Shop manual ô tô NISSAN 2000 Xterra CONTENTS FRONT AXLE 2 Precautions 2 PRECAUTIONS .2 Preparation 2 SPECIAL SERVICE TOOLS 2 COMMERCIAL SERVICE TOOLS 2
ENGINE MECHANICALSECTIONEMCONTENTSPRECAUTIONS .4Supplemental Restraint System (SRS) ″AIRBAG″ 4Parts Requiring Angular Tightening .4Liquid Gasket Application Procedure 4PREPARATION .5Special Service Tools 5Commercial Service Tools .8KA24DENOISE, VIBRATION AND HARSHNESS (NVH)TROUBLESHOOTING .10NVH Troubleshooting Chart - Engine Noise .11OUTER COMPONENT PARTS .12Removal and Installation .12MEASUREMENT OF COMPRESSION PRESSURE 15OIL PAN .16Components .16Removal .16Installation 17TIMING CHAIN 18Components .18LIQUID GASKET APPLICATION PLACES 19Removal .20UPPER TIMING CHAIN 20IDLER SPROCKET 21LOWER TIMING CHAIN .21Inspection .22Installation 23LOWER TIMING CHAIN .23IDLER SPROCKET 24UPPER TIMING CHAIN 24OIL SEAL .26Replacement 26VALVE OIL SEAL .26OIL SEAL INSTALLING DIRECTION .26FRONT OIL SEAL 26REAR OIL SEAL 27CYLINDER HEAD 29Components .29Removal .30Installation 31Disassembly .31Inspection .31CYLINDER HEAD DISTORTION .31CAMSHAFT VISUAL CHECK 32CAMSHAFT RUNOUT 32CAMSHAFT CAM HEIGHT .32CAMSHAFT JOURNAL CLEARANCE 32CAMSHAFT END PLAY 33CAMSHAFT SPROCKET RUNOUT .33VALVE GUIDE CLEARANCE 33VALVE GUIDE REPLACEMENT 34VALVE SEATS .35REPLACING VALVE SEAT FOR SERVICE PARTS 35VALVE DIMENSIONS .36VALVE SPRING .37VALVE LIFTER AND VALVE SHIM 37Assembly .38Valve Clearance .38CHECKING .38ADJUSTING 39ENGINE ASSEMBLY .41Removal and Installation .41REMOVAL .42INSTALLATION 43CYLINDER BLOCK .44Components .44Removal and Installation .45Disassembly .45PISTON AND CRANKSHAFT 45Inspection .45PISTON AND PISTON PIN CLEARANCE 45PISTON RING SIDE CLEARANCE 46PISTON RING END GAP 46CONNECTING ROD BEND AND TORSION .46CYLINDER BLOCK DISTORTION AND WEAR .47PISTON-TO-BORE CLEARANCE 47CRANKSHAFT .48BEARING CLEARANCE .49GIMALCECFECLMTATTFPDAXSUBRSTRSBTHASCELIDX CONNECTING ROD BUSHING CLEARANCE(SMALL END) 51REPLACEMENT OF CONNECTING RODBUSHING (SMALL END) 51FLYWHEEL/DRIVE PLATE RUNOUT 52Assembly .52PISTON 52CRANKSHAFT .53REPLACING PILOT BUSHING 54SERVICE DATA AND SPECIFICATIONS (SDS) .55General Specifications .55COMPRESSION PRESSURE .55Cylinder Head 55Valve 56VALVE 56VALVE SPRING .56VALVE GUIDE .57VALVE LIFTER 57VALVE CLEARANCE ADJUSTMENT .57AVAILABLE SHIMS 58VALVE SEAT .59Cylinder Block 60Camshaft and Camshaft Bearing 61Piston, Piston Ring and Piston pin 62PISTON 62PISTON PIN 62PISTON RING .62Connecting Rod .63Crankshaft 63Bearing Clearance .64Available Main Bearing 64STANDARD .64UNDERSIZE (SERVICE) 64Available Connecting Rod Bearing 64STANDARD .64UNDERSIZE (SERVICE) 64Miscellaneous Components .65VG33ENOISE, VIBRATION AND HARSHNESS (NVH)TROUBLESHOOTING .66NVH Troubleshooting Chart - Engine Noise .67OUTER COMPONENT PARTS .68Removal and Installation .68MEASUREMENT OF COMPRESSION PRESSURE 70OIL PAN .72Removal .72Installation 73TIMING BELT 75Components .75Removal .76Inspection .77BELT TENSIONER AND TENSIONER SPRING 78Installation 78Tension Adjustment 79AFTER BELT REPLACEMENT 79AFTER ENGINE OVERHAUL OR ENGINEREASSEMBLY (WITH ROCKER COVERSREMOVED) .80OIL SEAL .82Replacement 82VALVE OIL SEAL .82OIL SEAL INSTALLING DIRECTION .82CAMSHAFT OIL SEAL .83FRONT OIL SEAL 83REAR OIL SEAL 83CYLINDER HEAD 84Components .84Removal .85Disassembly .87Inspection .88CYLINDER HEAD DISTORTION .88CAMSHAFT VISUAL CHECK 88CAMSHAFT RUNOUT 88CAMSHAFT CAM HEIGHT .89CAMSHAFT JOURNAL CLEARANCE 89CAMSHAFT END PLAY 89CAMSHAFT SPROCKET RUNOUT .90VALVE GUIDE CLEARANCE 90VALVE GUIDE REPLACEMENT 91VALVE SEATS .91REPLACING VALVE SEAT FOR SERVICE PARTS 92VALVE DIMENSIONS .92VALVE SPRING .93ROCKER SHAFT AND ROCKER ARM 93HYDRAULIC VALVE LIFTER 94Assembly .94Installation 95ENGINE ASSEMBLY .99Removal and Installation .99REMOVAL .100CYLINDER BLOCK .102Components .102Removal and Installation .103Disassembly .103PISTON AND CRANKSHAFT 103Inspection .104PISTON AND PISTON PIN CLEARANCE 104PISTON RING SIDE CLEARANCE 104PISTON RING END GAP 104CONNECTING ROD BEND AND TORSION .105CYLINDER BLOCK DISTORTION AND WEAR .105PISTON-TO-BORE CLEARANCE 106CRANKSHAFT .107BEARING CLEARANCE .108CONNECTING ROD BUSHING CLEARANCE(SMALL END) 110REPLACEMENT OF CONNECTING RODBUSHING (SMALL END) 110CONTENTS(Cont’d)EM-2 FLYWHEEL/DRIVE PLATE RUNOUT 110Assembly .111PISTON 111CRANKSHAFT .111REPLACING PILOT BUSHING (M/T) OR PILOTCONVERTER (A/T) 113SERVICE DATA AND SPECIFICATIONS (SDS) .114General Specifications .114Cylinder Head 115Valve 115VALVE 115VALVE SPRING .116HYDRAULIC VALVE LIFTER 116VALVE GUIDE .116ROCKER SHAFT AND ROCKER ARM 116Valve Seat 117INTAKE VALVE SEAT 117EXHAUST VALVE SEAT .118Camshaft and Camshaft Bearing 119Cylinder Block 120Piston, Piston Ring and Piston Pin .122AVAILABLE PISTON 122PISTON RING .122AVAILABLE PISTON 123PISTON RING .123PISTON PIN 124Connecting Rod .124Crankshaft 124Available Main Bearing 125NO. 1 MAIN BEARING .125NO. 2 AND 3 MAIN BEARING 125NO. 4 MAIN BEARING .125UNDER SIZE .126Available Connecting Rod Bearing 126CONNECTING ROD BEARING UNDERSIZE .126Miscellaneous Components .126BEARING CLEARANCE .126GIMALCECFECLMTATTFPDAXSUBRSTRSBTHASCELIDXCONTENTS(Cont’d)EM-3 Supplemental Restraint System (SRS) “AIRBAG”NGEM0081The Supplemental Restraint System “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a seatbelt, helps to reduce the risk or severity of injury to the driver and front passenger in certain types of colli-sions. The Supplemental Restraint System consists of air bag module (located in the center of the steeringwheel), a front passenger air bag model (located on the instrument panel on the passenger side), seat beltpre-tensioners, a diagnosis sensor unit, a crash zone sensor (4WD models), a 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:¼ To avoid rendering the SRS inoperative, which could increase the risk of personal injury or deathin the event of a collision which would result in air bag inflation, all maintenance should be per-formed by an authorized NISSAN dealer.¼ 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 AirBag Module, see RS section.¼ Do not use electrical test equipment on any circuit related to the SRS unless instructed to in thisService Manual. Spiral cable and wiring harnesses (except “SEAT BELT PRE-TENSIONER”) arecovered with yellow insulation either just before the harness connectors or on the completeharness, are related to the SRS.Parts Requiring Angular TighteningNGEM0001¼ Use an angle wrench for the final tightening of the followingengine parts:a) Cylinder head boltsb) Connecting rod cap nuts¼ Do not use a torque value for final tightening.¼ The torque value for these parts are for a preliminary step.¼ Ensure thread and seat surfaces are clean and coated withengine oil.SEM371CAEM080Liquid Gasket Application ProcedureNGEM00021) Use a scraper to remove all traces of old liquid gasket frommating surfaces and grooves. Also completely clean any oilstains from these portions.2) Apply a continuous bead of liquid gasket to mating surfaces.(Use Genuine RTV silicone sealant Part No. 999MP-A7007 orequivalent.)¼ Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) dia.(for oil pan).¼ Be sure liquid gasket is 2.0 to 3.0 mm (0.079 to 0.118 in) dia.(in areas except oil pan).3) Apply liquid gasket to inner surface around hole perimeter area(unless otherwise specified).4) Assembly should be done within 5 minutes after coating.5) Wait at least 30 minutes before refilling engine oil and enginecoolant.PRECAUTIONSSupplemental Restraint System (SRS) “AIR BAG”EM-4 Special Service ToolsNGEM0003The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.Tool number(Kent-Moore No.)Tool nameDescriptionST0501S000( — )Engine stand assembly1 ST05011000( — )Engine stand2 ST05012000( — )BaseNT042Disassembling and assemblingKV10106500( — )Engine stand shaftNT028KV10105001( — )Engine attachmentNT031KV101092S0(J26336-B)Valve spring compressor1 KV10109210( — )Compressor2 KV100109220( — )AdapterNT021Disassembling and assembling valve compo-nentsKV10110001( — )Engine sub-attachmentNT032ST10120000(J24239-01)Cylinder head bolt wrenchNT583Loosening and tightening cylinder head bolta: 13 mm (0.51 in) dia.b: 12 mm (0.47 in)c: 10 mm (0.39 in)GIMALCECFECLMTATTFPDAXSUBRSTRSBTHASCELIDXPREPARATIONSpecial Service ToolsEM-5 Tool number(Kent-Moore No.)Tool nameDescriptionKV10112100(BT8653-A)Angle wrenchNT014Tightening bearing cap, cylinder head bolts,etc.KV10116300(J-38955)Valve oil seal driftNT602Installing valve oil seala: 25 (0.98) dia.b: 14.4 (0.567) dia.c: 11.8 (0.465) dia.d: 10 (0.39) dia.e: 11 (0.43)f: 9 (0.35)KV10110600(J33986)Valve spring compressorNT033Disassembling and assembling valve compo-nentsKV10107501( — )Valve oil seal driftNT025Installing valve oil sealKV10110300( — )Piston pin press standassembly1 KV10110310( — )Cap2 KV10110330( — )Spacer3 ST13030020( — )Press stand4 ST13030030( — )Spring5 KV10110340( — )Drift6 KV10110320( — )Center shaftNT036Disassembling and assembling piston withconnecting rodEM03470000(J8037)Piston ring compressorNT044Installing piston assembly into cylinder borePREPARATIONSpecial Service Tools (Cont’d)EM-6 Tool number(Kent-Moore No.)Tool nameDescription(J36467)Valve oil seal removerNT034Removing valve oil sealST16610001(J23907)Pilot bushing pullerNT045Removing crankshaft pilot bushingKV10111100(J37228)Seal cutterNT046Removing oil panWS39930000( — )Tube presserNT052Pressing the tube of liquid gasketKV101151S0(J38972)Lifter stopper set1 KV10115110(J38972-1)Camshaft pliers2 KV10115120(J38972-2)Lifter stopperNT041Changing valve lifter shimsKV10117100(J3647-A)Heated oxygen sensorwrenchNT379Loosening or tightening heated oxygen sensorFor 22 mm (0.87 in) hexagon nutKV10114400(J38365)Heated oxygen sensorwrenchNT636Loosening or tightening rear heated oxygensensor (For right bank)a: 22 mm (0.87 in)GIMALCECFECLMTATTFPDAXSUBRSTRSBTHASCELIDXPREPARATIONSpecial Service Tools (Cont’d)EM-7 Commercial Service ToolsNGEM0004Tool name DescriptionSpark plug wrenchNT047Removing and installing spark plugPulley holderNT035Holding camshaft pulley while tightening orloosening camshaft boltValve seat cutter setNT048Finishing valve seat dimensionsPiston ring expanderNT030Removing and installing piston ringValve guide driftNT015Removing and installing valve guideIntake & Exhaust:a = 10.5 mm (0.413 in) dia.b = 6.6 mm (0.260 in) dia.Valve guide reamerNT016Reaming valve guide 1 or hole for oversizevalve guide 2Intake:d1= 7.0 mm (0.276 in) dia.d2= 11.2 mm (0.441 in) dia.Exhaust:d1= 8.0 mm (0.315 in) dia.d2= 12.2 mm (0.480 in) dia.Camshaft oil seal driftNT613Installing camshaft oil seala: 60 mm (2.36 in) dia.b: 44.5 mm (1.752 in) dia.c: 75 mm (2.95 in)Front oil seal driftNT049Installing front oil seala: 52 mm (2.05 in) dia.b: 44 mm (1.73 in) dia.PREPARATIONCommercial Service ToolsEM-8 Tool name DescriptionRear oil seal driftNT719Installing rear oil seala: 46 mm (1.81 in)b: 110 mm (4.33 in)c: 84 mm (3.31 in)d: 96 mm (3.78 in)a: (J-43897-18)b: (J-43897-12)Thread repair tool for oxy-gen sensorAEM488a: 18 mm (0.71 in)b: 12 mm (0.47 in)Anti-seize thread com-poundAEM489For preventing corrosion, seizing, and gallingon high temperature applications.GIMALCECFECLMTATTFPDAXSUBRSTRSBTHASCELIDXPREPARATIONCommercial Service Tools (Cont’d)EM-9 NGEM0046AEM466NOISE, VIBRATION AND HARSHNESS (NVH)TROUBLESHOOTINGKA24DEEM-10 [...]... sprocket cover Refer to EM-19 JEM547G 6 Install rocker cover Tighten bolts in numerical order : 8 - 11 N·m (0.8 - 1.1 kg-m, 69 - 95 in-lb) AEM357 EM-24 TIMING CHAIN KA24DE Installation (Cont’d) 7 8 Install distributor, aligning as shown Install vacuum hoses, electrical harnesses, connectors, and harness clamps GI MA LC WEM067 EC FE CL MT AT TF PD AX SU BR ST RS BT HA SC EL EM-25 IDX OIL SEAL KA24DE Replacement... parts): Intake & Exhaust 11.175 - 11.196 mm (0.4400 - 0.4408 in) SEM008A SEM299D SEM300D EM-34 CYLINDER HEAD KA24DE Inspection (Cont’d) 4 Heat cylinder head to 120 to 140°C (248 to 284°F) and press service valve guide onto cylinder head Projection “L”: 13.3 - 13.9 mm (0.524 - 0.547 in) GI MA LC SEM301D 5 Ream valve guide Finished size: Intake & Exhaust 7.000 - 7.018 mm (0.2756 - 0.2763 in) EC FE CL MT SEM300D... Water pump operation pump noise LC EC FE CL EM-45, 51 MT AT TF PD AX SU EM-22 BR MA-17, (“Checking Drive Belts”, “ENGINE MAINTENANCE”) LC-12, (“Water Pump Inspection”, “ENGINE COOLING SYSTEM”) ST RS BT HA SC C: Sometimes related —: Not related EL EM-11 IDX OUTER COMPONENT PARTS KA24DE Removal and Installation Removal and Installation NGEM0047 AEM465 EM-12 OUTER COMPONENT PARTS KA24DE Removal and Installation... AEM352 ¼ 4) SEM274D EM-30 CYLINDER HEAD KA24DE Installation Installation 1) a) b) c) d) e) SEM275D 2) a) ¼ b) c) SEM276D ¼ 3) ¼ NGEM0083 Tighten cylinder head bolts in numerical order using the following procedure: Tighten all bolts to 29 N·m (3.0 kg-m, 22 ft-lb) Tighten all bolts to 79 N·m (8.1 kg-m, 59 ft-lb) Loosen all bolts completely Tighten all bolts to 25 to 34 N·m (2.5 to 3.5 kg-m, 18 to 25 ftlb)... o’clock positions when installing the camshafts Tighten all bolts to 2 N·m (0.2 kg-m, 17 in-lb) Tighten all bolts to 9.0 to 11.8 N·m (0.92 to 1.2 kg-m, 79.9 to 104.2 in-lb) Apply new engine oil to bolt threads and seat surfaces Install upper timing chain and idler sprocket Refer to “UPPER TIMING CHAIN” EM-24 and “IDLER SPROCKET” EM-24 in “Installation”, “TIMING CHAIN” GI MA LC EC FE CL MT AT TF PD AX AEM352... journals 28.000 - 28.025 mm (1.1024 - 1.1033 in) SEM295D EM-32 CYLINDER HEAD KA24DE Inspection (Cont’d) 3 4 Measure outer diameter of camshaft journal Standard outer diameter: #1 to #5 journals 27.935 - 27.955 mm (1.0998 - 1.1006 in) If clearance exceeds the limit, replace camshaft and/or cylinder head Camshaft journal clearance: Standard 0.045 - 0.090 mm (0.0018 - 0.0035 in) Limit 0.12 mm (0.0047 in)... within 5 minutes after coating SU BR ST RS AEM301 3 ¼ ¼ 4 Install oil pan Tighten oil pan bolts in numerical order : 6.4 - 7.5 N·m (0.65 - 0.76 kg-m, 56 - 66 in-lb) Wait at least 30 minutes before refilling engine oil Install parts in reverse order of removal BT HA SC EL AEM494 EM-17 IDX TIMING CHAIN KA24DE Components Components NGEM0052 AEM464 1 2 3 4 5 6 Upper timing chain tensioner Cam sprocket Upper... resurface limit “L”: Intake 42.02 - 42.52 mm (1.6543 - 1.6740 in) Exhaust 42.03 - 42.53 mm (1.6547 - 1.6744 in) SEM621F VALVE DIMENSIONS NGEM0060S12 Check dimensions of each valve For dimensions, refer to SDS (EM-56) When valve head has been worn down to 0.5 mm (0.020 in) in margin thickness, replace valve Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or less SEM188A EM-36 ... bead of liquid gasket to front cover (Refer to EM-19) NOTE: Use Genuine Nissan RTV Silicone Sealant P/N 999MP-A7007 or equivalent ¼ Be sure to install new front oil seal Refer to EM-26 ¼ Also place RTV sealant on the head gasket surface ¼ Install the front cover to the engine 6 Install oil strainer and oil pan Refer to “Installation” in “OIL PAN”, EM-17 AT TF PD AX SU BR ST RS SEM292D AEM391 7 Install... EM-33 IDX CYLINDER HEAD KA24DE Inspection (Cont’d) 2 a b If it exceeds the limit, check valve to valve guide clearance Measure valve stem diameter and valve guide inner diameter Check that clearance is within specification Valve to valve guide clearance = Valve guide inner diameter - Valve stem diameter: Unit: mm (in) Standard Limit Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031) Exhaust 0.040 - . (3.78 in)a: (J-4389 7-1 8)b: (J-4389 7-1 2)Thread repair tool for oxy-gen sensorAEM488a: 18 mm (0.71 in)b: 12 mm (0.47 in)Anti-seize thread com-poundAEM489For. ofengineSqueak-ing orfizzingAB— B — COther drivebelts (Stick-ing or slip-ping)Drive belt deflectionMA-17,(“CheckingDriveBelts”,“ENGINEMAINTE-NANCE”)Creaking