Engine Mechanical: Overhaul Nissan Quest IV

Disassembly

1. Remove drive belt. Refer to " «REMOVAL AND INSTALLATION»(ref-672620-S17250281432014112400000) "
2. Remove intake manifold collector. Refer to " «EXPLODED VIEW»(ref-672620-S20207820862014112400000) ".
3. Remove intake manifold. Refer to " «EXPLODED VIEW»(ref-672620-S06144586132014112400000) ".
4. Remove compressor. Refer to " «COMPRESSOR: REMOVAL AND INSTALLATION»(ref-672613-S13536270442014112400000) ".
5. Remove alternator. " «REMOVAL AND INSTALLATION»(ref-672637-S06617790012014112400000) ".
6. Remove exhaust manifold. Refer to " «EXPLODED VIEW»(ref-672620-S26863074632014112400000) ".
7. Remove oil pan (lower and upper). Refer to " «EXPLODED VIEW»(ref-672620-S21429898042014112400000) ".
8. Remove ignition coil, spark plug and rocker cover. Refer to " «EXPLODED VIEW»(ref-672620-S14189085292014112400000) ".
9. Remove fuel injector and fuel tube. Refer to " «EXPLODED VIEW»(ref-672620-S01496591682014112400000) ".
10. Remove timing chain and rear timing chain case. Refer to " «REMOVAL AND INSTALLATION»(ref-672620-S32563752882014112400000) ".
11. Remove camshaft. Refer to " «EXPLODED VIEW»(ref-672620-S27549891992014112400000) ".
12. Remove cylinder head. Refer to " «EXPLODED VIEW»(ref-672620-S02052188792014112400000) ".

Assembly

Assembly in the reverse order of disassembly.

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1. Remove the following parts: Remove intake manifold collector. Refer to " «REMOVAL AND INSTALLATION»(ref-672620-S14030500572014112400000) ". Remove rocker covers (bank 1 and bank 2). Refer to " «EXPLODED VIEW»(ref-672620-S14189085292014112400000) ". Remove oil pans (lower and upper) and oil strainer. Refer to " «EXPLODED VIEW»(ref-672620-S21429898042014112400000) ". Remove drive belt and auto tensioner. Refer to " «REMOVAL AND INSTALLATION»(ref-672620-S02403723332014112400000) " and " «EXPLODED VIEW»(ref-672620-S20914499362014112400000) ".
2. Separate engine harness removing their brackets from front timing chain case.
3. Remove camshaft sprocket covers. Loosen mounting bolts in the reverse order as shown in the figure below. CAUTION: Shaft is internally jointed with camshaft sprocket (INT) center hole. When removing, keep it horizontal until it is completely disconnected.
4. Obtain No. 1 cylinder at TDC of its compression stroke as follows: Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) (<==) with timing indicator. Check that intake and exhaust cam noses on No. 1 cylinder (engine front side of bank 1) are located as shown in the figure below. If not, turn crankshaft one revolution (360 degrees) and align as shown in the figure below.
5. Remove crankshaft pulley as follows: Fix crankshaft with the pulley holder (commercial service tool) (A). Loosen crankshaft pulley bolt and locate bolt seating surface at 10 mm (0.39 in) from its original position. CAUTION: Never remove crankshaft pulley bolt as it will be used as a supporting point for suitable puller. Place suitable puller tab on holes of crankshaft pulley, and pull crankshaft pulley through. CAUTION: Never put suitable puller tab on crankshaft pulley periphery, as this will damage internal damper.
6. Remove front timing chain case as follows: Loosen mounting bolts in the reverse order as shown in the figure below. Insert a suitable tool (A) into the notch at the top of front timing chain case as shown in the figure below. Pry off case by moving the tool as shown below. Use the seal cutter [SST: KV10111100 (J-37228)] to cut liquid gasket for removal. CAUTION: Never use screwdrivers or something similar. After removal, handle front timing chain case carefully so it does not tilt, cant, or warp under a load.
7. Remove water pump cover from front timing chain case. Use the seal cutter [SST: KV10111100 (J-37228)] to cut liquid gasket for removal.
8. Remove front oil seal from front timing chain case using a suitable tool. Use a screwdriver for removal. CAUTION: Be careful not to damage front timing chain case.
9. Remove O-ring (1) from rear timing chain case.
10. Remove timing chain tensioner (primary) as follows: Remove lower mounting bolt (A). Loosen upper mounting bolt (B) slowly, and then turn timing chain tensioner (primary) (1) on the mounting bolt so that plunger (C) is fully expanded. NOTE: Even if plunger is fully expanded, it is not dropped from the body of timing chain tensioner (primary). Remove upper mounting bolt, and then remove timing chain tensioner (primary).
11. Remove internal chain guide, tension guide and slack guide. NOTE: Tension guide can be removed after removing timing chain (primary). CAUTION: After removing timing chain (primary), never turn crankshaft and camshaft separately, or valves will strike the piston heads.
12. Remove timing chain (primary) and crankshaft sprocket.
13. Remove timing chain (secondary) and camshaft sprockets as follows: Attach a suitable stopper pin (B) to the bank 1 (A) and bank 2 (C) timing chain tensioners (secondary) (1). NOTE: Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a stopper pin. For removal of timing chain tensioner (secondary), refer to " «EXPLODED VIEW»(ref-672620-S27549891992014112400000) ". [Removing camshaft bracket (No. 1) is required.] Remove camshaft sprockets (INT and EXH) mounting bolts. Secure the hexagonal portion of camshaft using a wrench to loosen mounting bolts. CAUTION: Never loosen mounting bolts with securing anything other than the camshaft hexagonal portion or with tensioning the timing chain. Remove timing chain (secondary) together with camshaft sprockets. Turn camshaft slightly to secure slackness of timing chain on timing chain tensioner (secondary) side. Insert 0.5 mm (0.020 in) thick metal or resin plate between timing chain and timing chain tensioner plunger (guide) (E). Remove timing chain (secondary) (2) together with camshaft sprockets with timing chain loose from guide groove. CAUTION: Be careful of plunger coming-off when removing timing chain (secondary). This is because plunger of timing chain tensioner (secondary) moves during operation, leading to coming-off of fixed stopper pin. NOTE: Camshaft sprocket (INT) is two-for-one structure of sprockets for timing chain (primary) and for timing chain (secondary). Figure is shown as an example of bank 1. When handling camshaft sprocket (INT), be careful of the following caution: CAUTION: Handle carefully to avoid any shock to camshaft sprocket. Never disassemble. [Never loosen bolts (A) as shown in the figure below].
14. Remove water pump. Refer to " «REMOVAL AND INSTALLATION»(ref-672622-S36362390632014112400000) ".
15. Remove oil pump. Refer to " «REMOVAL AND INSTALLATION»(ref-672629-S31989881232014112400000) ".
16. Remove rear timing chain case as follows: Loosen and remove mounting bolts in the reverse order as shown in the figure below. Cut liquid gasket using the seal cutter [SST: KV10111100 (J-37228)] and remove rear timing chain case. CAUTION: Never remove plate metal cover (1) of oil passage. After removal, handle rear timing chain case carefully so it does not tilt, cant, or warp under a load.
17. Remove oil temperature sensor from timing chain case (rear) if necessary.
18. Remove O-rings (1) from cylinder block.
19. Remove timing chain tensioners (secondary) from cylinder head as follows, if necessary. Remove camshaft brackets (No. 1). Refer to " «EXPLODED VIEW»(ref-672620-S27549891992014112400000) ". Remove timing chain tensioners (secondary) (1) with a stopper pin (B) attached.
20. Use a scraper to remove all traces of old liquid gasket from front timing chain case, and opposite mating surfaces. Remove old liquid gasket from bolt hole (B) and thread.
21. Use a scraper to remove all traces of old liquid gasket from water pump cover.

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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. CAUTION: Use a goggles to protect your eye.
2. Install each plug to cylinder block as shown in the figure below. CAUTION: Do not reuse washers. Apply sealant to the thread of water drain plug (A). Use Anaerobic Liquid Gasket or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-672611-S40047121162014112400000) ". NOTE: For Canada, water drain plug (A) in the figure is not water drain plug but block heater. Refer to " «EXPLODED VIEW»(ref-672620-S26513912932014112400000) ". Apply sealant to the thread of connector bolt (D). Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-672611-S40047121162014112400000) ". 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-672611-S40047121162014112400000) ". Replace washers with new one. Tighten each plug and connector bolt as specified below. Part Washer Tightening torque A Yes 62.0 N.m (6.3 kg-m, 46 ft-lb) B No 9.8 N.m (1.0 kg-m, 87 in-lb) C Yes 62.0 N.m (6.3 kg-m, 46 ft-lb) D No 39.2 N.m (4.0 kg-m, 29 ft-lb)
3. Install oil jet. Insert oil jet dowel pin (A) into cylinder block dowel pin hole, and tighten mounting bolts.
4. Install main bearings and thrust bearings as follows: CAUTION: Be careful not to drop main bearing, and to scratch the surface. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and main bearing caps. Install thrust bearings (1) to the both sides of the No. 3 journal housing on cylinder block and main bearing cap. Install thrust bearings with the oil groove (E) facing crankshaft arm (outside). Install thrust bearing with a projection on one end on cylinder block, and thrust bearing with a projection at center on main bearing cap. Align each projection with mating notch. Install main bearings paying attention to the direction. Main bearing with oil hole (B) and groove (C) goes on cylinder block. The one without them goes on main bearing cap. 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 main bearing caps. 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. Install main bearing caps. Main bearing caps are identified by identification mark cast on them. For installation, face front mark (E) to front side. NOTE: Main bearing cap cannot be replaced as a single part, because it is machined together with cylinder block.
7. Install main bearing beam. Install main bearing beam with front mark facing downward (oil pan side). Install main bearing beam with front mark facing front of the engine.
8. Install main bearing cap bolts in numerical order as shown in the figure below as follows: Inspect the outer diameter of main bearing cap bolt. Refer to " «INSPECTION»(ref-672620-S01955854212014112400000) ". Apply new engine oil to threads and seat surfaces of main bearing cap bolts. Tighten main bearing cap bolts in several different steps. Torque: 35.3 N.m (3.6 kg-m, 26 ft-lb) Turn all main bearing cap bolts 90 degrees clockwise (angle tightening). CAUTION: Use the angle wrench [SST: KV10112100 (BT8653-A)] to check tightening angle. Never make judgment by visual inspection. After installing main bearing cap bolts, check that crankshaft can be rotated smoothly by hand. Check the crankshaft end play. Refer to " «INSPECTION»(ref-672620-S01955854212014112400000) ".
9. Install piston to connecting rod as follows: Using snap ring pliers, install new snap ring to the groove of piston rear side. Insert it fully into groove to install. Install piston to connecting rod. Using an industrial drier or similar tool, heat piston until piston pin can be pushed in by hand without excess force [approximately 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 crown and the cylinder number on connecting rod are positioned as shown in the figure below. Install new snap ring to the groove of the piston front side. Insert it fully into groove to install. After installing, check that connecting rod moves smoothly.
10. Using a piston ring expander (commercial service tool) (A), install piston rings. 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 (A): - Second ring (B): 2 R Position each ring with the gap as shown in the figure below referring to the piston front mark (D). Check the piston rings side clearance. Refer to " «INSPECTION»(ref-672620-S01955854212014112400000) ".
11. Install connecting rod bearings to connecting rod and connecting rod bearing cap. CAUTION: Be careful not to drop connecting rod bearing, and to scratch the surface. 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 (B) with cutout (C) of connecting rod and connecting rod bearing cap to install. Ensure the oil hole (A) on connecting rod and that on the corresponding bearing are aligned.
12. Install piston and connecting rod assembly to crankshaft. Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center. Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal. Match the cylinder position with the cylinder number on connecting rod to install. Be sure that front mark on piston crown is facing front of engine. Using a piston ring compressor [SST: EM03470000 (J-8037)] (A) or suitable tool, install piston with the front mark on the piston crown facing the front of the engine. CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
13. 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 (H) on connecting rod bearing cap is facing front of the engine.
14. Tighten connecting rod bolt as follows: Inspect the outer diameter of connecting rod bolt. Refer to " «INSPECTION»(ref-672620-S01955854212014112400000) ". Apply engine oil to the threads and seats of connecting rod bolts. Tighten connecting rod bolts. Torque: 19.6 N.m (2.0 kg-m, 14 ft-lb) Then tighten all connecting rod bolts 90 degrees clockwise (angle tightening). CAUTION: Always use the angle wrench [SST: KV10112100 (BT8653-A)]. Avoid tightening based on visual check alone. After tightening connecting rod bolts, check that crankshaft rotates smoothly. Check the connecting rod side clearance. Refer to " «INSPECTION»(ref-672620-S01955854212014112400000) ".
15. Install baffle plate to main bearing beam.
16. Install new rear oil seal retainer to cylinder block. Refer to " «REAR OIL SEAL: REMOVAL AND INSTALLATION»(ref-672620-S03257760802014112400000) ".
17. Install pilot converter. With drift [outer diameter: approximately 33 mm (1.30 in)], press-fit as far as it will go. Press-fit pilot converter with its chamfer facing crankshaft as shown in the figure below.
18. Install knock sensors. Install knock sensor so that connector faces the rear of the engine. After installing knock sensor, connect harness connector, and lay it out to rear of engine. CAUTION: Never tighten mounting bolts while holding connector. If any impact by dropping is applied to knock sensor, replace it with new one. NOTE: Check that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor. Check that knock sensor does not interfere with other parts.
19. Note the following, assemble in the reverse order of disassembly after this step. Drive plate When installing drive plate to crankshaft, be sure to correctly align crankshaft side dowel pin and drive plate side dowel pin hole. If these are not aligned correctly, engine runs roughly and "MIL" turns on. Install drive plate (2) and reinforcement plate (3) as shown in the figure below. Holding ring gear with the pulley holder (commercial service tool). Tighten mounting bolts crosswise over several times.

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1. Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with a dial indicator. Standard and limit: Refer to " «CYLINDER BLOCK»(ref-672620-S24296865982014112400000) ".
2. If the measured value exceeds the limit, replace thrust bearings, and measure again. If it still exceeds the limit, replace crankshaft also.

Scheme 201

1. Measure the side clearance between connecting rod and crankshaft arm with a feeler gauge (A). Standard and limit: Refer to " «CYLINDER BLOCK»(ref-672620-S24296865982014112400000) ".
2. If the measured value exceeds the limit, replace connecting rod, and measure again. If it still exceeds the limit, replace crankshaft also.