring, replace piston.

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End gap

1. Top ring 0.23 - 0.33 mm (0.0091 - 0.0130 in)
2. 2nd ring 0.33 - 0.48 mm (0.0130- 0.0189 in)
3. Oil ring 0.20 - 0.80 mm (0.0079 - 0.0315 in)

Max. limit of ring gap

1. Top ring 0.54 mm (0.0213 in)
2. 2nd ring 0.80 mm (0.0315 in)
3. Oil ring 0.50 mm (0.0197 in)

If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, do the following. Rebore cylinder and use oversized piston and piston rings.

Refer to SDS ( PISTON, PISTON RING AND PISTON PIN ).

1. When replacing the piston, check the cylinder block surface for scratches or seizure. If scratches or seizure is found, hone or replace the cylinder block.

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Bend

1. Limit 0.15 mm (0.0059 in)
2. per 100 mm (3.94 in) length

Torsion

1. Limit 0.30 mm (0.0118 in)
2. per 100 mm (3.94 in) length

If it exceeds the limit, replace connecting rod assembly.

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1. Clean upper surface of cylinder block. Use a reliable straightedge and feeler gauge to check the flatness of cylinder block surface. Check along six positions shown in the figure. Distortion limit: 0.10 mm (0.0039 in)
2. If out of specification, resurface it. The limit for cylinder block resurfacing is determined by cylinder head resurfacing in engine. Resurfacing limit: Amount of cylinder head resurfacing is "A". Amount of cylinder block resurfacing is "B". The maximum limit is as follows: A + B = 0.2 mm (0.008 in) Nominal cylinder block height from crankshaft center: 214.95 - 215.05 mm (8.4626 - 8.4665 in) Refer to SDS ( «CYLINDER BLOCK»(ref-159268-S35460705702005081400000) ).
3. If necessary, replace cylinder block.

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1. Using a bore gauge, measure cylinder bore for wear, out-of-round and taper. Cylinder bore inner diameter If it exceeds the limit, rebore all cylinders. Replace cylinder block if necessary. Out-of-round (X - Y): Limit 0.015 mm (0.0006 in) Taper (A - B - C): Limit 0.015 mm (0.0006 in)
2. Check for scratches and seizure. If seizure is found, hone it. If both cylinder block and piston are replaced with new ones, select piston of the same grade number punched on cylinder block rear position. These numbers are punched in either Arabic or Roman numerals.
3. Measure piston skirt diameter. Piston diameter "A": Refer to SDS ( «PISTON, PISTON RING AND PISTON PIN»(ref-159268-S15096679192005081400000) ). Measuring point "a" (Distance from the top): 41.0 mm (1.61 in)
4. Check that piston-to-bore clearance is within specification. Piston-to-bore clearance "B": 0.010 - 0.030 mm (0.0004 - 0.0012 in)
5. Determine piston oversize according to amount of cylinder wear. Oversize pistons are available for service. Refer to SDS ( «PISTON, PISTON RING AND PISTON PIN»(ref-159268-S15096679192005081400000) ). If oversize piston is used, use oversize piston ring also.
6. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter "A". Rebored size calculation: D = A + B - C where, D: Bored diameter A: Piston diameter as measured B: Piston-to-bore clearance C: Honing allowance 0.02 mm (0.0008 in)
7. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted in final assembly.
8. Cut cylinder bores. When any cylinder needs boring, all other cylinders must also be bored. Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a time.
9. Hone cylinders to obtain specified piston-to-bore clearance.
10. Measure finished cylinder bore for out-of-round and taper. Measurement should be done after cylinder bore cools down.

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1. Check crankshaft main and pin journals for score, wear or cracks.
2. With a micrometer, measure journals for taper and out-of-round. Out-of-round (X - Y): Standard 0.002 mm (0.0001 in) Taper (A - B): Standard 0.002 mm (0.0001 in)
3. Measure crankshaft runout. Runout (Total indicator reading): Limit 0.10 mm (0.0039 in)

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1. Use either of the following two methods, however, method "A" gives more reliable results and is preferable.

Method A (Using bore gauge & micrometer)

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1. Set main bearings in their proper positions on cylinder block and main bearing cap.
2. Install main bearing cap and bearing beam to cylinder block. Tighten all bolts in correct order.
3. Measure inner diameters "A" of each main bearing.
4. Measure outer diameters "Dm" of each crankshaft main journal.
5. Calculate main bearing clearance. Main bearing clearance = A - Dm Standard: 0.035 - 0.045 mm (0.0014 - 0.0018 in) Limit: 0.065 mm (0.0026 in) If it exceeds the limit, replace bearing. If clearance cannot be adjusted using any standard bearing grade, grind crankshaft journal and use undersized bearing. When grinding crankshaft journal, confirm that "L" dimension in fillet roll is more than the specified limit. "L": 0.1 mm (0.004 in) Refer to SDS for grinding crankshaft and available service parts.
6. If crankshaft or cylinder block is replaced with a new one, select thickness of main bearings as follows: Grade number of each cylinder block main journal is punched on the respective cylinder block. These numbers are punched in either Arabic or Alphabet. Refer to SDS, «CYLINDER BLOCK»(ref-159268-S35460705702005081400000) . If measured diameter is out of grade punched, decide suitable grade using table in SDS. Grade number of each crankshaft main journal is punched on the respective crankshaft. These numbers are punched in either Arabic or Alphabet. Refer to SDS, «CRANKSHAFT»(ref-159268-S02163951692005081400000) . If measured diameter is out of grade punched, decide suitable grade using table in SDS. Select main bearing with suitable thickness according to the following table. Refer to SDS, «AVAILABLE MAIN BEARING»(ref-159268-S35194385092005081400000) , for available main bearings.

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1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod. Tighten bolts to the specified torque.
3. Measure inner diameter "C" of connecting rod.
4. Measure outer diameter "Dp" of each crankshaft pin journal.
5. Calculate connecting rod bearing clearance. Connecting rod bearing clearance = C - Dp Standard: 0.034 - 0.059 mm (0.0013 - 0.0023 in) Limit: 0.070 mm (0.0028 in)
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any bearing, grind crankshaft journal and use undersized bearing. Refer to «BEARING CLEARANCE»(ref-159268-S21623578732005081400000) .
8. If crankshaft is replaced with a new one, select connecting rod bearing according to the following table. Connecting rod bearing grade number (Identification color): These numbers are punched in either Arabic or Roman numerals. Method B (Using plastigage) CAUTION: Do not turn crankshaft or connecting rod while plastigage is being inserted. When bearing clearance exceeds the specified limit, ensure that the proper bearing has been installed. If incorrect bearing clearance exists, use a thicker or undersized main bearing to ensure specified clearance.

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1. Measure inner diameter "C" of bushing.
2. Measure outer diameter "Dp" of piston pin.
3. Calculate connecting rod bushing clearance. Connecting rod bushing clearance = C - Dp Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 in) Limit: 0.030 mm (0.0012 in) If it exceeds the limit, replace connecting rod assembly or connecting rod bushing and/or piston set with pin.