Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Xterra 2000-2004 Approved Nissan Xterra 2002 EM
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ENGINE MECHANICAL GI
SECTION EM MA
LC
EC
CONTENTS FE
KA24DE Removal.....................................................................30
CL
Installation..................................................................31
PRECAUTIONS ...............................................................4
Disassembly...............................................................31 MT
Supplemental Restraint System (SRS) AIR
Inspection...................................................................31
BAG and SEAT BELT PRE-TENSIONER...............4
CYLINDER HEAD DISTORTION ...............................31
Parts Requiring Angular Tightening.............................4 CAMSHAFT VISUAL CHECK ....................................32 AT
Liquid Gasket Application Procedure ..........................5 CAMSHAFT RUNOUT ..............................................32
PREPARATION ...............................................................6 CAMSHAFT CAM HEIGHT .......................................32
Special Service Tools ..................................................6 CAMSHAFT JOURNAL CLEARANCE ........................32 TF
Commercial Service Tools ...........................................8 CAMSHAFT END PLAY............................................33
NOISE, VIBRATION AND HARSHNESS (NVH) CAMSHAFT SPROCKET RUNOUT ...........................33
TROUBLESHOOTING ...................................................10 VALVE GUIDE CLEARANCE ....................................33 PD
NVH Troubleshooting Chart - Engine Noise .............11 VALVE GUIDE REPLACEMENT ................................34
OUTER COMPONENT PARTS .....................................12 VALVE SEATS .........................................................35
Removal and Installation ...........................................12 REPLACING VALVE SEAT FOR SERVICE PARTS ....35 AX
VALVE DIMENSIONS ...............................................36
MEASUREMENT OF COMPRESSION PRESSURE ....15
VALVE SPRING .......................................................37
OIL PAN.........................................................................16 SU
VALVE LIFTER AND VALVE SHIM ............................37
Components...............................................................16 Assembly ...................................................................38
Removal.....................................................................16 Valve Clearance.........................................................38
Installation..................................................................17 CHECKING .............................................................38
BR
TIMING CHAIN ..............................................................18 ADJUSTING ............................................................39
Components...............................................................18 ENGINE ASSEMBLY.....................................................41
LIQUID GASKET APPLICATION PLACES..................19
ST
Removal and Installation ...........................................41
Removal.....................................................................20 REMOVAL ...............................................................42
UPPER TIMING CHAIN ............................................20 INSTALLATION........................................................43
IDLER SPROCKET ..................................................21
RS
CYLINDER BLOCK .......................................................44
LOWER TIMING CHAIN ...........................................21 Components...............................................................44
Inspection...................................................................22 Removal and Installation ...........................................45 BT
Installation..................................................................23 Disassembly...............................................................45
LOWER TIMING CHAIN ...........................................23
PISTON AND CRANKSHAFT ....................................45
IDLER SPROCKET ..................................................24 HA
Inspection...................................................................45
UPPER TIMING CHAIN ............................................24
PISTON AND PISTON PIN CLEARANCE ..................45
OIL SEAL.......................................................................26
PISTON RING SIDE CLEARANCE ............................46
Replacement..............................................................26 PISTON RING END GAP..........................................46 SC
VALVE OIL SEAL .....................................................26 CONNECTING ROD BEND AND TORSION ...............46
OIL SEAL INSTALLING DIRECTION .........................26 CYLINDER BLOCK DISTORTION AND WEAR ...........47
FRONT OIL SEAL ....................................................26 PISTON-TO-BORE CLEARANCE ..............................47
EL
REAR OIL SEAL ......................................................27 CRANKSHAFT.........................................................48
CYLINDER HEAD..........................................................29 BEARING CLEARANCE ...........................................49
Components...............................................................29 IDX
CONTENTS (Cont'd)
CONNECTING ROD BUSHING CLEARANCE OIL PAN.........................................................................79
(SMALL END) ..........................................................51 Removal.....................................................................79
REPLACEMENT OF CONNECTING ROD Installation..................................................................80
BUSHING (SMALL END) ..........................................51 TIMING BELT ................................................................82
FLYWHEEL RUNOUT ..............................................52
Components...............................................................82
Assembly ...................................................................52
Removal.....................................................................83
PISTON ..................................................................52
Inspection...................................................................84
CRANKSHAFT.........................................................53
BELT TENSIONER AND TENSIONER SPRING ..........85
REPLACING PILOT BUSHING ..................................54
Installation..................................................................85
SERVICE DATA AND SPECIFICATIONS (SDS) .........55
Tension Adjustment....................................................86
General Specifications...............................................55
AFTER BELT REPLACEMENT..................................86
COMPRESSION PRESSURE ...................................55
AFTER ENGINE OVERHAUL OR ENGINE
Cylinder Head ............................................................55
REASSEMBLY (WITH ROCKER COVERS
Valve ..........................................................................56 REMOVED) .............................................................87
VALVE ....................................................................56
OIL SEAL.......................................................................90
VALVE SPRING .......................................................56
Replacement..............................................................90
VALVE GUIDE .........................................................57
VALVE OIL SEAL .....................................................90
VALVE LIFTER ........................................................57
OIL SEAL INSTALLING DIRECTION .........................90
VALVE CLEARANCE ADJUSTMENT .........................57
CAMSHAFT OIL SEAL .............................................91
AVAILABLE SHIMS ..................................................58
FRONT OIL SEAL ....................................................91
VALVE SEAT ...........................................................59
REAR OIL SEAL ......................................................91
Cylinder Block............................................................60
CYLINDER HEAD..........................................................92
Camshaft and Camshaft Bearing ..............................61
Components...............................................................92
Piston, Piston Ring and Piston Pin ...........................62
Removal.....................................................................93
PISTON ..................................................................62
Disassembly...............................................................95
PISTON PIN ............................................................62
PISTON RING .........................................................62 Inspection...................................................................96
Connecting Rod .........................................................63 CYLINDER HEAD DISTORTION ...............................96
CAMSHAFT VISUAL CHECK ....................................96
Crankshaft..................................................................63
CAMSHAFT RUNOUT ..............................................96
Bearing Clearance .....................................................64
CAMSHAFT CAM HEIGHT .......................................96
Available Main Bearing..............................................64 CAMSHAFT JOURNAL CLEARANCE ........................96
STANDARD .............................................................64 CAMSHAFT END PLAY............................................97
UNDERSIZE (SERVICE) ..........................................64 CAMSHAFT SPROCKET RUNOUT ...........................97
Available Connecting Rod Bearing............................64 VALVE GUIDE CLEARANCE ....................................97
STANDARD .............................................................64 VALVE GUIDE REPLACEMENT ................................98
UNDERSIZE (SERVICE) ..........................................64 VALVE SEATS .........................................................99
Miscellaneous Components.......................................65 REPLACING VALVE SEAT FOR SERVICE PARTS ..100
VALVE DIMENSIONS .............................................100
VG33E AND VG33ER VALVE SPRING .....................................................101
ROCKER SHAFT AND ROCKER ARM ....................102
PRECAUTIONS .............................................................66 HYDRAULIC VALVE LIFTER ..................................102
Supplemental Restraint System (SRS) AIR Assembly .................................................................102
BAG and SEAT BELT PRE-TENSIONER.............66 Installation................................................................103
Parts Requiring Angular Tightening...........................66 SUPERCHARGER .......................................................108
Liquid Gasket Application Procedure ........................67 Components.............................................................108
PREPARATION .............................................................68 Removal...................................................................109
Special Service Tools ................................................68 Inspection.................................................................110
Commercial Service Tools .........................................70 SUPERCHARGER FLANGE ...................................110
NOISE, VIBRATION AND HARSHNESS (NVH) ROTOR SYSTEM ..................................................110
TROUBLESHOOTING ...................................................72 SUPERCHARGER BYPASS VALVE ACTUATOR ..... 111
NVH Troubleshooting Chart - Engine Noise .............73 Installation................................................................ 111
OUTER COMPONENT PARTS .....................................74 ENGINE ASSEMBLY...................................................112
Removal and Installation ...........................................74 Removal and Installation .........................................112
MEASUREMENT OF COMPRESSION PRESSURE ....77 REMOVAL .............................................................113
CYLINDER BLOCK .....................................................115
EM-2
CONTENTS (Cont'd)
Components.............................................................115 VALVE ..................................................................128 GI
Removal and Installation .........................................116 VALVE SPRING .....................................................129
Disassembly.............................................................116 HYDRAULIC VALVE LIFTER ..................................129
PISTON AND CRANKSHAFT ..................................116 VALVE GUIDE .......................................................129 MA
Inspection.................................................................117 ROCKER SHAFT AND ROCKER ARM ....................129
PISTON AND PISTON PIN CLEARANCE ................117 Valve Seat................................................................130
PISTON RING SIDE CLEARANCE ..........................117 INTAKE VALVE SEAT ............................................130
PISTON RING END GAP........................................118 EXHAUST VALVE SEAT.........................................131
CONNECTING ROD BEND AND TORSION .............118 Camshaft and Camshaft Bearing ............................132
CYLINDER BLOCK DISTORTION AND WEAR .........118 Cylinder Block..........................................................133 LC
PISTON-TO-BORE CLEARANCE ............................119 Piston, Piston Ring and Piston Pin .........................134
CRANKSHAFT.......................................................120 AVAILABLE PISTON ..............................................134
BEARING CLEARANCE .........................................121 PISTON RING .......................................................134
EC
CONNECTING ROD BUSHING CLEARANCE PISTON PIN ..........................................................135
(SMALL END) ........................................................123 Connecting Rod .......................................................135
REPLACEMENT OF CONNECTING ROD
FE
Crankshaft................................................................135
BUSHING (SMALL END) ........................................124 Available Main Bearing............................................136
FLYWHEEL/DRIVE PLATE RUNOUT ......................124 NO. 1 MAIN BEARING ...........................................136 CL
Assembly .................................................................124 NO. 2 AND 3 MAIN BEARING.................................136
PISTON ................................................................124 NO. 4 MAIN BEARING ...........................................136
CRANKSHAFT.......................................................125 UNDER SIZE .........................................................136 MT
REPLACING PILOT BUSHING (M/T) OR PILOT Available Connecting Rod Bearing..........................137
CONVERTER (A/T) ................................................126 CONNECTING ROD BEARING UNDERSIZE ...........137
SERVICE DATA AND SPECIFICATIONS (SDS) .......127 Miscellaneous Components.....................................137 AT
General Specifications.............................................127 BEARING CLEARANCE .........................................137
Cylinder Head ..........................................................128
Valve ........................................................................128 TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-3
PRECAUTIONS KA24DE
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
Supplemental Restraint System (SRS) "AIR
BAG" and "SEAT BELT PRE-TENSIONER" NGEM0085
The Supplemental Restraint System such as "AIR BAG" and "SEAT
BELT PRE-TENSIONER", used along with a seat belt, helps to
reduce the risk or severity of injury to the driver and front passen-
ger for certain types of collision. The Supplemental Restraint Sys-
tem consists of driver air bag module (located in the center of the
steering wheel), front passenger air bag module (located on the
instrument panel on passenger side), seat belt pre-tensioners, a
diagnosis sensor unit, crash zone sensor, seat belt buckle
switches, warning lamp, wiring harness and spiral cable.
Information necessary to service the system safely is included in
the RS section of this Service Manual.
WARNING:
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