Engine Mechanical (VQ40DE): Overhaul Nissan Pathfinder III рестайлинг

DISASSEMBLY

1. Remove spark plug.
2. Remove valve lifter. Identify installation positions, and store them without mixing them up.
3. Remove valve collet. Compress valve spring and remove valve collet with magnet hand using Tool. CAUTION: When working, take care not to damage valve lifter holes. Tool numbers: KV10109220 (-) : KV10116200 (J-26336-B) : KV10115900 (J-26336-20)
4. Remove valve spring retainer, valve spring and valve spring seat.
5. Push valve stem to combustion chamber side, and remove valve. Identify installation positions, and store them without mixing them up.
6. Remove valve oil seals using Tool. Tool number: KV10107902 (J-38959)
7. If valve seat must be replaced, refer to " «INSPECTION AFTER DISASSEMBLY»(ref-519775-S14167579912012122900000) ".
8. If valve guide must be replaced, refer to " «INSPECTION AFTER DISASSEMBLY»(ref-519775-S14167579912012122900000) ".
9. Remove spark plug tube, as necessary. Using pair of pliers, pull spark plug tube out of cylinder head. CAUTION: Take care not to damage cylinder head. Once removed, spark plug tube will be deformed and cannot be reused. Do not remove it unless absolutely necessary.

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1. When valve guide is removed, install it. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-519775-S14167579912012122900000) ".
2. When valve seat is removed, install it. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-519775-S14167579912012122900000) ".
3. Install valve oil seals using Tool. Tool number: - (J-39386) Height "H" (Without valve spring seat installed)
4. Install valve spring seat.
5. Install valves. Install it in the original position. NOTE: Larger diameter valves are for intake side.
6. Install valve spring (uneven pitch type). Install narrow pitch end (paint mark) to cylinder head side (valve spring seat side). Intake and exhaust: 14.3 - 14.9 mm (0.563 - 0.587 in)
7. Install valve spring retainer.
8. Install valve collet. Compress valve spring using Tool, attachment and adapter using Tool. Install valve collet with magnet hand. Tool numbers: KV10109220 (-) : KV10116200 (J-26336-B) : KV10115900 (J-26336-20) CAUTION: When working, take care not to damage valve lifter holes or valve stems. Tap valve stem edge lightly with plastic hammer after installation to check its installed condition.
9. Install valve lifter. Install it in the original position.
10. Install spark plug tube. Press-fit spark plug tube as follows: Remove old liquid gasket adhering to cylinder head mounting hole. Apply sealant to area within approximately 12 mm (0.47 in) from edge of spark plug tube press-fit side. Use Genuine High Strength Locking Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-519769-S26436216272012122900000) ". Press-fit spark plug tube so that its height "H" is as specified using suitable drift. Standard press-fit height "H" : 38.1 - 39.1 mm (1.500 - 1.539 in) CAUTION: When press-fitting, take care not to deform spark plug tube. After press-fitting, wipe off liquid gasket protruding onto cylinder-head upper face.
11. Install spark plug.

Note. The following procedures explain how to disassemble the engine with the engine stand fastened to the bell housing. Some steps may be different if using a different type of engine stand.

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1. Remove engine assembly from vehicle. Refer to " «REMOVAL AND INSTALLATION»(ref-519775-S09530632242012122900000) ".
2. Remove the parts that may restrict installation of engine to engine stand. Remove drive plate. Refer to " «DOWEL PIN ALIGNMENT»(ref-519775-S29115206972012122900000) ". Remove fuel tube and fuel injector assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-519775-S26748525772012122900000) ". Remove intake manifold. Refer to " «REMOVAL AND INSTALLATION»(ref-519775-S30366359512012122900000) ". Remove rocker cover. Refer to " «REMOVAL AND INSTALLATION»(ref-519775-S20224943652012122900000) ". Other removable brackets. Remove both exhaust manifolds. Refer to " «REMOVAL AND INSTALLATION (EXHAUST MANIFOLD)»(ref-519775-S00208265502012122900000) ".
3. Lift engine, and mount to engine stand. CAUTION: Before removing the hanging chains, make sure engine stand is stable and there is no risk of overturning. Any widely used commercially available engine stand can be used.
4. Drain engine coolant by removing the cylinder block drain plugs (A), (B), (C) and (D) from cylinder block as shown. NOTE: For Canada, (D) is a block heater not a plug.
5. Remove cylinder head. Refer to " «REMOVAL AND INSTALLATION»(ref-519775-S41838232972012122900000) ".
6. Remove sub harness, and remove knock sensors. CAUTION: Handle sensor carefully; do not shock or drop.
7. Remove pilot converter using Tool as necessary. Tool number: ST16610001 (J-23907)
8. Remove piston and connecting rod assembly as follows: Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-519775-S00686409902012122900000) ". CAUTION: Be careful not to drop connecting rod bearing or scratch the surface.
9. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
10. Remove connecting rod bearing cap.
11. Push piston and connecting rod assembly out of the cylinder head side using suitable tool. CAUTION: Be careful not to damage the cylinder wall or crankshaft pin resulting from an interference of the connecting rod big end.
12. Remove connecting rod bearings from connecting rod and connecting rod bearing cap. CAUTION: Identify installation position, and store them without mixing them up.
13. Remove piston rings from piston. Before removing piston rings, check the piston ring side clearance. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-519775-S00686409902012122900000) ". Remove piston rings using piston ring expander or suitable tool. CAUTION: When removing piston rings, be careful not to damage piston. Be careful not to damage piston rings by expanding them excessively.
14. Remove piston from connecting rod as follows: Remove snap ring using snap ring pliers. Heat piston to 60° to 70°C (140° to 158°F) with industrial use drier or equivalent. Push out piston pin with drift which has an outer diameter of approximately 20 mm (0.79 in).
15. Remove lower cylinder block bolts. Before loosening lower cylinder block bolts, measure the crankshaft end play. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-519775-S00686409902012122900000) ". Loosen lower cylinder block bolts in reverse order as shown in several different steps. NOTE: Use TORX socket (size E14) for bolts No. 1 to 16 (M10 bolt).
16. Remove lower cylinder block. Cut liquid gasket for removal. Refer to " «PRECAUTION FOR LIQUID GASKET»(ref-519775-S37591060012012122900000) ". Tool number: KV10111100 (J-37228) CAUTION: Be careful not to damage the mounting surfaces.
17. Remove crankshaft.
18. Pull rear oil seal out from rear end of crankshaft. NOTE: When replacing rear oil seal without removing lower cylinder block, use a suitable tool to pull the rear oil seal installed between crankshaft and cylinder block out. CAUTION: Be careful not to damage crankshaft or cylinder block.
19. Remove main bearings and thrust bearings from cylinder block and lower cylinder block. CAUTION: Do not drop main bearing, or scratch the surface. Identify installation positions, and store them without mixing them up.
20. Remove oil jet.

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1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to remove any foreign material. WARNING: Use goggles to protect your eyes.
2. Install each plug to cylinder block as shown. Apply sealant to the thread of water drain plugs (A) and (B). Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-519769-S26436216272012122900000) ". Apply sealant to the thread of plug (C). Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-519769-S26436216272012122900000) ". Apply sealant to the threads of plug (D). Use Anaerobic Liquid Gasket or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-519769-S26436216272012122900000) ". NOTE: For Canada, (D) is not plug but block heater. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-519775-S38215718692012122900000) ". Replace washers with new washers. Tighten each plug as specified below. BLOCK PLUG AND BLOCK HEATER INSTALLATION SPECIFICATIONS Part Washer Tightening Torque A No 19.6 N.m (2.0 kg-m, 14 ft-lb) B Reuse No 9.8 N.m (1.0 kg-m, 87 in-lb) New 6.0 N.m (0.61 kg-m, 53 in-lb) C Yes 116 N.m (11.8 kg-m, 85 ft-lb) D Plug Yes 62 N.m (6.3 kg-m, 46 ft-lb) Block heater 73.5 N.m (7.5 kg-m, 54 ft-lb)
3. Install oil jet. Insert oil jet dowel pin into cylinder block dowel pin hole, and tighten bolts to specification. Oil jet bolts: 27.0 N.m (2.8 kg-m, 20 ft-lb)
4. Install main bearings and thrust bearings as follows: Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and main bearing caps. Install thrust bearings to the both sides of the No. 3 journal housing on cylinder block. Install thrust bearings with the oil groove facing crankshaft arm (outside). Install thrust bearing with a projection on one end on cylinder block, Align projection with mating notch. Install main bearings paying attention to the direction. Main bearing with oil hole and groove goes on cylinder block. The one without them goes on lower cylinder block. Before installing main bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it. When installing, align main bearing stopper protrusion to cutout of cylinder block and lower cylinder block. Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.
5. Install crankshaft to cylinder block. While turning crankshaft by hand, check that it turns smoothly.
6. Inspect the outer diameter of lower cylinder block bolt. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-519775-S00686409902012122900000) ".
7. Install lower cylinder block as follows: NOTE: Lower cylinder block cannot be replaced as a single part, because it is machined together with cylinder block. Apply a continuous bead of liquid gasket using Tool to lower cylinder block as shown. Tool number: WS39930000 (-) Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-519769-S26436216272012122900000) ". CAUTION: After liquid gasket is applied, rear oil seal installation must be finished within 5 minutes. Therefore, the following procedure must be performed quickly. Tighten lower cylinder block as follows: Apply new engine oil to threads and seat surfaces of the bolts. Tighten M8 bolts in numerical order as shown from No. 17 to 24. Bolts 17 - 24: 22.1 N.m (2.3 kg-m, 16 ft-lb) CAUTION: Wipe off completely any protruding liquid gasket on rear oil seal installation surface. NOTE: There are more processes to complete the tightening bolts. However stop procedure here to install rear oil seal. Install rear oil seal. Refer to " «REMOVAL AND INSTALLATION OF REAR OIL SEAL»(ref-519775-S37330914512012122900000) ". Restart tightening of lower cylinder block bolts as follows: Tighten M10 bolts in numerical order as shown from No. 1 to 16. NOTE: Use TORX socket (size E14) for bolts No. 1 to 16 (M10 bolt). Bolts 1 - 16: 35.3 N.m (3.6 kg-m, 26 ft-lb) Turn M10 bolts 90° clockwise in numerical order from No. 1 to 16 using Tool. Tool number: KV10112100 (BT-8653-A) CAUTION: Use angle wrench Tool to check tightening angle. Do not make judgement by visual inspection. After installing the bolts, make sure that crankshaft can be rotated smoothly by hand. Wipe off completely any protruding liquid gasket on front side of the engine. Check the crankshaft end play. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-519775-S00686409902012122900000) ".
8. Inspect the outer diameter of connecting rod bolt. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-519775-S00686409902012122900000) ".
9. Install piston to connecting rod as follows: Install new snap ring to the groove of piston rear side using suitable tool. Insert it fully into groove to install. Install piston to connecting rod. Using industrial use drier or similar tool, heat piston until piston pin can be pushed in by hand without excess force [approx. 60° to 70°C (140° to 158°F)]. From the front to the rear, insert piston pin into piston and connecting rod. Assemble so that the front mark on the piston head and the cylinder number on connecting rod are positioned as shown. Install new snap ring to the groove of the piston front side. Insert it fully into groove to install. After installing, make sure that connecting rod moves smoothly.
10. Install piston rings using piston ring expander or suitable tool. CAUTION: When installing piston rings, be careful not to damage piston. Be careful not to damage piston rings by expending them excessively. If there is stamped mark on ring, mount it with marked side up. NOTE: If there is no stamp on ring, no specific orientation is required for installation. Stamped mark: Top ring: - Second ring: R Position each ring with the gap as shown referring to the piston front mark. Check the piston ring side clearance. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-519775-S00686409902012122900000) ".
11. Install connecting rod bearings to connecting rod and connecting rod bearing cap. Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it. When installing, align connecting rod bearing stopper protrusion with cutout of connecting rods and connecting rod bearing caps to install. Ensure the oil hole on connecting rod and that on the corresponding bearing are aligned.
12. Install piston and connecting rod assembly to crankshaft.
13. Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
14. Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal.
15. Match the cylinder position with the cylinder number on connecting rod to install. NOTE: Be sure that front mark on piston head is facing front of engine.
16. Install piston with the front mark on the piston head facing the front of engine using Tool. Tool number: EM03470000 (J-8037) CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
17. Install connecting rod bearing cap. Match the stamped cylinder number marks on connecting rod with those on connecting rod bearing cap to install. Be sure that front mark on connecting rod bearing cap is facing front of engine.
18. Tighten connecting rod bolts as follows: Apply engine oil to the threads and seats of connecting rod bolts. Tighten connecting rod bolts. Connecting rod bolt: 19.6 N.m (2.0 kg-m, 14 ft-lb) Then tighten all connecting rod bolts 90° clockwise. CAUTION: Always use Tool. Avoid tightening based on visual check alone. Tool number: KV10112100 (BT-8653-A) After tightening connecting rod bolts, make sure that crankshaft rotates smoothly. Check the connecting rod side clearance. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-519775-S00686409902012122900000) ".
19. Install pilot converter. With drift of the following outer diameter, press-fit as far as it will go. Pilot converter: Approx. 33 mm (1.30 in) Press-fit pilot converter with its chamfer facing crankshaft as shown.
20. Install knock sensors. CAUTION: Do not tighten bolts while holding connector. If knock sensor is dropped, replace it with new one. NOTE: Make sure that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor. Make sure that knock sensor does not interfere with other parts. Install knock sensor so that connector faces rear of engine. After installing knock sensor, connect harness connector, and lay it out to rear of engine. Knock sensor bolts: 18.1 N.m (1.8 kg-m, 13 ft-lb)
21. Assembly is in the reverse order of disassembly after this step.

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1. Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with dial indicator. Standard: 0.10 - 0.25 mm (0.0039 - 0.0098 in) Limit: 0.30 mm (0.0118 in)
2. If the measured value exceeds the limit, replace thrust bearings, and measure again. If it still exceeds the limit, replace crankshaft also.

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1. Measure the side clearance between connecting rod and crankshaft arm with feeler gauge. Standard: 0.20 - 0.35 mm (0.0079 - 0.0138 in) Limit: 0.40 mm (0.0157 in)
2. If the measured value exceeds the limit, replace connecting rod, and measure again. If it still exceeds the limit, replace crankshaft also.