Config book(EM fm) ENGINE C D E SECTION EM A EM ENGINE MECHANICAL F G H I J K L M N O P CONTENTS QR20DE•QR25DE PRECAUTION 5 PRECAUTIONS 5 Precaution for Procedure without Cowl Top Cover 5 Precautions[.]
ENGINE SECTION EM ENGINE MECHANICAL A EM C D E CONTENTS QR20DE•QR25DE AIR CLEANER FILTER 23 F Exploded View 23 Removal and Installation 24 Inspection (Dry Paper Type) 24 G PRECAUTION PRECAUTIONS Precaution for Procedure without Cowl Top Cover Precautions Necessary for Steering Wheel Rotation After Battery Disconnection Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" Precautions For Engine Service Parts Requiring Angle Tightening Liquid Gasket SPARK PLUG 25 PREPARATION DRIVE BELT AUTO TENSIONER AND IDLER PULLEY 28 PREPARATION Exploded View 28 Removal and Installation 28 Special Service Tools Commercial Service Tools 10 Removal and Installation 25 Inspection 25 REMOVAL AND INSTALLATION 26 ENGINE ROOM COVER 26 Exploded View 26 Removal and Installation 27 AIR CLEANER AND AIR DUCT 29 BASIC INSPECTION 13 Exploded View 29 Removal and Installation 30 Inspection 31 CAMSHAFT VALVE CLEARANCE 13 Inspection and Adjustment 13 INTAKE MANIFOLD 32 COMPRESSION PRESSURE 16 Exploded View 32 Removal and Installation 32 Inspection 34 Inspection 16 SYMPTOM DIAGNOSIS 18 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING 18 H I J K L M N EXHAUST MANIFOLD 36 O NVH troubleshooting Chart 18 Exploded View 36 Removal and Installation 36 Inspection 38 PERIODIC MAINTENANCE 20 OIL PAN 39 P DRIVE BELT .20 Exploded View 39 Removal and Installation 39 Inspection 41 Exploded View 20 Removal and Installation 20 Inspection 21 Adjustment 22 Revision: 2012 November IGNITION COIL, SPARK PLUG AND ROCKER COVER 42 EM-1 E26 Exploded View 42 Removal and Installation 42 FUEL INJECTOR AND FUEL TUBE 44 Exploded View 44 Removal and Installation 44 Inspection 48 CAMSHAFT 49 Exploded View 49 Removal and Installation 49 Inspection 54 TIMING CHAIN 59 Exploded View 59 Removal and Installation 60 Inspection 67 OIL SEAL 68 VALVE OIL SEAL 68 VALVE OIL SEAL : Removal and Installation 68 FRONT OIL SEAL 68 FRONT OIL SEAL : Removal and Installation 69 REAR OIL SEAL 69 REAR OIL SEAL : Removal and Installation 69 CYLINDER HEAD 71 Exploded View 71 Removal and Installation 72 Disassembly and Assembly 73 Inspection 74 UNIT REMOVAL AND INSTALLATION 79 ENGINE ASSEMBLY 79 HOW TO SELECT PISTON AND BEARING 108 Description 108 Connecting Rod Bearing 108 Main Bearing 112 SERVICE DATA AND SPECIFICATIONS (SDS) 115 SERVICE DATA AND SPECIFICATIONS (SDS) 115 General Specification 115 Drive Belt 116 Spark Plug 116 Intake Manifold 116 Exhaust Manifold 116 Camshaft 116 Cylinder head 118 Cylinder Block 121 Main Bearing 124 Connecting Rod Bearing 125 YD25DDTi PRECAUTION 127 PRECAUTIONS 127 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" 127 Precautions For Engine Service 127 Parts Requiring Angle Tightening 128 Precaution for Liquid Gasket 128 PREPARATION 130 PREPARATION 130 Special Service Tool 130 Commercial Service Tool 133 Exploded View 79 Removal and Installation 79 Inspection 81 BASIC INSPECTION 135 UNIT DISASSEMBLY AND ASSEMBLY 83 CAMSHAFT VALVE CLEARANCE 135 ENGINE STAND SETTING 83 Setting 83 DRIVE PLATE 84 Exploded View 84 Removal and Installation 84 Inspection 85 FLYWHEEL 86 Inspection and Adjustment 135 COMPRESSION PRESSURE 139 Inspection 139 SYMPTOM DIAGNOSIS 141 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING 141 NVH Troubleshooting - Engine Noise 141 Use the Chart Below to Help You Find the Cause of the Symptom 142 Exploded View 86 Removal and Installation 87 Inspection (Double Mass Flywheel Models) 88 Inspection (Single Mass Flywheel Models) 88 PERIODIC MAINTENANCE 143 CYLINDER BLOCK 90 DRIVE BELT 143 Exploded View 90 Disassembly and Assembly 91 Inspection 98 Revision: 2012 November Exploded View 143 Removal and Installation 143 Inspection 144 Adjustment 145 EM-2 E26 AIR CLEANER FILTER 147 FUEL PUMP 191 Exploded View 147 Removal and Installation 148 Inspection (Dry Paper Type) 148 Exploded View 191 Removal and Installation 192 Disassembly and Assembly 197 Inspection 198 REMOVAL AND INSTALLATION 149 ENGINE ROOM COVER 149 Exploded View 199 Removal and Installation 199 Inspection 203 DRIVE BELT AUTO TENSIONER AND IDLER PULLEY 151 CYLINDER HEAD 206 Exploded View 206 Removal and Installation 207 Disassembly and Assembly 210 Inspection 211 Exploded View 151 Removal and Installation 151 AIR CLEANER AND AIR DUCT 153 PRIMARY TIMING CHAIN 222 G Exploded View 222 Removal and Installation 223 Inspection 231 H VACUUM PUMP 232 Exploded View 232 Removal and Installation 232 Inspection 233 I DRIVE PLATE 234 J Exploded View 234 Removal and Installation 234 Inspection 236 TURBO CHARGER 168 Exploded View 168 Removal and Installation 169 Inspection 170 GLOW PLUG 177 Exploded View 177 Removal and Installation 177 K FLYWHEEL 237 Exploded View 237 Removal and Installation 237 Inspection 238 EXHAUST MANIFOLD 174 Exploded View 174 Removal and Installation 174 Inspection 175 E F EGR SYSTEM 164 Exploded View 164 Removal and Installation 166 D Exploded View 217 Removal and Installation 217 Inspection 221 INTAKE MANIFOLD 160 Exploded View 160 Removal and Installation 161 Inspection 163 C OIL PAN AND OIL STRAINER 217 CHARGE AIR COOLER 157 Exploded View 157 Removal and Installation 158 Inspection 159 EM CAMSHAFT 199 Exploded View 149 Removal and Installation 150 Exploded View 153 Removal and Installation 154 A OIL SEAL 240 L M VALVE OIL SEAL 240 VALVE OIL SEAL : Removal and Installation 240 N INJECTION TUBE AND FUEL INJECTOR 178 FRONT OIL SEAL 240 FRONT OIL SEAL : Removal and Installation 241 Exploded View 178 Removal and Installation 179 Inspection 182 REAR OIL SEAL 242 REAR OIL SEAL : Removal and Installation 242 O ROCKER COVER 183 UNIT REMOVAL AND INSTALLATION 243 Exploded View 183 Removal and Installation 183 Inspection 185 P ENGINE ASSEMBLY 243 Exploded View 243 Removal and Installation 243 Inspection 246 SECONDARY TIMING CHAIN 186 Exploded View 186 Removal and Installation 186 Inspection 190 Revision: 2012 November UNIT DISASSEMBLY AND ASSEMBLY 247 EM-3 E26 ENGINE STAND SETTING 247 Setting 247 CYLINDER BLOCK 248 Exploded View .248 Disassembly and Assembly 249 Inspection 255 HOW TO SELECT PISTON AND BEARING 266 Description .266 Piston .266 Connecting Rod Bearing .267 Main Bearing 269 Revision: 2012 November SERVICE DATA AND SPECIFICATIONS (SDS) 272 SERVICE DATA AND SPECIFICATIONS (SDS) 272 General Specification 272 Drive belt 272 Intake Manifold 273 Exhaust Manifold 273 Camshaft 273 Cylinder Head 275 Cylinder Block 278 Main Bearing 280 Connecting Rod Bearing 281 EM-4 E26 PRECAUTIONS [QR20DE ･ QR25DE] < PRECAUTION > PRECAUTION A PRECAUTIONS Precaution for Procedure without Cowl Top Cover INFOID:0000000008272244 When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc to prevent damage to windshield EM C D E PIIB3706J Precautions Necessary for Steering Wheel Rotation After Battery Disconnection F INFOID:0000000008272245 CAUTION: Comply with the following cautions to prevent any error and malfunction • Before removing and installing any control units, first turn the ignition switch to the LOCK position, then disconnect both battery cables • After finishing work, confirm that all control unit connectors are connected properly, then re-connect both battery cables • Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing work If a DTC is detected, perform trouble diagnosis according to self-diagnosis results For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and cannot be turned If turning the steering wheel is required with the battery disconnected or discharged, follow the operation procedure below before starting the repair operation G H I J OPERATION PROCEDURE Connect both battery cables NOTE: Supply power using jumper cables if battery is discharged Turn the ignition switch to ACC position (At this time, the steering lock will be released.) Disconnect both battery cables The steering lock will remain released with both battery cables disconnected and the steering wheel can be turned Perform the necessary repair operation When the repair work is completed, re-connect both battery cables With the brake pedal released, turn the ignition switch from ACC position to ON position, then to LOCK position (The steering wheel will lock when the ignition switch is turned to LOCK position.) Perform self-diagnosis check of all control units using CONSULT Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" K L M N O INFOID:0000000008749231 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 Information necessary to service the system safely is included in the “SRS AIR BAG” and “SEAT BELT” of this Service Manual WARNING: Always observe the following items for preventing accidental activation • To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision that would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer Revision: 2012 November EM-5 E26 P PRECAUTIONS [QR20DE ･ QR25DE] < PRECAUTION > • Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system For removal of Spiral Cable and Air Bag Module, see “SRS AIR BAG” • Never 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 PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS WARNING: Always observe the following items for preventing accidental activation • When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with a hammer Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing serious injury • When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the battery, and wait at least minutes before performing any service Precautions For Engine Service INFOID:0000000008272249 DISCONNECTING FUEL PIPING • Before starting work, check no fire or spark producing items are in the work area • Release fuel pressure before disconnecting and disassembly • After disconnecting pipes, plug openings to stop fuel leakage DRAINING ENGINE COOLANT Drain engine coolant and engine oil when the engine is cooled INSPECTION, REPAIR AND REPLACEMENT Before repairing or replacing, thoroughly inspect parts Inspect new replacement parts in the same way, and replace if necessary REMOVAL AND DISASSEMBLY • When instructed to use SST, use specified tools Always be careful to work safely, avoid forceful or uninstructed operations • Exercise maximum care to avoid damage to mating or sliding surfaces • Dowel pins are used for several parts alignment When replacing and reassembling parts with dowel pins, check that dowel pins are installed in the original position • Cover openings of engine system with a tape or equivalent, if necessary, to seal out foreign materials • Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly • 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, exactly as specified Power tools may be used in the step ASSEMBLY AND INSTALLATION • Use torque wrench to tighten bolts or nuts to specification • 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 specified, exactly as specified • Replace with new gasket, packing, oil seal or O-ring • Thoroughly wash, clean, and air-blow each part Carefully check engine oil or engine coolant passages for any restriction and blockage • Avoid damaging sliding or mating surfaces Completely remove foreign materials such as cloth lint or dust Before assembly, oil sliding surfaces well • Release air within route when refilling after draining engine coolant • After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and exhaust gases for leakage Revision: 2012 November EM-6 E26 PRECAUTIONS [QR20DE ･ QR25DE] < PRECAUTION > Parts Requiring Angle Tightening INFOID:0000000008272250 A Use the angle wrench [SST: KV10112100] for the final tightening of the following engine parts: Camshaft sprocket (INT) bolt Cylinder head bolts EM Main bearing cap bolts Connecting rod cap bolts Crankshaft pulley bolt (No the angle wrench is required as bolt flange is provided with notches for angle C tightening) • Do not use a torque value for final tightening • The torque value for these parts are for a preliminary step • Ensure thread and seat surfaces are clean and coated with engine oil D • - Liquid Gasket INFOID:0000000008272251 E REMOVAL OF LIQUID GASKET SEALING • After removing mounting nuts and bolts, separate the mating surface using the seal cutter [SST: KV10111100] (A) and remove old liquid gasket sealing CAUTION: Be careful not to damage the mating surfaces • Tap the seal cutter [SST: KV10111100] to insert it , and then slide it by tapping on the side as shown in the figure • In areas where the seal cutter [SST: KV10111100] is difficult to use, lightly tap the parts using a plastic hammer to remove it CAUTION: If for some unavoidable reason tool such as a screwdriver is used, be careful not to damage the mating surfaces F G H JPBIA0052ZZ I LIQUID GASKET APPLICATION PROCEDURE Using a scraper (A), remove old liquid gasket adhering to the liquid gasket application surface and the mating surface • Remove liquid gasket completely from the groove of the liquid gasket application surface, mounting bolts, and bolt holes Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove adhering moisture, grease and foreign materials J K L JPBIA0053ZZ M Attach liquid gasket tube to the tube presser (commercial service tool) Use Genuine Liquid Gasket or equivalent Apply liquid gasket without gaps to the specified location according to the specified dimensions • If there is a groove for liquid gasket application, apply liquid gasket to the groove N O P EMA0622D Revision: 2012 November EM-7 E26 PRECAUTIONS < PRECAUTION > • As for bolt holes , normally apply liquid gasket inside the holes Occasionally, it should be applied outside the holes Check to read the text of this manual [QR20DE ･ QR25DE] : Groove : Inside • Within five minutes of liquid gasket application, install the mating component • If liquid gasket protrudes, wipe it off immediately • Do not retighten mounting bolts or nuts after the installation • After 30 minutes or more have passed from the installation, fill engine oil and engine coolant CAUTION: If there are specific instructions in this manual, observe them Revision: 2012 November EM-8 JPBIA0010ZZ E26 PREPARATION [QR20DE ･ QR25DE] < PREPARATION > PREPARATION A PREPARATION Special Service Tools INFOID:0000000008272252 Tool number Tool name Description KV10111100 Seal cutter EM C Removing oil pan and front cover, etc D E S-NT046 Disassembling valve mechanism KV10116200 Valve spring compressor KV10115900 Attachment KV10109220 Adapter Part is a component of KV10116200, but Part is not so F G PBIC1650E KV10112100 Angle wrench H Tightening bolts for connecting rod bearing cap, cylinder head, etc in angle I J NT014 KV10117100 Heated oxygen sensor wrench Loosening or tightening air fuel ratio sensor For 22 mm (0.87 in) width hexagon nut K L NT379 KV10107902 Valve oil seal puller M Replacing valve oil seal N O NT011 KV10115600 Valve oil seal drift Installing valve oil seal P NT024 Revision: 2012 November EM-9 E26 PREPARATION [QR20DE ･ QR25DE] < PREPARATION > Tool number Tool name Description EM03470000 Piston ring compressor Installing piston assembly into cylinder bore NT044 ST16610001 Pilot bushing puller Removing pilot bush NT045 — Quick connector release Removing fuel tube quick connectors in engine room (Available in SEC 164 of PARTS CATALOG: part No 16441 6N210) PBIC0198E Stopper plate KV11105210 Removing and installing the drive plate and flywheel ZZA0009D Commercial Service Tools INFOID:0000000008272253 Tool name Description Tube presser Pressing the tube of liquid gasket NT052 Power tool Loosening nuts and bolts PBIC0190E Revision: 2012 November EM-10 E26