Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Xterra 2000-2004 Approved Nissan Xterra 2004 EM
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B ENGINE
A
EM
SECTION
ENGINE MECHANICAL C
D
E
CONTENTS
KA24DE CYLINDER HEAD .................................................... 30 . F
On-Vehicle Service ................................................ 30 .
PRECAUTIONS ......................................................... 4 . CHECKING COMPRESSION PRESSURE ........ 30 .
Precautions for Supplemental Restraint System Components .......................................................... 31
. G
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Removal ................................................................ 31
.
SIONER" ................................................................. 4
. Disassembly .......................................................... 32
.
Parts Requiring Angular Tightening ........................ 4 . Inspection .............................................................. 32
.
Precautions for Liquid Gasket ................................. 4 . H
CYLINDER HEAD DISTORTION ....................... 32 .
REMOVAL OF LIQUID GASKET SEALING ......... 4 . CAMSHAFT VISUAL CHECK ............................ 33 .
LIQUID GASKET APPLICATION PROCEDURE 4 ..... CAMSHAFT RUNOUT ....................................... 33 .
PREPARATION .......................................................... 6 . CAMSHAFT CAM HEIGHT ................................ 33 . I
Special Service Tools .............................................. 6 . CAMSHAFT JOURNAL CLEARANCE ............... 33 .
Commercial Service Tools ....................................... 8 . CAMSHAFT END PLAY ..................................... 34 .
NOISE, VIBRATION, AND HARSHNESS (NVH) CAMSHAFT SPROCKET RUNOUT ................... 34 . J
TROUBLESHOOTING ..............................................11 . VALVE GUIDE CLEARANCE ............................. 35 .
Noise, Vibration and Harshness (NVH) ..................11 . VALVE GUIDE REPLACEMENT ........................ 35 .
NVH TROUBLESHOOTING CHART -- ENGINE VALVE SEAT INSPECTION ............................... 37 .
NOISE ................................................................ 12
. K
REPLACING VALVE SEAT ................................ 37 .
OUTER COMPONENT PARTS ............................... 13 . VALVE DIMENSIONS ......................................... 38 .
Removal and Installation ....................................... 13 . VALVE SPRING .................................................. 38 .
OIL PAN ................................................................... 16
. VALVE LIFTER AND ADJUSTING SHIM ........... 39 . L
Components .......................................................... 16
. Assembly ............................................................... 40
.
Removal ................................................................ 16
. Installation ............................................................. 40
.
Installation ............................................................. 17
. Valve Clearance .................................................... 41. M
TIMING CHAIN ........................................................ 19 . CHECKING ........................................................ 41 .
Components .......................................................... 19
. ADJUSTING ....................................................... 42 .
LIQUID GASKET APPLICATION ....................... 20 . ENGINE ASSEMBLY ............................................... 44 .
Removal ................................................................ 20
. Removal and Installation ....................................... 44 .
UPPER TIMING CHAIN ..................................... 21 . REMOVAL .......................................................... 45.
IDLER SPROCKET ............................................ 22 . INSTALLATION .................................................. 45 .
LOWER TIMING CHAIN .................................... 22 . CYLINDER BLOCK ................................................. 46 .
Inspection .............................................................. 24
. Components .......................................................... 46
.
Installation ............................................................. 24
. Removal and Installation ....................................... 47 .
LOWER TIMING CHAIN .................................... 24 . Disassembly .......................................................... 47
.
IDLER SPROCKET ............................................ 25 . PISTON AND CRANKSHAFT ............................ 47 .
UPPER TIMING CHAIN ..................................... 25 . Inspection .............................................................. 48
.
OIL SEAL ................................................................. 27
. PISTON AND PISTON PIN CLEARANCE ......... 48 .
Replacement ......................................................... 27
. PISTON RING SIDE CLEARANCE .................... 49 .
VALVE OIL SEAL ............................................... 27 . PISTON RING END GAP ................................... 49 .
FRONT OIL SEAL .............................................. 27 . CONNECTING ROD BEND AND TORSION ..... 49 .
REAR OIL SEAL ................................................ 28 .
EM-1
CYLINDER BLOCK DISTORTION AND WEAR... 50 NOISE .................................................................77
.
PISTON-TO-CYLINDER BORE CLEARANCE ... 50 OUTER COMPONENT PARTS ................................78 .
CRANKSHAFT ................................................... 51 . Removal and Installation ........................................78 .
BEARING CLEARANCE .................................... 53 . OIL PAN ....................................................................85
.
CONNECTING ROD BUSHING CLEARANCE Removal .................................................................85
.
(SMALL END) ..................................................... 56 . Installation ..............................................................86
.
REPLACEMENT OF CONNECTING ROD TIMING BELT ...........................................................88 .
BUSHING (SMALL END) ................................... 56 . Components ...........................................................88.
FLYWHEEL RUNOUT ........................................ 56 . Removal .................................................................88
.
Assembly ............................................................... 56
. Inspection ...............................................................90
.
PISTON .............................................................. 56
. BELT TENSIONER AND TENSIONER SPRING...91
CRANKSHAFT ................................................... 58 . Installation ..............................................................91
.
REPLACING PILOT BUSHING .......................... 60 . Tension Adjustment ................................................92 .
SERVICE DATA AND SPECIFICATIONS (SDS) ..... 61 . AFTER BELT REPLACEMENT ..........................92 .
General Specifications ........................................... 61 . AFTER ENGINE OVERHAUL OR ENGINE
COMPRESSION PRESSURE ............................ 61 . REASSEMBLY (WITH ROCKER COVERS
Cylinder Head ........................................................ 61. REMOVED) .........................................................93 .
Valve ...................................................................... 61
. OIL SEAL .................................................................96
.
VALVE ................................................................. 61
. Replacement ..........................................................96.
VALVE SPRING .................................................. 62 . VALVE OIL SEAL ................................................96 .
VALVE GUIDE .................................................... 62 . CAMSHAFT OIL SEAL .......................................96 .
VALVE LIFTER ................................................... 62 . FRONT OIL SEAL ...............................................97 .
VALVE CLEARANCE ADJUSTMENT ................ 63 . REAR OIL SEAL .................................................98 .
AVAILABLE SHIMS ............................................ 63 . CYLINDER HEAD ....................................................99 .
VALVE SEAT ...................................................... 64 . Measurement of Compression ...............................99 .
Cylinder Block ........................................................ 65
. Components ......................................................... 101.
Camshaft and Camshaft Bearing .......................... 66 . Removal ............................................................... 102
.
Piston, Piston Ring and Piston Pin ........................ 67 . Disassembly ......................................................... 105
.
PISTON .............................................................. 67
. Inspection ............................................................. 106
.
PISTON PIN ....................................................... 67 . CYLINDER HEAD DISTORTION ...................... 106 .
PISTON RING .................................................... 67 . CAMSHAFT VISUAL CHECK ........................... 106 .
Connecting Rod ..................................................... 68 . CAMSHAFT RUNOUT ...................................... 107 .
Crankshaft ............................................................. 68
. CAMSHAFT CAM HEIGHT ............................... 107 .
Bearing Clearance ................................................. 69 . CAMSHAFT JOURNAL CLEARANCE ............. 107 .
Available Main Bearing .......................................... 69 . CAMSHAFT END PLAY .................................... 108 .
STANDARD ........................................................ 69 . CAMSHAFT SPROCKET RUNOUT ................. 108 .
UNDERSIZE (SERVICE) .................................... 69 . VALVE GUIDE CLEARANCE ........................... 108 .
Available Connecting Rod Bearing ........................ 69 . VALVE GUIDE REPLACEMENT ...................... 109 .
STANDARD ........................................................ 69 . VALVE SEATS .................................................. 110 .
UNDERSIZE (SERVICE) .................................... 69 . REPLACING VALVE SEAT FOR SERVICE
Miscellaneous Components ................................... 69 . PARTS .............................................................. 110
.
VALVE DIMENSIONS ....................................... 112 .
VG33E and VG33ER VALVE SPRING ................................................ 112 .
ROCKER SHAFT AND ROCKER ARM ............ 112 .
PRECAUTIONS ........................................................ 70
. HYDRAULIC VALVE LIFTER ............................ 113 .
Precautions for Supplemental Restraint System Assembly ............................................................. 113
.
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Installation ............................................................ 114
.
SIONER" ................................................................ 70
. SUPERCHARGER ................................................. 120 .
Parts Requiring Angular Tightening ....................... 70 . Components ......................................................... 120.
Precautions for Liquid Gasket ............................... 70 . Removal ............................................................... 121
.
REMOVAL OF LIQUID GASKET SEALING ....... 70 . Inspection ............................................................. 122
.
LIQUID GASKET APPLICATION PROCEDURE 70 ... SUPERCHARGER FLANGE ............................ 122 .
PREPARATION ........................................................ 72
. ROTOR SYSTEM ............................................. 122 .
Special Service Tools ............................................ 72. SUPERCHARGER BYPASS VALVE ACTUA-
Commercial Service Tools ..................................... 74 . TOR .................................................................. 122
.
NOISE, VIBRATION, AND HARSHNESS (NVH) Installation ............................................................ 123
.
TROUBLESHOOTING ............................................. 76 .
Noise, Vibration and Harshness (NVH) ................. 76 .
NVH TROUBLESHOOTING CHART -- ENGINE
EM-2
ENGINE ASSEMBLY ............................................. 124 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 141 .
Removal and Installation ..................................... 124 . General Specifications ......................................... 141 . A
REMOVAL ........................................................ 125. Cylinder Head ...................................................... 142 .
INSTALLATION ................................................ 126 . Valve .................................................................... 142
.
CYLINDER BLOCK ............................................... 127 . VALVE .............................................................. 142
. EM
Components ........................................................ 127
. VALVE SPRING ................................................ 142 .
Removal and Installation ..................................... 128 . HYDRAULIC VALVE LIFTER ........................... 143 .
Disassembly ........................................................ 128
. VALVE GUIDE .................................................. 143 .
PISTON AND CRANKSHAFT .......................... 128 . ROCKER SHAFT AND ROCKER ARM ........... 143 . C
Inspection ............................................................ 129
. Valve Seat ........................................................... 144
.
PISTON AND PISTON PIN CLEARANCE ....... 129 . INTAKE VALVE SEAT ....................................... 144 .
PISTON RING SIDE CLEARANCE ................. 130 . EXHAUST VALVE SEAT .................................. 144 . D
PISTON RING END GAP ................................. 130 . Camshaft and Camshaft Bearing ........................ 145 .
CONNECTING ROD BEND AND TORSION ... 130 . Cylinder Block ...................................................... 146.
CYLINDER BLOCK DISTORTION AND WEAR 131 . Piston, Piston Ring and Piston Pin ...................... 147 . E
PISTON-TO-CYLINDER BORE CLEARANCE . 131 AVAILABLE PISTON ........................................ 147 .
CRANKSHAFT ................................................. 133 . PISTON RING .................................................. 147 .
BEARING CLEARANCE .................................. 133 . PISTON PIN ..................................................... 147 .
CONNECTING ROD BUSHING CLEARANCE Connecting Rod ................................................... 148 . F
(SMALL END) .................................................. 136 . Crankshaft ........................................................... 148
.
REPLACEMENT OF CONNECTING ROD Available Main Bearing ........................................ 149 .
BUSHING (SMALL END) ................................. 136 . NO. 1 MAIN BEARING ..................................... 149 . G
FLYWHEEL/DRIVE PLATE RUNOUT .............. 137 . NO. 2 AND 3 MAIN BEARING ......................... 149 .
Assembly ............................................................. 137
. NO. 4 MAIN BEARING ..................................... 149 .
PISTON ............................................................ 137
. UNDER SIZE .................................................... 149 . H
CRANKSHAFT ................................................. 137 . Available Connecting Rod Bearing ...................... 149 .
REPLACING PILOT BUSHING (M/T) OR PILOT CONNECTING ROD BEARING UNDERSIZE . 149
CONVERTER (A/T) .......................................... 139 . Miscellaneous Components ................................ 150 .
I
BEARING CLEARANCE .................................. 150 .
J
K
L
M
EM-3
PRECAUTIONS
[KA24DE]
PRECAUTIONS PFP:00001
Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT
BELT PRE-TENSIONER" EBS00EY4
The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along
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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
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.
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.
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.
Parts Requiring Angular Tightening EBS00EY5
q Use an angle wrench for the final tightening of the following engine parts:
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