Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Altima 2000-2005 Approved Nissan Altima 2003 EM
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B ENGINE
A
EM
SECTION
ENGINE MECHANICAL C
D
E
CONTENTS
QR25DE INTAKE MANIFOLD ................................................ 18 . F
Removal and Installation ....................................... 18 .
PRECAUTIONS ......................................................... 5 . REMOVAL .......................................................... 18 .
Precautions for Draining Coolant ............................ 5 . INSPECTION AFTER REMOVAL ...................... 20 . G
Precautions for Disconnecting Fuel Piping ............. 5 . INSTALLATION .................................................. 20 .
Precautions for Removal and Disassembly ............ 5 . INSPECTION AFTER INSTALLATION ............... 22 .
Precautions for Inspection, Repair and Replace- EXHAUST MANIFOLD AND THREE WAY CATA-
ment ........................................................................ 5
. H
LYST ......................................................................... 23
.
Precautions for Assembly and Installation .............. 5 . Removal and Installation ....................................... 23 .
Parts Requiring Angular Tightening ........................ 5 . REMOVAL .......................................................... 23 .
Precautions for Liquid Gasket ................................. 6 . INSPECTION AFTER REMOVAL ...................... 24 . I
REMOVAL OF LIQUID GASKET SEALING ......... 6 . INSTALLATION .................................................. 24 .
LIQUID GASKET APPLICATION PROCEDURE 6 ..... OIL PAN AND OIL STRAINER ................................ 25 .
PREPARATION .......................................................... 7 . Removal and Installation ....................................... 25 . J
Special Service Tools .............................................. 7 . REMOVAL .......................................................... 25 .
Commercial Service Tools ....................................... 9 . INSPECTION AFTER REMOVAL ...................... 27 .
NOISE, VIBRATION, AND HARSHNESS (NVH) INSTALLATION .................................................. 27 .
TROUBLESHOOTING ..............................................11 . K
INSPECTION AFTER INSTALLATION ............... 28 .
NVH Troubleshooting --Engine Noise ...................11 . IGNITION COIL ........................................................ 29 .
Use the Chart Below to Help You Find the Cause Removal and Installation ....................................... 29 .
of the Symptom. .................................................... 12 . REMOVAL .......................................................... 29 . L
DRIVE BELTS .......................................................... 13. INSTALLATION .................................................. 29 .
Checking Drive Belts ............................................. 13 . SPARK PLUG .......................................................... 30 .
Tension Adjustment ............................................... 13 . Removal and Installation ....................................... 30 . M
Removal and Installation ....................................... 13 . REMOVAL .......................................................... 30 .
REMOVAL .......................................................... 13 . INSPECTION AFTER REMOVAL ...................... 30 .
INSTALLATION .................................................. 14 . INSTALLATION .................................................. 31 .
Removal and Installation of Drive Belt Auto-ten- FUEL INJECTOR AND FUEL TUBE ....................... 32 .
sioner .................................................................... 14
. Removal and Installation ....................................... 32 .
REMOVAL .......................................................... 14 . REMOVAL .......................................................... 32 .
INSTALLATION .................................................. 14 . INSTALLATION .................................................. 33 .
AIR CLEANER AND AIR DUCT .............................. 16 . INSPECTION AFTER INSTALLATION ............... 34 .
Removal and Installation ....................................... 16 . ROCKER COVER .................................................... 35 .
REMOVAL .......................................................... 16 . Removal and Installation ....................................... 35 .
INSTALLATION .................................................. 16 . REMOVAL .......................................................... 35 .
CHANGING THE AIR CLEANER ELEMENT ..... 17 . INSTALLATION .................................................. 35 .
CAMSHAFT ............................................................. 37 .
Removal and Installation ....................................... 37 .
REMOVAL .......................................................... 37 .
INSPECTION AFTER REMOVAL ...................... 39 .
Revision: May 2004 EM-1 2003 Altima
INSTALLATION ................................................... 42 . HOW TO SELECT A MAIN BEARING ................87 .
Valve Clearance ..................................................... 44. Inspection After Disassembly .................................90 .
INSPECTION ...................................................... 44 . CRANKSHAFT SIDE CLEARANCE ...................90 .
ADJUSTMENT ................................................... 46 . CONNECTING ROD SIDE CLEARANCE ..........91 .
TIMING CHAIN ......................................................... 48 . PISTON AND PISTON PIN CLEARANCE ..........91 .
Removal and Installation ....................................... 48 . PISTON RING SIDE CLEARANCE ....................92 .
REMOVAL .......................................................... 49 . PISTON RING END GAP ...................................92 .
INSPECTION AFTER REMOVAL ....................... 51 . CONNECTING ROD BEND AND TORSION ......92 .
INSTALLATION ................................................... 52 . CONNECTING ROD BEARING (BIG END) .......93 .
OIL SEAL ................................................................. 56
. CONNECTING ROD BUSHING OIL CLEAR-
Removal and installation of Valve Oil Seal ............ 56 . ANCE (SMALL END) ..........................................93 .
REMOVAL .......................................................... 56 . CYLINDER BLOCK DISTORTION .....................94 .
INSTALLATION ................................................... 56 . INNER DIAMETER OF MAIN BEARING HOUS-
Removal and Installation of Front Oil Seal ............ 57 . ING ......................................................................94
.
REMOVAL .......................................................... 57 . PISTON TO CYLINDER BORE CLEARANCE ...95
INSTALLATION ................................................... 57 . OUTER DIAMETER OF CRANKSHAFT JOUR-
Removal and Installation of Rear Oil Seal ............. 58 . NAL .....................................................................96
.
REMOVAL .......................................................... 58 . OUTER DIAMETER OF CRANKSHAFT PIN .....96 .
INSTALLATION ................................................... 58 . OUT-OF-ROUND AND TAPER OF CRANK-
CYLINDER HEAD .................................................... 59 . SHAFT ................................................................96
.
On-Vehicle Service ................................................ 59 . CRANKSHAFT RUNOUT ...................................96 .
CHECKING COMPRESSION PRESSURE ........ 59 . OIL CLEARANCE OF CONNECTING ROD
Removal and Installation ....................................... 61 . BEARING ............................................................97 .
REMOVAL .......................................................... 62 . OIL CLEARANCE OF MAIN BEARING ..............97 .
INSPECTION AFTER REMOVAL ....................... 63 . CRUSH HEIGHT OF MAIN BEARING ...............98 .
INSTALLATION ................................................... 64 . OUTER DIAMETER OF LOWER CYLINDER
Disassembly and Assembly ................................... 65 . BLOCK MOUNTING BOLT .................................98 .
DISASSEMBLY .................................................. 65 . OUTER DIAMETER OF CONNECTING ROD
ASSEMBLY ........................................................ 66 . BOLT ...................................................................98
.
Inspection After Disassembly ................................ 67 . MOVEMENT AMOUNT OF FLYWHEEL (M/T
CYLINDER HEAD DISTORTION ....................... 67 . MODEL) ..............................................................98.
VALVE DIMENSIONS ......................................... 67 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 100 .
VALVE GUIDE CLEARANCE ............................. 67 . Standard and Limit ............................................... 100 .
VALVE GUIDE REPLACEMENT ........................ 67 . GENERAL SPECIFICATIONS .......................... 100 .
VALVE SEAT CONTACT .................................... 69 . DRIVE BELTS ................................................... 100 .
VALVE SEAT REPLACEMENT .......................... 69 . INTAKE MANIFOLD AND EXHAUST MANI-
VALVE SPRING SQUARENESS ........................ 70 . FOLD ................................................................ 100
.
VALVE SPRING DIMENSIONS AND VALVE SPARK PLUG ................................................... 100 .
SPRING PRESSURE LOAD .............................. 70 . CYLINDER HEAD ............................................. 101 .
ENGINE ASSEMBLY ............................................... 72 . VALVE ............................................................... 101
.
Removal and Installation ....................................... 72 . CAMSHAFT AND CAMSHAFT BEARING ........ 104 .
REMOVAL .......................................................... 73 . CYLINDER BLOCK ........................................... 105 .
INSTALLATION ................................................... 74 . PISTON, PISTON RING, AND PISTON PIN ..... 106 .
INSPECTION AFTER INSTALLATION ............... 75 . CONNECTING ROD ......................................... 106 .
CYLINDER BLOCK .................................................. 76 . CRANKSHAFT .................................................. 107 .
Disassembly and Assembly ................................... 76 . MAIN BEARING ................................................ 108 .
DISASSEMBLY .................................................. 77 . CONNECTING ROD BEARING ........................ 109 .
ASSEMBLY ........................................................ 79 .
How to Select Piston and Bearing ......................... 84 . VQ35DE
DESCRIPTION ................................................... 84 .
HOW TO SELECT A PISTON ............................ 84 . PRECAUTIONS ...................................................... 110 .
HOW TO SELECT A CONNECTING ROD BEAR- Precautions for Drain Coolant .............................. 110 .
ING ..................................................................... 85
. Precautions for Disconnecting Fuel Piping .......... 110 .
Precautions for Removal and Disassembly ......... 110 .
Precautions for Inspection, Repair and Replace-
ment ..................................................................... 110
.
Precautions for Assembly and Installation ........... 110 .
Revision: May 2004 EM-2 2003 Altima
Parts Requiring Angular Tightening .....................110 . INSPECTION AFTER REMOVAL .................... 149 .
Precautions for Liquid Gasket .............................. 111 . Valve Clearance .................................................. 153 . A
REMOVAL OF LIQUID GASKET SEALING ...... 111 . CHECKING ...................................................... 153 .
LIQUID GASKET APPLICATION PROCEDURE 111 .. VALVE ADJUSTING ......................................... 156 .
PREPARATION .......................................................112 . TIMING CHAIN ....................................................... 157 . EM
Special Service Tools ...........................................112 . Components ........................................................ 157.
Commercial Service Tools ....................................114 . POSITION FOR APPLYING LIQUID GASKET . 159
NOISE, VIBRATION, AND HARSHNESS (NVH) Removal .............................................................. 160
.
TROUBLESHOOTING ............................................116 . Inspection ............................................................ 168
. C
NVH Troubleshooting -- Engine Noise ................116 . Installation ........................................................... 168
.
Use the Chart Below to Help You Find the Cause OIL SEAL ............................................................... 179
.
of the Symptom. ...................................................117 . Removal and installation of Valve Oil Seal .......... 179 . D
DRIVE BELTS .........................................................118 . REMOVAL ........................................................ 179 .
Checking Drive Belts ............................................118 . INSTALLATION ................................................ 179 .
AIR CLEANER AND AIR DUCT .............................119 . Removal and Installation of Front Oil Seal .......... 179 . E
Removal and Installation ......................................119 . REMOVAL ........................................................ 179 .
REMOVAL .........................................................119 . INSTALLATION ................................................ 181 .
INSTALLATION .................................................119 . Removal and Installation of Rear Oil Seal ........... 182 .
CHANGING AIR CLEANER ELEMENT ............119 . REMOVAL ........................................................ 182 . F
INTAKE MANIFOLD .............................................. 121 . INSTALLATION ................................................ 182 .
Removal and Installation ..................................... 121 . CYLINDER HEAD .................................................. 183 .
REMOVAL ........................................................ 122 . On-Vehicle Service .............................................. 183 . G
INSPECTION AFTER REMOVAL .................... 123 . CHECKING COMPRESSION PRESSURE ...... 183 .
INSTALLATION ................................................ 123 . Removal and Installation ..................................... 184 .
INSPECTION AFTER INSTALLATION ............ 124 . REMOVAL ........................................................ 184 . H
EXHAUST MANIFOLD AND THREE WAY CATA- INSTALLATION ................................................ 187 .
LYST ...................................................................... 126
. Disassembly and Assembly ................................. 195 .
Removal and Installation ..................................... 126 . DISASSEMBLY ................................................ 196 .
I
REMOVAL ........................................................ 127 . ASSEMBLY ...................................................... 196 .
INSPECTION AFTER REMOVAL .................... 127 . Inspection After Disassembly .............................. 197 .
INSTALLATION ................................................ 128 . CYLINDER HEAD DISTORTION ..................... 197 .
OIL PAN ................................................................. 129
. VALVE GUIDE CLEARANCE ........................... 198 . J
Removal and Installation ..................................... 129 . VALVE GUIDE REPLACEMENT ...................... 198 .
REMOVAL ........................................................ 129 . VALVE SEAT CONTACT .................................. 200 .
INSTALLATION ................................................ 133 . VALVE SEAT REPLACEMENT ........................ 200 . K
IGNITION COIL ...................................................... 136 . VALVE SPRING SQUARENESS ...................... 201 .
Removal and Installation ..................................... 136 . VALVE SPRING DIMENSIONS AND VALVE
REMOVAL ........................................................ 136 . SPRING PRESSURE LOAD ............................ 201 . L
INSTALLATION ................................................ 136 . ENGINE ASSEMBLY ............................................. 202 .
SPARK PLUG (PLATINUM-TIPPED TYPE) .......... 137 . Removal and Installation ..................................... 202 .
Removal and Installation ..................................... 137 . REMOVAL ........................................................ 203 .
REMOVAL ........................................................ 137 . INSTALLATION ................................................ 205 . M
INSPECTION AFTER REMOVAL .................... 138 . INSPECTION AFTER INSTALLATION ............. 205 .
INSTALLATION ................................................ 138 . CYLINDER BLOCK ............................................... 206 .
FUEL INJECTOR AND FUEL TUBE ..................... 139 . Disassembly and Assembly ................................. 206 .
Removal and Installation ..................................... 139 . DISASSEMBLY ................................................ 207 .
REMOVAL ........................................................ 139 . ASSEMBLY ...................................................... 209 .
INSTALLATION ................................................ 140 . Inspection ............................................................ 216
.
INSPECTION AFTER INSTALLATION ............ 141 . PISTON AND PISTON PIN CLEARANCE ....... 216 .
ROCKER COVER .................................................. 142 . PISTON RING SIDE CLEARANCE .................. 216 .
Removal and Installation ..................................... 142 . PISTON RING END GAP ................................. 217 .
REMOVAL ........................................................ 142 . CONNECTING ROD BEND AND TORSION ... 217 .
INSTALLATION ................................................ 143 . CONNECTING ROD BEARING HOUSING
CAMSHAFT ........................................................... 144 . DIAMETER (BIG END) ..................................... 218 .
Removal and Installation ..................................... 144 . CONNECTING ROD BUSHING OIL CLEAR-
REMOVAL ........................................................ 145 . ANCE (SMALL END) ........................................ 218 .
INSTALLATION ................................................ 146 . CYLINDER BLOCK DISTORTION ................... 219 .
INNER DIAMETER OF MAIN BEARING HOUS-
Revision: May 2004 EM-3 2003 Altima
ING ................................................................... 219
. FOLD ................................................................ 228
.
PISTON-TO-CYLINDER BORE CLEARANCE . 219 SPARK PLUG ................................................... 228 .
CRANKSHAFT ................................................. 221 . CYLINDER HEAD ............................................. 229 .
BEARING CLEARANCE .................................. 221 . VALVE ............................................................... 229
.
DRIVE PLATE RUNOUT (A/T) ......................... 225 . CAMSHAFT AND CAMSHAFT BEARING ........ 233 .
FLYWHEEL RUNOUT (M/T) ............................. 225 . CYLINDER BLOCK ........................................... 233 .
OIL JET ............................................................ 226
. PISTON, PISTON RING AND PISTON PIN ..... 234 .
OIL JET RELIEF VALVE ................................... 226 . CONNECTING ROD ......................................... 235 .
SERVICE DATA AND SPECIFICATIONS (SDS) ... 227 . CRANKSHAFT .................................................. 236 .
Standard and Limit ............................................... 227 . AVAILABLE MAIN BEARING ............................ 237 .
GENERAL SPECIFICATIONS .......................... 227 . CONNECTING ROD BEARING ........................ 237 .
DRIVE BELT ..................................................... 228 . MISCELLANEOUS COMPONENTS ................. 238 .
INTAKE MANIFOLD AND EXHAUST MANI- BEARING CLEARANCE ................................... 238 .
Revision: May 2004 EM-4 2003 Altima
PRECAUTIONS
[QR25DE]
PRECAUTIONS PFP:00001
A
Precautions for Draining Coolant EBS00DTQ
q Drain coolant when engine is cooled.
EM
Precautions for Disconnecting Fuel Piping EBS00DTR
q Before starting work, make sure no fire or spark producing items are in the work area.
q Release fuel pressure before any removal or disassembly. C
q After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly EBS00DTS
D
q When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful operations.
q Use maximum care to avoid damage to mating or sliding surfaces. E
q Cover openings of engine system with tape or equivalent, if necessary, to seal out foreign materials.
q Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly.
q When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally F
opposite, and so on. If the order of loosening is specified, follow the specifications.
Precautions for Inspection, Repair and Replacement EBS00DTT
G
q Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way,
and replace if necessary.
Precautions for Assembly and Installation EBS00DTU H
q Use torque wrench to tighten bolts or nuts.
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- I
fied, follow the specifications.
q Always replace the old with a 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 J
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. K
q Bleed the air trapped within the system after draining the 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. L
q After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems
for leakage or rattles.
M
Parts Requiring Angular Tightening EBS00DTV
q Use an angle wrench for the final tightening of the following engine parts.
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