Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Maxima 2000-2005 Approved Nissan Maxima 2004 EM
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B ENGINE
A
EM
SECTION
ENGINE MECHANICAL C
D
E
CONTENTS
PRECAUTIONS ......................................................... 3 . EGR VOLUME CONTROL VALVE .......................... 21 . F
Precautions for Supplemental Restraint System Removal and Installation ....................................... 21 .
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- REMOVAL .......................................................... 22 .
SIONER" ................................................................. 3
. INSTALLATION .................................................. 22 . G
Precautions for Drain Coolant ................................. 3 . INTAKE MANIFOLD ................................................ 24 .
Precautions for Disconnecting Fuel Piping ............. 3 . Removal and Installation ....................................... 24 .
Precautions for Removal and Disassembly ............ 3 . REMOVAL .......................................................... 24 .
H
Precautions for Inspection, Repair and Replace- INSPECTION AFTER REMOVAL ...................... 25 .
ment ........................................................................ 3
. INSTALLATION .................................................. 25 .
Precautions for Assembly and Installation .............. 3 . EXHAUST MANIFOLD AND THREE WAY CATA-
Parts Requiring Angular Tightening ........................ 4 . LYST ......................................................................... 26
. I
Precautions for Liquid Gasket ................................. 4 . Removal and Installation ....................................... 26 .
REMOVAL OF LIQUID GASKET SEALING ......... 4 . REMOVAL .......................................................... 27 .
LIQUID GASKET APPLICATION PROCEDURE 4 ..... INSPECTION AFTER REMOVAL ...................... 28 . J
PREPARATION .......................................................... 6 . INSTALLATION .................................................. 28 .
Special Service Tools .............................................. 6 . OIL PAN AND OIL STRAINER ................................ 30 .
Commercial Service Tools ....................................... 8 . Removal and Installation ....................................... 30 .
K
NOISE, VIBRATION, AND HARSHNESS (NVH) REMOVAL .......................................................... 30 .
TROUBLESHOOTING ............................................. 10 . INSPECTION AFTER REMOVAL ...................... 33 .
NVH Troubleshooting -- Engine Noise ................. 10 . INSTALLATION .................................................. 33 .
Use the Chart Below to Help You Find the Cause INSPECTION AFTER INSTALLATION ............... 35 . L
of the Symptom. .....................................................11 . IGNITION COIL ........................................................ 36 .
DRIVE BELTS .......................................................... 12 . Removal and Installation ....................................... 36 .
Checking Drive Belts ............................................. 12 . REMOVAL .......................................................... 36 . M
Tension Adjustment ............................................... 12 . INSTALLATION .................................................. 36 .
GENERATOR AND AIR CONDITIONER COM- SPARK PLUG (PLATINUM-TIPPED TYPE) ............ 37 .
PRESSOR BELT ................................................ 13 . Removal and Installation ....................................... 37 .
POWER STEERING OIL PUMP BELT .............. 14 . REMOVAL .......................................................... 37 .
Removal and Installation ....................................... 14 . INSPECTION AFTER REMOVAL ...................... 37 .
REMOVAL .......................................................... 14 . INSTALLATION .................................................. 38 .
INSTALLATION .................................................. 14 . FUEL INJECTOR AND FUEL TUBE ....................... 39 .
AIR CLEANER AND AIR DUCT .............................. 15 . Removal and Installation ....................................... 39 .
Removal and Installation ....................................... 15 . REMOVAL .......................................................... 39 .
REMOVAL .......................................................... 15 . INSTALLATION .................................................. 40 .
INSTALLATION .................................................. 16 . INSPECTION AFTER INSTALLATION ............... 40 .
CHANGING AIR CLEANER FILTER .................. 16 . ROCKER COVER .................................................... 42 .
INTAKE MANIFOLD COLLECTOR ......................... 17 . Removal and Installation ....................................... 42 .
Removal and Installation ....................................... 17 . REMOVAL .......................................................... 42 .
REMOVAL .......................................................... 18 . INSTALLATION .................................................. 43 .
INSTALLATION .................................................. 19 .
EM-1
FRONT TIMING CHAIN CASE ................................ 45 . HOW TO SELECT A PISTON .......................... 133 .
Removal and Installation ....................................... 45 . HOW TO SELECT CONNECTING ROD BEAR-
REMOVAL .......................................................... 46
. INGS ................................................................. 134
.
INSTALLATION ................................................... 52. HOW TO SELECT MAIN BEARINGS ............... 135 .
TIMING CHAIN ......................................................... 56
. Inspection After Disassembly ............................... 138 .
Removal and Installation ....................................... 56 . CRANKSHAFT END PLAY ............................... 138 .
REMOVAL .......................................................... 57
. CONNECTING ROD SIDE CLEARANCE ........ 138 .
INSPECTION AFTER REMOVAL ....................... 66 . PISTON AND PISTON PIN CLEARANCE ........ 138 .
INSTALLATION ................................................... 67. PISTON RING SIDE CLEARANCE .................. 139 .
CAMSHAFT .............................................................. 80
. PISTON RING END GAP ................................. 139 .
Removal and Installation ....................................... 80 . CONNECTING ROD BEND AND TORSION .... 140 .
REMOVAL .......................................................... 81
. CONNECTING ROD BEARING HOUSING
INSTALLATION ................................................... 82. DIAMETER (BIG END) ..................................... 140 .
INSPECTION AFTER REMOVAL ....................... 86 . CONNECTING ROD BUSHING OIL CLEAR-
Valve Clearance ..................................................... 89
. ANCE (SMALL END) ........................................ 140 .
CHECKING ......................................................... 89
. CYLINDER BLOCK DISTORTION ................... 141 .
VALVE ADJUSTING ........................................... 92 . INNER DIAMETER OF MAIN BEARING HOUS-
OIL SEAL ................................................................. 93
. ING .................................................................... 142
.
Removal and Installation of Valve Oil Seal ............ 93 . PISTON-TO-CYLINDER BORE CLEARANCE . 142
REMOVAL .......................................................... 93
. OUTER DIAMETER OF CRANKSHAFT JOUR-
INSTALLATION ................................................... 93. NAL ................................................................... 144
.
Removal and Installation of Front Oil Seal ............ 93 . OUTER DIAMETER OF CRANKSHAFT PIN ... 144 .
REMOVAL .......................................................... 93
. OUT-OF-ROUND AND TAPER OF CRANK-
INSTALLATION ................................................... 95. SHAFT .............................................................. 144
.
Removal and Installation of Rear Oil Seal ............. 97 . CRANKSHAFT RUNOUT ................................. 144 .
REMOVAL .......................................................... 97
. OIL CLEARANCE OF CONNECTING ROD
INSTALLATION ................................................... 97. BEARING .......................................................... 144 .
CYLINDER HEAD .................................................... 99 . OIL CLEARANCE OF MAIN BEARING ............ 145 .
On-Vehicle Service ................................................ 99
. CRUSH HEIGHT OF MAIN BEARING ............. 146 .
CHECKING COMPRESSION PRESSURE ........ 99 . CRUSH HEIGHT OF CONNECTING ROD
Removal and Installation ..................................... 100 . BEARING .......................................................... 146 .
REMOVAL ........................................................ 100
. OUTER DIAMETER OF MAIN BEARING CAP
INSPECTION AFTER REMOVAL ..................... 102 . BOLTS .............................................................. 146
.
INSTALLATION ................................................. 102 . OUTER DIAMETER OF CONNECTING ROD
Disassembly and Assembly ................................. 109 . BOLTS .............................................................. 147
.
DISASSEMBLY ................................................ 110 . DRIVE PLATE RUNOUT (A/T) ......................... 147 .
Inspection After Disassembly ...............................111 . FLYWHEEL RUNOUT (M/T) ............................. 147 .
CYLINDER HEAD DISTORTION ......................111 . OIL JET ............................................................. 148
.
VALVE DIMENSIONS ........................................111 . OIL JET RELIEF VALVE ................................... 148 .
VALVE GUIDE CLEARANCE ............................111 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 149 .
VALVE GUIDE REPLACEMENT ...................... 112 . Standard and Limit ............................................... 149 .
VALVE SEAT CONTACT .................................. 113 . GENERAL SPECIFICATIONS .......................... 149 .
VALVE SEAT REPLACEMENT ........................ 113 . DRIVE BELT ..................................................... 150 .
VALVE SPRING SQUARENESS ...................... 114 . INTAKE MANIFOLD COLLECTOR, INTAKE
VALVE SPRING DIMENSIONS AND VALVE MANIFOLD AND EXHAUST MANIFOLD ......... 150 .
SPRING PRESSURE LOAD ............................ 114 . SPARK PLUG ................................................... 150 .
ASSEMBLY ...................................................... 114. CYLINDER HEAD ............................................. 151 .
ENGINE ASSEMBLY ............................................. 116 . VALVE ............................................................... 151
.
Removal and Installation ..................................... 116 . CAMSHAFT AND CAMSHAFT BEARING ........ 155 .
REMOVAL ........................................................ 116
. CYLINDER BLOCK ........................................... 155 .
INSTALLATION ................................................. 119 . PISTON, PISTON RING AND PISTON PIN ..... 156 .
INSPECTION AFTER INSTALLATION ............. 120 . CONNECTING ROD ......................................... 157 .
CYLINDER BLOCK ................................................ 121 . CRANKSHAFT .................................................. 158 .
Disassembly and Assembly ................................. 121 . AVAILABLE MAIN BEARING ............................ 159 .
DISASSEMBLY ................................................ 122 . CONNECTING ROD BEARING ........................ 159 .
ASSEMBLY ...................................................... 126. MISCELLANEOUS COMPONENTS ................. 160 .
How to Select Piston and Bearing ....................... 133 . BEARING CLEARANCE ................................... 160 .
DESCRIPTION ................................................. 133 .
EM-2
PRECAUTIONS
PRECAUTIONS PFP:00001
A
Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT
BELT PRE-TENSIONER" EBS00G4E
The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along EM
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual. C
WARNING:
q To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer. D
q Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section. E
q Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors. F
Precautions for Drain Coolant EBS00F2I
q Drain coolant when engine is cooled. G
Precautions for Disconnecting Fuel Piping EBS00F2J
q Before starting work, make sure no fire or spark producing items are in the work area.
H
q Release fuel pressure before disassembly.
q After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly EBS00F2K
I
q When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
J
q Exercise maximum care to avoid damage to mating or sliding surfaces.
q Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
q Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly. K
q 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.
L
Precautions for Inspection, Repair and Replacement EBS00F2L
q Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way,
and replace if necessary. M
Precautions for Assembly and Installation EBS00F2M
q Use torque wrench to tighten bolts or nuts to specification.
q 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.
q Replace with new gasket, packing, oil seal or O-ring.
q Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
q Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
q Release air within route after draining coolant.
q Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine
stopped). Then make sure that there are no leaks at fuel line connections.
EM-3
PRECAUTIONS
q After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems
for leakage.
Parts Requiring Angular Tightening EBS00F2N
q Use an angle wrench for the final tightening of the following engine parts:
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