B ENGINE A
EM
SECTION
ENGINE MECHANICAL
C
D
E
CONTENTS QR25DE PRECAUTIONS ....................... .......... .......................... ............. ................. ............. ......... ..... 5 Precautions for Draining Coolant ...................... ........................ ....... ..... 5 Precautions for Disconnecting Fuel Piping .............. ..... 5 Precautions for Removal and Disassembly ............. ..... 5 Precautions for Inspection, Repair and Replacement ....................... ................................... ......................... ......................... .................... ........ ..... 5 Precautions for Assembly and Installation ............... ..... 5 Parts Requiring Angular Tightening .................... ............. ............ ..... 5 Precautions for Liquid Gasket ....................... ............................. ........... ..... 6 REMOVAL OF LIQUID GASKET SEALING .......... ..... 6 LIQUID GASKET APPLICATION PROCEDURE..... 6 PREPARATION PREPARATION ........................ ............ ......................... ............. ................. ............. ......... ..... 7 Special Specia l Service Servi ce Tools Tools ......................... ............ .......................... ................. ......... ..... 7 Commercial Commerci al Service Servic e Tools Tools .................. ..... .......................... ................. ......... ..... 9 NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING ................... ............. ...............11 .... 11 NVH Troubleshooting —Engine Noise ................ ....................11 ....11 Use the Chart Below to Help Hel p You You Find the Cause of the Symptom. ........................ .................................... ........................ .............. ..... ... 12 DRIVE BELTS ............. ......................... ............. ........................ .................. ......... ... 13 Checking Drive Belts ....................... ................................... .................... ........... ... 13 Tension Adjustment Adjus tment ............... .. .......................... .......................... ................. ....... ... 13 Removal and Installation ....................... ................................... .............. ..... ... 13 REMOVAL ....................... .................................... ......................... .................... ........... ... 13 INSTALLATION ................................................... ................................................ ... 14 Removal and Installation of Drive Belt Auto-tensioner .............. ... ....................... ....................... ....................... ......................... ................. ....... ... 14 REMOVAL ....................... .................................... ......................... .................... ........... ... 14 INSTALLATION ................................................... ................................................ ... 14 AIR CLEANER AND AIR DUCT ............................ ... ... 16 Removal and Installation ....................... ................................... .............. ..... ... 16 REMOVAL ....................... .................................... ......................... .................... ........... ... 16 INSTALLATION ................................................... ................................................ ... 16 CHANGING THE AIR CLEANER ELEMENT ...... ... 17
Revision: May 2004
INTAKE MANIFOLD .................... ......... ....................... ........................ .............. ...18 .. Removal and Installation ...................... .................................. ............... ..... .... 18 REMOVAL REMOVAL ......................... ...................................... ......................... .................. ........ .... 18 INSPECTION AFTER REMOVAL .................... ....................... . .. 20 INSTALLATION .................................................. .................................................... 20 INSPECTION AFTER INSTALLATION INSTALLATION ............. ................ . .. 22 EXHAUST MANIFOLD AND THREE WAY CATALYST ....................................................................... ...23 Removal and Installation ...................... .................................. ............... ..... .... 23 REMOVAL REMOVAL ......................... ...................................... ......................... .................. ........ .... 23 INSPECTION AFTER REMOVAL REMOVAL .................... ....................... . .. 24 INSTALLATION .................................................. .................................................... 24 OIL PAN PAN AND OIL STRAINER .............. ... ...................... ................ ..... ...25 Removal and Installation ...................... .................................. ............... ..... .... 25 REMOVAL REMOVAL ......................... ...................................... ......................... .................. ........ .... 25 INSPECTION AFTER REMOVAL REMOVAL .................... ....................... . .. 27 INSTALLATION .................................................. .................................................... 27 INSPECTION AFTER INSTALLATION INSTALLATION ............. ................ . .. 28 IGNITION COIL ...................................................... ...29 Removal and Installation ...................... .................................. ............... ..... .... 29 REMOVAL REMOVAL ......................... ...................................... ......................... .................. ........ .... 29 INSTALLATION .................................................. .................................................... 29 SPARK PLUG ........................................................ ...30 Removal and Installation ...................... .................................. ............... ..... .... 30 REMOVAL REMOVAL ......................... ...................................... ......................... .................. ........ .... 30 INSPECTION AFTER REMOVAL REMOVAL .................... ....................... . .. 30 INSTALLATION .................................................. .................................................... 31 FUEL INJECTOR AND FUEL TUBE ..................... ............ ............32 Removal and Installation ...................... .................................. ............... ..... .... 32 REMOVAL REMOVAL ......................... ...................................... ......................... .................. ........ .... 32 INSTALLATION .................................................. .................................................... 33 INSPECTION AFTER INSTALLATION INSTALLATION ............. ................ . .. 34 ROCKER COVER .................................................. ...35 Removal and Installation ...................... .................................. ............... ..... .... 35 REMOVAL REMOVAL ......................... ...................................... ......................... .................. ........ .... 35 INSTALLATION .................................................. .................................................... 35 CAMSHAFT ........................................................... ...37 Removal and Installation ...................... .................................. ............... ..... .... 37 REMOVAL REMOVAL ......................... ...................................... ......................... .................. ........ .... 37 INSPECTION AFTER REMOVAL REMOVAL .................... ....................... . .. 39
EM-1
2003 Altima
F
G
H
I
J
K
L
M
INSTALLATION ................................................... ................................................. .... 42 Valve Clearance Clear ance ........................ ............ ........................ ........................ ............... ...... ... 44 INSPECTION ......................... ...................................... ......................... .............. .... .... 44 ADJUSTMENT ........................ .................................... ......................... ............... .... 46 TIMING CHAIN ....................................................... ...48 Removal and Installation ...................... ................................ ............... ....... .... 48 REMOVAL .......................................................... ........................................................ .... 49 INSPECTION AFTER REMOVAL ..................... ........................ . .. 51 INSTALLATION ................................................... ................................................. .... 52 OIL SEAL ......................... ...................................... ......................... ......................... ............. ...56 Removal and installation of Valve Valve Oil Seal ............. . .. 56 REMOVAL .......................................................... ........................................................ .... 56 INSTALLATION ................................................... ................................................. .... 56 Removal and Installation of Front Oil Seal ............. . .. 57 REMOVAL .......................................................... ........................................................ .... 57 INSTALLATION ................................................... ................................................. .... 57 Removal and Installation of Rear Oil Seal ........... .............. . .. 58 REMOVAL .......................................................... ........................................................ .... 58 INSTALLATION ................................................... ................................................. .... 58 CYLINDER HEAD .................................................. ...59 On-Vehicle On-Vehicl e Service Servi ce ...................... .......... ......................... ........................ .............. ... 59 CHECKING COMPRESSION PRESSURE ......... . .. 59 Removal and Installation ...................... ................................ ............... ....... .... 61 REMOVAL .......................................................... ........................................................ .... 62 INSPECTION AFTER REMOVAL ..................... ........................ . .. 63 INSTALLATION ................................................... ................................................. .... 64 Disassembly and Assembly ........................ ................................. ........... .... 65 DISASSEMBLY DISASSEMBLY ....................... ................................... ......................... ............... .... 65 ASSEMBLY ........................................................ ...................................................... .... 66 Inspection After Disassembly ...................... .............................. .......... .... 67 CYLINDER HEAD DISTORTION DISTORTION ..................... ........................ . .. 67 VALVE VALVE DIMENSIONS DIMENSI ONS ............................ ................ ....................... .............. ... 67 VALVE VALVE GUIDE CLEARANCE ........................ ............ ............... ...... ... 67 VALVE VALVE GUIDE REPLACEMENT R EPLACEMENT ...................... ......................... . .. 67 VALVE VALVE SEAT CONTACT ....................... .......... ........................ ............. .... 69 VALVE VALVE SEAT REPLACEMEN REPL ACEMENT T ........................ ............. ............. .... 69 VALVE VALVE SPRING SQUARENESS SQUA RENESS ...................... ......................... . .. 70 VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD ....................... ............................ ....... .... 70 ENGINE ASSEMBLY ............................................. ...72 Removal and Installation ...................... ................................ ............... ....... .... 72 REMOVAL .......................................................... ........................................................ .... 73 INSTALLATION ................................................... ................................................. .... 74 INSPECTION INSPEC TION AFTER INSTALLATION INSTALLATION ............. ........ ........ ... 75 CYLINDER BLOCK ................................................ ...76 Disassembly and Assembly ........................ ................................. ........... .... 76 DISASSEMBLY DISASSEMBLY ....................... ................................... ......................... ............... .... 77 ASSEMBLY ........................................................ ...................................................... .... 79 How to Select Piston and Bearing ....................... ......................... .... 84 DESCRIPTION ........................ .................................... ......................... ............... .... 84 HOW TO SELECT A PISTON ........................ .......................... .... .... 84 HOW TO SELECT A CONNECTING ROD BEARING ....................... .................................... ......................... ........................ ................... ....... ... ... 85
Revision: May 2004
HOW TO SELECT A MAIN BEARING .............. ..................87 ..87 Inspection After A fter Disassembly ...................... ............................... ............90 ...90 CRANKSHAFT SIDE CLEARANCE ................. .....................90 ..90 CONNECTING ROD SIDE CLEARANCE ............91 ..91 PISTON AND PISTON PIN CLEARANCE ............91 ..91 PISTON RING SIDE CLEARANCE .................. ......................92 ..92 PISTON RING END GAP ........................ ................................. ............92 ...92 CONNECTING ROD BEND AND TORSION ........92 ..92 CONNECTING ROD BEARING (BIG END) .........93 ..93 CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END) ....................... .................................... ................. .......93 ...93 CYLINDER BLOCK DISTORTION DISTORTION ................... .......................94 ..94 INNER DIAMETER OF MAIN BEARING HOUSING ......................... ..................................... ......................... ......................... .................. ...... ...94 PISTON TO TO CYLINDER BORE CLEARANCE ....95 ..95 OUTER DIAMETER OF CRANKSHAFT JOURNAL ......................... ...................................... ......................... ........................ ................. ..... ...96 OUTER DIAMETER OF CRANKSHAFT PIN .......96 ..96 OUT-OF-ROUND AND TAPER OF CRANKSHAFT ......................... ..................................... ......................... ......................... ...............96 ...96 CRANKSHAFT RUNOUT ........................ ................................. ............96 ...96 OIL CLEARANCE OF CONNECTING ROD BEARING ...................... ................................... ......................... ....................... ..............97 ...97 OIL CLEARANCE OF MAIN BEARING ................97 ..97 CRUSH HEIGHT OF MAIN MAIN BEARING ............. .................98 ..98 OUTER DIAMETER OF LOWER CYLINDER BLOCK MOUNTING BOLT ......................... ............................... .........98 ...98 OUTER DIAMETER OF CONNECTING ROD BOLT ................................................................. ...98 MOVEMENT AMOUNT OF FLYWHEEL FLYWHEEL (M/T MODEL) ....................... .................................... ......................... ........................ ...............98 ...98 SERVICE DATA DATA AND SPECIFICATIONS (SDS) ....100 .100 Standard and Limit ....................... ................................... ...................... ............ ...100 .100 GENERAL SPECIFICATIONS ........................ .......................... ...100 .100 DRIVE BELTS ......................... .................................... ....................... ............... ....100 .100 INTAKE INTAKE MANIFOLD AND EXHAUST MANIFOLD ......................... .................................... ........................ ......................... ............... ... .100 SPARK PLUG ...................... .................................. ........................ ................. ......100 .100 CYLINDER HEAD ...................... ................................... ....................... ...........101 .101 VALVE ............................................................... .101 CAMSHAFT AND CAMSHAFT BEARING .........104 .104 CYLINDER BLOCK ......................... ..................................... .................. .......105 .105 PISTON, PISTON RING, RING, AND PISTON PIN ......106 .106 CONNECTING ROD .......................... ...................................... ............... ....106 .106 CRANKSHAFT ......................... ...................................... ......................... .............107 .107 MAIN BEARING ....................... .................................... ....................... ............ ...108 .108 CONNECTING ROD BEARING ........................ .........................109 .109
VQ35DE PRECAUTIONS ...................................................... .110 Precautions for Drain Coolant ........................ .............................. .......110 .110 Precautions for Disconnecting Fuel Piping ...........110 .110 Precautions for Removal and Disassembly ..........110 .110 Precautions for Inspection, Repair and Replacement ......................... ..................................... ........................ ....................... .................... ......... .110 Precautions for Assembly and Installation ............110 .110
EM-2
2003 Altima
Parts Requiring Requi ring Angular Tighten Tightening ing .................... ............. ......... .. 110 Precautions for Liquid Gasket ....................... ............................. ........ .. 111 REMOVAL OF LIQUID GASKET SEALING ....... .. 111 LIQUID GASKET APPLICATION PROCEDURE.. 111 PREPARATION PREPARATION .................... ......... ....................... ....................... ...................... .............112 ..112 Special Specia l Service Servi ce Tools ......................... ............ .......................... ................. ......112 .. 112 Commercial Commerci al Service Tools Tools .................. ..... .......................... ................. ......114 .. 114 NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING ........................... ................ ....................... ................ ......116 ..116 NVH Troubleshooting — Engine Noise ............... .................116 ..116 Use the Chart Below to Help Hel p You You Find the Cause of the Symptom. ........................ .................................... ........................ .............. ....117 ..117 DRIVE BELTS BELTS ..................... .......... ....................... ........................ ....................... .............118 ..118 Checking Drive Belts ....................... ................................... .................... ..........118 ..118 AIR CLEANER AND AIR DUCT ............................ ..119 Removal and Installation ....................... ................................... .............. ....119 ..119 REMOVAL ....................... .................................... ......................... .................... ..........119 ..119 INSTALLATION ..................................................119 ................................................ ..119 CHANGING AIR CLEANER ELEMENT .............119 ..119 INTAKE MANIFOLD .............................................. . 12 1 Removal and Installation ....................... ................................... .............. .... 121 REMOVAL ....................... .................................... ......................... .................... .......... 122 INSPECTION AFTER REMOVAL .................... ..................... 123 INSTALLATION ................................................. ................................................ . 123 INSPECTION AFTER INSTALLATION INSTALLATION ............. 124 EXHAUST MANIFOLD M ANIFOLD AND THREE WAY WAY CATACATALYST ...................................................................... . 12 6 Removal and Installation ....................... ................................... .............. .... 126 REMOVAL ....................... .................................... ......................... .................... .......... 127 INSPECTION AFTER REMOVAL .................... ..................... 127 INSTALLATION ................................................. ................................................ . 128 OIL PAN ................................................................. . 12 9 Removal and Installation ....................... ................................... .............. .... 129 REMOVAL ....................... .................................... ......................... .................... .......... 129 INSTALLATION ................................................. ................................................ . 133 IGNITION COIL ......................... .................................... ........................ .................. ..... . 13 6 Removal and Installation ....................... ................................... .............. .... 136 REMOVAL ....................... .................................... ......................... .................... .......... 136 INSTALLATION ................................................. ................................................ . 136 SPARK PLUG (PLATINUM-TIPPED (PLATINUM-TIPPED TYPE) ........... 137 Removal and Installation ....................... ................................... .............. .... 137 REMOVAL ....................... .................................... ......................... .................... .......... 137 INSPECTION AFTER REMOVAL .................... ..................... 138 INSTALLATION ................................................. ................................................ . 138 FUEL INJECTOR AND FUEL TUBE ................. ...... ............... ..... 139 Removal and Installation ....................... ................................... .............. .... 139 REMOVAL ....................... .................................... ......................... .................... .......... 139 INSTALLATION ....................... ................................... ......................... ............... 140 INSPECTION AFTER INSTALLATION INSTALLATION ............. 141 ROCKER COVER .................................................. . 14 2 Removal and Installation ....................... ................................... .............. .... 142 REMOVAL ....................... .................................... ......................... .................... .......... 142 INSTALLATION ................................................. ................................................ . 143 CAMSHAFT ........................................................... . 14 4 Removal and Installation ....................... ................................... .............. .... 144 REMOVAL ....................... .................................... ......................... .................... .......... 145 INSTALLATION ................................................. ................................................ . 146
Revision: May 2004
INSPECTION AFTER REMOVAL REMOVAL .................... ..................... 149 149 Valve Clearance ........................ ................................... ....................... ............... ..... 153 153 CHECKING ........................ ..................................... .......................... ................. ...... 153 153 VALVE ADJUSTING ........................ .................................... ................. ....... 156 156 TIMING CHAIN ......................... ...................................... ......................... ................. ..... .157 Components ........................ .................................... ....................... .................... ........... 157 157 POSITION FOR APPLYING APPLYING LIQUID GASKET . 159 Removal ......................... ..................................... ......................... ......................... .............. 160 160 Inspection ....................... ................................... ......................... ....................... ............ .. . 168 168 Installation ...................... ................................... ......................... ........................ .............. 168 168 OIL SEAL ........................ ................................... ........................ ......................... ............... ... .179 Removal and installation of Valve Valve Oil Seal ........... 179 179 REMOVAL ......................................................... ........................................................ . 179 179 INSTALLATION ................................................. ................................................. 179 179 Removal and Installation of Front Oil Seal ........... 179 179 REMOVAL ......................................................... ........................................................ . 179 179 INSTALLATION ................................................. ................................................. 181 181 Removal and Installation of Rear Oil Seal ............ 182 182 REMOVAL ......................................................... ........................................................ . 182 182 INSTALLATION ................................................. ................................................. 182 182 CYLINDER HEAD .................................................. .183 On-Vehicle On-Vehicl e Service Servic e ......................... ............ .......................... ..................... ......... 183 CHECKING COMPRESSION PRESSURE ....... 183 183 Removal and Installation ...................... .................................. ............... ..... 184 184 REMOVAL ......................................................... ........................................................ . 184 184 INSTALLATION ................................................. ................................................. 187 187 Disassembly and a nd Assembly A ssembly ....................... ................................. ............ 195 195 DISASSEMBLY ......................... ..................................... ....................... ............. 196 196 ASSEMBLY ASSEMBLY ......................... ..................................... ........................ ................. ....... 196 196 Inspection After Disassembly ........................ .............................. ........ 197 197 CYLINDER HEAD DISTORTION ..................... ...................... 197 197 VALVE GUIDE CLEARANCE ...................... ........................... ....... 198 198 VALVE GUIDE REPLACEMENT ...................... ....................... 198 198 VALVE VALVE SEAT CONTACT ....................... ............ ...................... ............. 200 200 VALVE VALVE SEAT REPLACEMEN REPLA CEMENT T ............. .. ...................... ............. 200 200 VALVE SPRING SQUARENESS ...................... ....................... 201 201 VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD ......................... ............................ ..... 201 201 ENGINE ASSEMBLY ............................................. .202 Removal and Installation ...................... .................................. ............... ..... 202 202 REMOVAL ......................................................... ........................................................ . 203 203 INSTALLATION ................................................. ................................................. 205 205 INSPECTION AFTER INSTALLATION INSTALLATION ............. .............. 205 205 CYLINDER BLOCK ............................................... .206 Disassembly and a nd Assembly A ssembly ....................... ................................. ............ 206 206 DISASSEMBLY ......................... ..................................... ....................... ............. 207 207 ASSEMBLY ASSEMBLY ......................... ..................................... ........................ ................. ....... 209 209 Inspection ....................... ................................... ......................... ....................... ............ .. . 216 216 PISTON AND PISTON PISTON PIN CLEARANCE ........ 216 216 PISTON RING SIDE CLEARANCE .................. ................... 216 216 PISTON RING END GAP ........................ ................................. ........... 217 217 CONNECTING ROD BEND AND TORSION .... 217 217 CONNECTING ROD BEARING HOUSING DIAMETER (BIG END) ......................... ..................................... .............. 218 218 CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END) ........................ .................................... ................ ...... 218 218 CYLINDER BLOCK DISTORTION ................... .................... 219 219 INNER DIAMETER OF MAIN BEARING HOUS-
EM-3
2003 Altima
A
EM
C
D
E
F
G
H
I
J
K
L
M
ING ....................... .................................... ......................... ........................ ................... ....... .219 PISTON-TO-CYLINDER BORE CLEARANCE .219 . 219 CRANKSHAFT ....................... .................................... .......................... ..............221 .221 BEARING CLEARANCE ........................ .................................. ...........221 .221 DRIVE PLATE RUNOUT (A/T) ......................... ..........................225 . 225 FLYWHEEL FLYWHEEL RUNOUT (M/T) ............................. ..............................225 .225 OIL JET ......................... ...................................... ......................... ...................... ...........226 .226 OIL JET RELIEF VALVE ....................................226 ....................................226 SERVICE DATA DATA AND SPECIFICATIONS (SDS) ....227 Standard and Limit .......................... ............... ....................... ..................... .......... 227 GENERAL SPECIFICATIONS SPECIFICATIONS .......................... ...........................227 . 227 DRIVE BELT ......................... ..................................... ....................... ................ ......228 .228 INTAKE INTAKE MANIFOLD AND EXHAUST E XHAUST MANI-
Revision: May 2004
EM-4
FOLD ......................... .................................... ........................ ......................... ............... ... .228 SPARK PLUG ...................... .................................. ........................ ................. ......228 .228 CYLINDER HEAD ...................... ................................... ....................... ...........229 .229 VALVE ............................................................... .229 CAMSHAFT AND CAMSHAFT BEARING .........233 .233 CYLINDER BLOCK ......................... ..................................... .................. .......233 .233 PISTON, PISTON RING AND PISTON PISTON PIN ......234 .234 CONNECTING ROD .......................... ...................................... ............... ....235 .235 CRANKSHAFT ......................... ...................................... ......................... .............236 .236 AVAILABLE MAIN BEARING .............................237 .............................237 CONNECTING ROD BEARING ........................ .........................237 .237 MISCELLANEOUS COMPONENTS ................. ..................238 .238 BEARING CLEARANCE CLEA RANCE ........................ ................................... ............238 .238
2003 Altima
PRECAUTIONS [QR25DE]
PRECAUTIONS Precautions for Draining Coolant q
PFP:00001
A EBS00DTQ
Drain coolant when engine is cooled.
Precautions for Disconnecting Fuel Piping q q q
Before starting work, make sure no fire or spark producing items are in the work area. Release fuel pressure before any removal or disassembly di sassembly.. After disconnecting pipes, plug openings to stop fuel leakage. le akage.
Precautions for Removal and Disassembly q
q q q q
q q
q q
q
q q
q
– – – –
q q q
EBS00DTU
E
F
G
H
I
J
K
L
M EBS00DTV
Use an angle wrench for the final tightening of the following engine parts. Cylinder head bolts Lower cylinder block bolts Connecting rod cap bolts Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular 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.
Revision: May 2004
D
EBS00DTT
Use torque wrench to tighten bolts or nuts. 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, follow the specifications. Always replace the old with a new gasket, packing, oil seal or O-ring. Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction re striction and blockage. Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, assembly, oil sliding surfaces well. Bleed the air trapped within the system after draining the coolant. 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. After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for leakage or rattles.
Parts Requiring Angular Tightening q
EBS00DTS
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and replace if necessary.
Precautions for Assembly and Installation
EM
C
When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid forceful operations. Use maximum care to avoid damage to mating or o r sliding surfaces. Cover openings of engine system with tape or equivalent, e quivalent, if necessary, necessary, to seal out foreign materials. Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly. assembly. 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 o f loosening is specified, follow the specifications.
Precautions for Inspection, Repair and Replacement q
EBS00DTR
EM-5
2003 Altima
PRECAUTIONS [QR25DE]
Precautions for Liquid Gasket
EBS00DTW
REMOVAL REMOVAL OF LIQUID GASKET SEALING After removing the mounting bolts and nuts, seperate the mating surface using a seal cutter and remove the liquid liqui d gasket sealing. CAUTION: Be careful not to damage the mating surfaces. q In areas where the cutter is difficult to use, use a plastic hammer to lightly tap (1) the cutter where the RTV Silicone Sealant is applied. Use a plastic hammer to slide the cutter (2) by tapping on the side. CAUTION: If for some unavoidable reason a tool such as a flat-bladed screwdriver is used, be careful not to damage the mating surfaces. q
PBIC0002E
LIQUID GASKET APPLICATION PROCEDURE 1.
2.
3.
4.
Using a scraper scraper,, remove remove the the old Silicone Silicone RTV RTV Sealant Sealant adherin adhering g to the gasket application surface and the mating surface. q Remove the sealant completely from the groove of the gasket application surface, mounting bolts, and bolt holes. Thoroughly Thoroughly clean the gasket application application surface surface and and the the mating mating surface and remove adhering moisture, grease and foreign materials. Attac Attach h the seal sealant ant tube tube to to the tube tube pres presser ser.. Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-43, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .
PBIC0003E
Apply the sealant sealant using Tool without without breaks to the the specifie specified d location. Tube presser q
q
q
q q q
WS39930000 (–)
If there is a groove for the sealant application, apply the sealant to the groove. As for the bolt holes, normally apply the sealant inside the holes. If specified, it should be applied outside the holes. Make sure to read the text of this manual. Within five minutes of the sealant application, install the mating component. If the sealant protrudes, wipe it off immediately. Do not retighten after the installation. After 30 minutes or more have passed from the installation, fill the engine with the specified oil and coolant. Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRICANTS" .
EMA0622D
SEM159F
CAUTION: Follow all specific instructions in this manual.
Revision: May 2004
EM-6
2003 Altima
PREPARATION [QR25DE]
PREPARATION Special Service Tools
PFP:00002
A EBS00DTX
The actual shapes of the Kent-Moore tools may differ from those of the special service tools illustrated here. EM
Tool number (Kent-Moore No.) Tool name
Description
KV10111100 (J-37228) Seal cutter
Removing steel oil pan and rear timing chain case
C
D
S-NT046
ST0501S000 Engine stand assembly 1. ST05011000 ( — ) Engine stand 2. ST05012000 ( — ) Base
E
Disassembling and assembling
F
G
NT042
KV10106500 ( — ) Engine stand shaft
H
I NT028
KV10115300 ( — ) Engine sub-attachment
J
K ZZA1078D
KV10116200 (J-26336-B) Valve spring compressor 1. KV10115900 (J-26336-20) Attachment
Disassembling valve mechanism
L
M NT022
KV10112100 (BT-8653-A) Angle wrench
Tightening bolts for bearing cap, cylinder head, etc.
S-NT014
KV10117100 (J-36471-A) Heated oxygen sensor wrench
Loosening or tightening heated oxygen sensors with 22 mm 80.87 in) hexagon nut
NT379
Revision: May 2004
EM-7
2003 Altima
PREPARATION [QR25DE] Tool number (Kent-Moore No.) Tool name
Description
KV10107902 (J-38959) Valve oil seal puller
Removing valve oil seal
S-NT011
KV10115600 (J-38958) Valve oil seal drift
Installing valve oil seal Use side A. a: 20 (0.79) dia. d: 8 (0.31) dia. b: 13 (0.51) dia. e: 10.7 (0.421) dia. c: 10.3 (0.406) dia. f: 5 (0.20) dia. Unit: mm (in) S-NT603
EM03470000 (J-8037) Piston ring compressor
Installing piston assembly into cylinder bore
S-NT044
ST16610001 (J-23907) Pilot bushing puller
Removing crankshaft pilot bushing
S-NT045
WS39930000 ( — ) Tube presser
Pressing the tube of liquid gasket
S-NT052
— (J-45488) Quick connector release
Removing fuel tube quick connectors in engine room
PBIC0198E
— (J-46535) Drive belt tension releaser
Releasing drive belt tension
WBIA0536E
Revision: May 2004
EM-8
2003 Altima
PREPARATION [QR25DE]
Commercial Service Tools
EBS00DTY
A
Tool number (Kent-Moore No.) Tool name
Description
Pulley holder
Crankshaft pulley removing and installing a: 68 mm (2.68 in) dia. b: 8 mm (0.31 in) dia.
EM
C
D
NT628
Crank puller
Crankshaft pulley removing
E
F ZZA0010D
Spark plug wrench
Removing and installing spark plug
G
H S-NT047
Valve seat cutter set
Finishing valve seat dimensions
I
J S-NT048
Piston ring expander
Removing and installing piston ring
K
L
S-NT030
Valve guide drift
M Removing and installing valve guide Intake & Exhaust: a: 9.5 mm (0.374 in) dia. b: 5.5 mm (0.217 in) dia.
S-NT015
Valve guide reamer
1: Reaming valve guide inner hole 2: Reaming hole for oversize v alve guide Intake & Exhaust: d1 : 6.0 mm (0.236 in) dia. d2 : 10.2 mm (0.402 in) dia.
S-NT016
Revision: May 2004
EM-9
2003 Altima
PREPARATION [QR25DE] Tool number (Kent-Moore No.) Tool name
Description
Oxygen sensor thread cleaner a: (J-43897-18) b: (J-43897-12)
Reconditioning the exhaust system threads before installing a new oxygen sensor (Use with anti-seize lubricant shown below.) a: (18 mm 0.71in) for zirconia oxygen sensor b: (12 mm 0.47 in) for titania oxygen sensor AEM488
Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907)
Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads
AEM489
Power tool
Loosening bolts and nuts
PBIC0190E
TP50 Torx ® plus ® plus Bit (J-45737)
Removing and installing M/T flywheel bolts
LBIA0284E
E20 Torx ® Socket ® Socket (J-45816)
Removing and installing A/T drive plate bolts
LBIA0285E
Revision: May 2004
EM-10
2003 Altima
NOISE, VIBRATION, AND HARSHNESS (NVH) (NV H) TROUBLESHOOTING [QR25DE]
NOISE, VIBRATION, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting —Engine Noise
PFP:00003
A EBS00DTZ
EM
C
D
E
F
G
H
I
J
K
L
M
WBIA0069E
Revision: May 2004
EM-11
2003 Altima
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING [QR25DE]
Use the Chart Below to Help You You Find the Cause of the t he Symptom.
EBS00DU0
1. Loca Locate te the the are area a where where noi noise se occ occur urs. s. 2. Co Conf nfir irm m the the type type of nois noise. e. 3. Specif Specify y the the operat operating ing condit condition ion of engin engine. e. 4. Ch Chec eck k spec specif ifie ied d nois noise es sou ourc rce. e. If necessary, repair or replace these parts. Operating condition of engine Location of noise Top of engine Rocker cover Cylinder head
Type of noise
Front of engine Timing chain cover
Front of engine
Reference page
After warmup
When starting
When idling
When racing
While driving
Ticking or clicking
C
A
—
A
B
—
Tappet noise
Valve clearance
EM-44
Rattle
C
A
—
A
B
C
Camshaft bearing noise
Camshaft journal clearance Camshaft runout
EM-39 EM-39
—
Piston pin noise
Piston and piston pin clearance Connecting rod bushing clearance
EM-93 EM-93
A
Piston slap noise
Piston-to-bore clearance Piston ring side clearance Piston ring end gap Connecting rod bend and torsion
EM-92 EM-92 EM-92 EM-92
Connecting rod bushing clearance (Small end) Connecting rod bearing clearance (Big end)
EM-93 EM-93
EM-97 EM-96
Slap or knock
Crankshaft pulley Cylinder block (Side of engine) Oil pan
Source of noise
Before warmup
Slap or rap
—
A
A
—
—
—
B
B
B
B
Check item
Knock
A
B
C
B
B
B
Connecting rod bearing noise
Knock
A
B
—
A
B
C
Main bearing noise
Main bearing oil clearance Crankshaft runout
B
Timing chain and chain tensioner noise
Timing chain cracks and wear Timing chain tensioner operation
B
Drive belts (Sticking or slipping)
Drive belts deflection
Tapping or ticking
A
A
—
B
B
Squeaking or fizzing
A
Creaking
A
B
A
B
A
B
Drive belts (Slipping)
Idler pulley bearing operation
Squall Creak
A
B
—
B
A
B
Water pump noise
Water pump operation
A: Clo Close sely ly rel relate ated d
B
—
B: Rel Relat ated ed C: Som Someti etime mes s rela relate ted d
Revision: May 2004
B
—
EM-48
EM-13
CO-7
—: Not related
EM-12
2003 Altima
DRIVE BELTS [QR25DE]
DRIVE BELTS Checking Drive Belts
PFP:02117
A EBS00KBT
EM
C
D
E
F
G SBIA0234E
NOTE: On vehicles not equipped with A/C, there is an idler pulley in the position for the drive belt routing. WARNING: Inspect the drive belt only when the engine is stopped. q Make sure that the stamp mark of drive belt auto-tensioner is within the usable range. NOTE: q Check the drive belt auto-tensioner indication when the engine is cold. q When the new drive belt is installed, i nstalled, the range should be A. q Visually check entire belt for wear, damage or cracks. q If the indicator is out of allowable use range or belt is damaged, replace the belt.
Tension Adjustment
H
I
J
K
EBS00KBU
Belt tension is not manually adjustable, it is automatically a utomatically adjusted by the drive belt auto-tensioner. L
Removal and Installation
EBS00KBV
REMOVAL 1. 2.
Remove front Remove front RH eng engine ine side side cove coverr. While securely securely holding holding the the hexagonal hexagonal part in pulley pulley center of drive belt auto-tensioner, move in the direction of arrow (loosening direction of tensioner) using Tool. Tool. Tool number
3.
4.
:
—
M
(J-46535)
CAUTION: q Avoid placing hand in a location where pinching may occur if the holding tool accidentally accidentally comes off. q Do not loosen the auto-tensioner pulley bolt. (Do not turn it counterclockwise.) If turned counterclockwise, the WBIA0561E complete auto-tensioner must be replaced as a unit, including pulley. Insert Insert a rod approximate approximately ly 6 mm (0.24 in) in) in diameter diameter through through the rear of tension tensioner er into retaining retaining boss boss to lock tensioner pulley. pulley. NOTE: Leave tensioner pulley arm locked until belt is installed again. Loosen auxiliary auxiliary drive drive belt from water pump pulley pulley in in sequence, sequence, and remove remove it. it.
Revision: May 2004
EM-13
2003 Altima
DRIVE BELTS [QR25DE] INSTALLATION Installation is in the reverse order of removal. CAUTION: q Do not loosen the auto-tensioner pulley bolt. (Do not turn it counterclockwise.) If turned counterclockwise, the complete auto-tensioner must be replaced as a unit, including pulley. q Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off. q Confirm belts are completely set on the pulleys. NOTE: q Turn crankshaft pulley clockwise several times to equalize tension between each pulley. q Confirm tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to EM-13 .
Removal and Installation of Drive Belt Auto-tensioner
EBS00KBW
SBIA0235E
CAUTION: The complete auto-tensioner must be replaced as a unit, including the pulley. pulley.
REMOVAL 1. Rem Remove ove the front front RH RH engin engine e side side cove coverr. 2. Re Remo move ve the the dri drive ve bel belt. t. Ref Refer er to to EM-13 . 3. Re Remo move ve the the alte altern rnat ator or.. Refe Referr to SC-33, "Removal" . 4. Remove Remove the the drive drive belt auto-tensi auto-tensioner oner,, using using power tool. CAUTION: Do not loosen the auto-tensioner pulley bolt. (Do not turn it counterclockwise.) If turned counterclockwise, the complete auto-tensioner must be replaced as a unit, including pulley. pulley.
INSTALLATION 1. 2.
Instal Installl driv drive e belt belt aut auto-t o-tens ensione ioner. r. While securel securely y holding the the hexagonal hexagonal part in pulley pulley center center of drive belt belt auto-tension auto-tensioner er,, move in the direcdirection of arrow (loosening direction of tensioner) using Tool. Tool number
:
—
(J-46535)
CAUTION: q Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off.
Revision: May 2004
EM-14
2003 Altima
DRIVE BELTS [QR25DE] Do not loosen the auto-tensioner pulley bolt. (Do not turn it counterclockwise.) counterclockwise.) If turned counterclockwise, the complete auto-tensioner must be replaced as a unit, including pulley. pulley. A 3. Insert Insert a rod approximate approximately ly 6 mm (0.24 in) in) in diameter diameter through through the rear of tension tensioner er into retaining retaining boss boss to lock tensioner pulley. pulley. NOTE: EM Leave tensioner pulley arm locked until belt is installed. CAUTION: q Install the drive belt auto-tensioner auto-tensioner carefully so not to damage the water pump pulley. C q If there is damage greater than peeled paint, replace the drive belt auto-tensioner. auto-tensioner. q Do not swap the pulley between the new and old auto-tensioner unit. D 4. Installat Installation ion of the the remaining remaining compon components ents is in the reverse reverse order order of removal. removal. q
E
F
G
H
I
J
K
L
M
Revision: May 2004
EM-15
2003 Altima
AIR CLEANER AND AIR DUCT [QR25DE]
AIR CLEANER AND AIR DUCT Removal and Installation
PFP:16500 EBS00DU5
LBIA0068E
1.
Resonator
2.
Air cleaner to electronic throttle control actuator tube
3.
Grommet
4.
Mass air flow sensor
5.
Air cleaner case (upper)
6.
Air cleaner case (lower)
7.
Air Air clea cleane nerr case case moun mounti ting ng brack racket et
8.
Reso Resona nato torr in fen fender der
REMOVAL 1. 2. 3. 4.
5.
Disconnect Disconnect the mass air flow sensor sensor electri electrical cal connect connector or.. Disconnect Disconnect the the tube clamp clamp at the the electronic electronic throttle throttle contro controll actuator actuator and the fresh fresh air intak intake e tube. Remove Remo ve air cleaner cleaner to electroni electronic c throttle throttle control control actuator actuator tube, tube, air cleaner cleaner case (upper) (upper),, with mass mass air flow sensor attached. Remove Remo ve mass air flow flow sensor sensor from air cleaner cleaner case case (upper), (upper), as necessary necessary.. CAUTION: Handle the mass air flow sensor with care: q Do not shock it. q Do not disassemble it. q Do not touch the internal sensor. Remove Remo ve the the resonat resonator or in in the the fender fender,, as necessary necessary..
INSTALLATION Installation is in the reverse order of removal. q Attach each joint according to the alignment marks made during removal. Screw all clamps firmly. firmly.
Revision: May 2004
EM-16
2003 Altima
AIR CLEANER AND AIR DUCT [QR25DE] CHANGING THE AIR CLEANER ELEMENT 1. 2. 3. 4.
A
Unhook the air air cleaner cleaner case case side side clips clips and raise raise the the air cleaner cleaner case (upper). (upper). Remo Re move ve the the air air clea cleane nerr elem elemen ent. t. Inst Instal alll a new new air air clea cleane nerr elem elemen ent. t. Insta Installat llation ion is is in the the rever reverse se order order of remov removal. al.
EM
C
D
E
F
G
H
I
J
K
L
M
Revision: May 2004
EM-17
2003 Altima
INTAKE MANIFOLD [QR25DE]
INTAKE MANIFOLD Removal and Installation
PFP:14003 EBS00DU6
WBIA0017E
1.
Cylinder head assembly
2.
PCV hose
3.
Intake manifold collector
4.
Gasket
5.
Electric throttle control actuator
6.
Intake manifold support
7.
Vacuum reservoir tank
8.
VIAS control solenoid valve
9.
Intake manifold
10. EVAP EVAP canister canister purge volume volume control control solenoid
REMOVAL WARNING: To avoid the danger of being scalded, never drain the coolant when the engine is hot. 1. Discon Disconnec nectt the the negati negative ve batt battery ery term termina inal. l. 2. Releas Release e the the fue fuell pres pressur sure. e. Ref Refer er to EC-50, "FUEL PRESSURE RELEASE" . 3. Drain Drain coola coolant nt when when eng engine ine is is coole cooled. d. Refe Referr to MA-15, "Changing Engine Coolant" . 4. Discon Disconnec nectt the MAF MAF sensor sensor elect electric rical al connec connector tor.. 5. Remo Remove ve air cleaner cleaner case case and air duct duct assemb assembly ly.. Refer Refer to to EM-16, "Removal and Installation" . 6. Discon Disconnec nectt the follow following ing compo componen nents ts at the the intake intake side: side: q PCV hose q EVAP EVAP canister purge volume control solenoid q Electric throttle control actuator q Brake booster vacuum hose
Revision: May 2004
EM-18
2003 Altima
INTAKE MANIFOLD [QR25DE] 7.
Discon Disconnec nectt the fuel fuel quick quick conne connecto ctorr on the engine engine side. side. q Using Tool Tool perform the following steps to disconnect the quick q uick connector. Tool nu numb mber er
A
: — (JJ-45 4548 488) 8)
EM
C WBIA0148E
D
a.
Remo Re move ve quic quick k con conne nect ctor or cap. cap. E
F
G LBIA0090E
b. c.
d.
8. a. b.
With the the sleeve sleeve side of Tool Tool facing facing quick connector connector,, install install Tool Tool onto fuel tube. Insert Insert Tool Tool into into quick quick connect connector or until until sleeve sleeve conta contacts cts and goes goes no further. Hold the Tool on that position. CAUTION: Inserting the Tool hard will not disconnect quick connector. Hold Tool where it contacts and goes no further. Pull the quick quick connector connector straight straight out out from from the fuel fuel tube. tube. CAUTION: q Pull quick connector holding it at the "A" position, as WBIA0295E shown. q Do not pull with lateral force applied. O-ring inside quick connector may be damaged. q Prepare container container and cloth c loth beforehand as fuel will leak out. q Avoid fire and sparks. q Be sure to cover c over openings of disconnected pipes with plug or plastic bag to avoid fuel leakage and entry of foreign materials. When removi removing ng fuel hose quick quick connector connector at vehicle vehicle piping piping side, side, perform perform as follows follows.. Remo Re move ve quic quick k con conne nect ctor or cap. cap. Hold the the sides sides of the the connecto connector, r, push in in tabs tabs and pull out out th the e tube. (The figure is shown for reference only.) q If the connector and the tube are stuck together, push and pull several times until they start to move. Then disconnect them by pulling. CAUTION: q The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary. q Do not use any tools to remove the quick connector. connector. q Keep the resin tube away from heat. Be especially e specially careful when welding near the tube. q Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube. q Do not bend or twist the tube during installation and removal.
Revision: May 2004
EM-19
SFE562A
2003 Altima
H
I
J
K
L
M
INTAKE MANIFOLD [QR25DE] Do not remove the remaining retainer on tube. q When the tube is replaced, also replace the retainer with a new one. Retainer color: Green. q To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar. similar. 9. Loosen Loosen mounting mounting bolts diagonally diagonally,, and remove remove the electric electric throttle throttle control control actuator actuator.. CAUTION: Handle carefully to avoid any damage. 10. Disconnect intake manifold manifold collector harness, and vacuum hose. hose. CAUTION: Cover engine openings to avoid entry of foreign materials. 11. Remove intake manifold collector mounting bolts on the support, support, using power tools. 12. Loosen Loosen the mounting mounting bolts and and nuts in the order shown shown to remove the intake manifold collector, using power tools. q
WBIA0018E
13. Loosen Loosen the bolts in the order order shown to remove remove the intake manimanifold assembly, using power tools.
WBIA0019E
INSPECTION AFTER REMOVAL Surface Distortion q Using straightedge and feeler gauge, inspect surface distortion of intake manifold collector and intake manifold surface. Standard
: 0.1 mm (0.004 in)
WBIA0020E
INSTALLATION q
Install the intake manifold bolts and nuts in the reverse order of removal, following the tightening sequences below.
Revision: May 2004
EM-20
2003 Altima
INTAKE MANIFOLD [QR25DE] Tightening Intake Manifold Bolts and Nuts q Tighten in numerical order as shown. CAUTION: After tightening No.5, retighten the No.1 mounting bolt to specification.
A
EM
C WBIA0021E
D
Tightening Intake Manifold Collector Bolts and Nuts q Tighten in numerical order as shown. CAUTION: After tightening No.7, retighten the No.1 mounting bolt to specification.
E
F
G LBIA0069E
Installation Installation of Electric Throttle Control Actuator : q Tighten the mounting bolts of electric throttle control actuator equally and diagonally in several steps. Electric throttle control actuator mounting bolts q
: 7.2 - 9.6 N·m (0.74 - 0.98 kg-m, 64 - 84 in-lb)
I
After installation perform procedure in EM-22, "INSPECTION AFTER INSTALLATION" . J
CONNECTING QUICK CONNECTOR ON THE FUEL HOSE (ENGINE SIDE) 1. 2. 3.
4.
H
Make sure sure no foreign foreign substanc substances es are deposite deposited d in and around around the fuel tube tube and quick quick connector connector,, and there is no damage to them. Thinly Thinly appl apply y new engin engine e oil aroun around d the fuel fuel tube tube tip tip end. end. Align center center to insert quick connector connector straight straight into fuel tube. q Insert fuel tube into quick connector until the top spool on fuel tubes is inserted completely and the second level spool is positioned slightly below the quick connector bottom end. CAUTION: q Hold at position "A" as shown, when inserting the fuel tube into the quick connector. q Carefully align to center to avoid inclined insertion to prevent damage to the O-ring inside the quick connector. q Insert the fuel tube until you hear a “click” sound and KBIA0272E actually feel the engagement. q To avoid misidentification of engagement with a similar sound, be sure to perform the next step. Before Before clamping clamping the fuel fuel hose with with the hose hose clamp, clamp, pull the quick quick connector connector hard by hand, hand, holding holding at the "A" position, as shown. Make sure it is completely engaged (connected) so that it does not come off of the fuel tube. NOTE: Recommended pulling force is 50 N (5.1 kg, 11.2 11.2 lb).
Revision: May 2004
EM-21
2003 Altima
K
L
M
INTAKE MANIFOLD [QR25DE] 5.
6.
Insta Installll quick quick connec connector tor cap cap on quick quick connec connector tor joint joint.. q Direct arrow mark on quick connector cap to upper side (fuel hose side). Inst Instal alll fuel fuel hos hose e to hos hose e clam clamp. p.
KBIA0298E
CONNECTING QUICK CONNECTOR ON THE FUEL HOSE (VEHICLE PIPING SIDE) 1. 2.
Make sure sure no foreign foreign substanc substances es are deposited deposited in in and around around the fuel fuel tube and quick quick connector connector,, and there is no damage to them. Align center center to insert quick connector connector straight straight into into fuel fuel tube. tube. q Insert fuel tube until a click is i s heard. q Install quick connector cap on quick connector joint. Direct arrow mark on quick connector cap upper side. q Install fuel hose to hose clamp.
PBIC0662E
INSPECTION AFTER INSTALLATION Make sure there is no fuel leakage l eakage at connections as follows: 1. Apply fuel fuel pressure pressure to fuel fuel lines by turning turning ignition ignition switch switch ON (with (with engine engine stopped). stopped). Then check check for fuel fuel leaks at connections. 2. Start Start the the engine engine and and rev itit up and and check check for for fuel leaks at connecti connections. ons. NOTE: Use mirrors for checking on connections out of the direct line of sight. CAUTION: Do not touch engine immediately after stopping as engine is extremely hot. q Perform procedures for “Throttle Valve Closed Position Learning” Learning” after finishing repairs. Refer to EC48, "Throttle Valve Closed Position Learning" . q If electric throttle control actuator is replaced, perform procedures for “Idle Air Volume Learning” Learning” after finishing repairs. Refer to EC-48, "Idle Air Volume Learning" .
Revision: May 2004
EM-22
2003 Altima
EXHAUST MANIFOLD AND THREE WAY CATALYST [QR25DE]
EXHAUST MANIFOLD AND THREE T HREE WAY WAY CATAL CATALYST YST Removal and Installation
PFP:14004
A EBS00DU7
EM
C
D
E
F
G
H
I PBIC0279E
1.
Exhaus Exhaustt manifo manifold ld and and three three way catcat- 2. alyst assembly
Exhaust manifold gasket
4.
Heated ted oxyge ygen sensor 1 (fr (front)
Heated oxygen ygen sensor sor 2 (rear)
5.
3.
Exhaust manifold cover (upper and lower)
K
REMOVAL 1. 2. 3.
4. 5. 6.
Remove eng Remove engine ine unde underr cover cover,, with with power power too tool. l. Disconnect Disconnect the electr electrical ical connector connector of each each heated heated oxygen sensor sensor,, and unhook unhook the harness harness from the bracket and middle clamp on the cover. Remove Rem ove the heat heated ed oxyge oxygen n sensor sensors s with with Tool Tool.. CAUTION: q Be careful not to damage heated oxygen sensor. sensor. q Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. Remove Rem ove the lower lower exha exhaust ust man manifo ifold ld cover cover.. Remove Rem ove the exhaus exhaustt fron frontt tube tube.. Refer Refer to EX-4, "Removal and Installation" . Remove Rem ove the upp upper er exhaus exhaustt manif manifold old cove coverr. WBIA0151E
Revision: May 2004
J
EM-23
2003 Altima
L
M
EXHAUST MANIFOLD AND THREE WAY CATALYST [QR25DE] 7. 8.
Loosen Loosen the nuts in the the sequence sequence shown, shown, on the exhaust exhaust manimanifold and three way catalyst. Remove Remo ve the the exhaust exhaust manifold manifold and and three three way way catalys catalystt assembly assembly and gasket. Discard the gasket.
WBIA0022E
INSPECTION AFTER REMOVAL REMOVAL Surface Distortion q Use a reliable straightedge and feeler gauge to check the flatness of exhaust manifold fitting surface. Limit
: 0.3 mm (0.012 in)
KBIA0046E
INSTALLATION Installation is in the reverse order of removal. Pay attention to the following. Tightening Exhaust Manifold Nuts q Tighten the nuts in the numerical order shown, to specification. After tightening No.5, retighten No.1 and then No.3 to specification.
WBIA0023E
Installation Installation of Heated Oxygen Sensors Clean the heated oxygen sensor threads with the Tool, Tool, then apply the anti-seize lubricant to the threads before installing the heated oxygen sensors. Oxygen sensor thread cleaner
J43897 - 18 J43897 - 12
CAUTION: Do not over-tighten the heated oxygen sensors. Doing so may cause damage to the heated oxygen sensors, resulting in a malfunction and the MIL coming on.
Revision: May 2004
EM-24
2003 Altima
OIL PAN AND OIL STRAINER [QR25DE]
OIL PAN AND OIL STRAINER Removal and Installation
PFP:11110
A EBS00DU8
EM
C
D
E
F
G
H
I WBIA0218E
1.
Oil dipstick tube
2.
Oil pan, upper
3.
Cylinder block
4.
Oil filter
5.
Oil pickup screen
6.
Drain plug
7.
Oil pan, lower
8.
Rear plate cover
J
K
REMOVAL WARNING: To avoid the danger of being scalded, never drain the engine oil when the engine is hot. 1. Remove Remove the the engine engine under under covers covers on both both sides, sides, using power tool. 2. Drai Drain n eng engin ine e oil oil.. Re Refe ferr to to LU-7, "Changing Engine Oil" . 3. Rem Remove ove the front front exha exhaust ust tub tube. e. Refe Referr to EX-4, "Removal and Installation" . 4. Remove Remove power power steering steering hose bracket bracket from from rear rear of of collecto collector. r. 5. Support Support the engine engine from from above above and underne underneath ath with with suitable suitable hoist hoist and floor floor jack. jack.
Revision: May 2004
EM-25
L
M
2003 Altima
OIL PAN AND OIL STRAINER [QR25DE] 6.
Remove Remove the front front suspension suspension member member for for clearance clearance to remove remove the the oil pan by disconne disconnecting cting the the following: following:
WBIA0034E
Position the power steering pump and reservoir aside. q Remove auxiliary drive belts. Refer to EM-13, "Removal and Installation" . q Dismount the A/C compressor and position it out of the way with wire. q Disconnect the upper swaybar links. Refer to FSU-1 FSU-11, 1, "Removal and Installation" . q Remove the through bolts from the front and rear engine mounts. q Disconnect the lower ball joints. Refer to FSU-5, "Components" . q Remove the two steering gear housing mounting bolts. Refer to PS-13, "Removal and Installation" . q Remove crossmember bolts and remove crossmember. crossmember. Remove Remove the lower oil pan pan bolts. bolts. Loosen Loosen the bolts bolts in th the e order order shown, using power tool. q
7.
LBIA0070E
8.
Insert Insert the the Tool Tool between between lower oil pan pan and the upper upper oil oil pan pan to separate them. Tap gently on the side to move the Tool around the pan; do not damage the mating surface. 9. Re Remo move ve the the low lower er oil oil pan pan.. 10. Remove Remove the oil pickup pickup screen. screen. 11. Remove rear plate cover, cover, and four engine-to transaxle bolts, bolts, using power tool.
SEM365E
Revision: May 2004
EM-26
2003 Altima
OIL PAN AND OIL STRAINER [QR25DE] 12. Loosen the the upper oil pan bolts bolts in the order order shown to remove remove upper oil pan, using power tool.
A
EM
C LBIA0072E
D
13. Insert the Tool Tool between the upper oil pan and and the cylinder block to separate them. Tap gently on the side to move the Tool around the pan; do not damage the mating surface.
E
F
G SEM365E
H
14. Rem Remove ove the the upper upper oil oil pan. pan.
INSPECTION AFTER REMOVAL q
Clean the oil pickup screen to remove any foreign material.
I
INSTALLATION 1. a.
Installati Installation on is in the the reverse reverse order order of remova removal. l. Paying Paying attentio attention n to the follow following. ing. Apply Genuine Genuine Silicon Silicone e RTV RTV Sealant, Sealant, or equivale equivalent, nt, to the the upper upper oil pan. Refer to GI-43, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" , and EM-6, "Precautions for Liquid Gasket" . q Install the two new O-rings in the upper oil oi l pan.
J
K
L
SBIA0253E
b.
Tight Tighten en the the upper upper oil oil pan bolt bolts s in the the order order as show shown. n. q Bolt No.10,11,18 No.10,11,18 indicate a double tightening in the sequence of bolt No.s 1, 2, 3. NOTE: Refer below for specified bolt sizes: M6 × 20 mm (0.79 in): No.19, 20 M8 × 25 mm (0.98 in): No.1, 3, 4, 9 M8 x 45 mm (1.77 in): No.2, 5, 6, 7, 8, 17 M8 x100 mm (3.97 in): No.12, 13, 14, 15, 16 LBIA0073E
Revision: May 2004
EM-27
2003 Altima
M
OIL PAN AND OIL STRAINER [QR25DE] c.
Apply Genuine Genuine Silicone Silicone RTV Sealant, Sealant, or equivale equivalent nt to to the lower oil pan. Refer to GI-43, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" , and EM-6, "Precautions for Liquid Gasket"
SBIA0254E
d.
Tighten Tighten the lower lower oil pan pan bolts bolts in the the numerical numerical order shown. q Wait at least 30 minutes after the oil pans are installed before filling the engine with oil.
LBIA0074E
INSPECTION AFTER INSTALLATION q
Check for any engine oil leaks le aks with the engine at operating temperature and running at idle.
Revision: May 2004
EM-28
2003 Altima
IGNITION COIL [QR25DE]
IGNITION COIL Removal and Installation
PFP:22448
A EBS00DU9
EM
C
D
E
F
WBIA0024E
1.
Ignition coil
2.
Spark plug
3.
Rocker cover
H
REMOVAL 1. 2. 3.
G
Remove Remo ve the the eng engin ine e cov cover er.. Disconnect Disconnect the harness harness connec connector tor from the ignition ignition coil. Remo Re move ve the the ignit ignitio ion n coil coil.. CAUTION: Do not drop or shock it.
I
J
INSTALLATION Installation is in the reverse order of removal.
K
L
M
Revision: May 2004
EM-29
2003 Altima
SPARK PLUG [QR25DE]
SPARK PLUG Removal and Installation
PFP:22401 EBS00DUA
WBIA0024E
1.
Ignition coil
2.
Spark plug
3.
Rocker cover
REMOVAL 1. 2.
Remove Remo ve the the igni igniti tion on coi coil. l. Ref Refer er to to EM-29, "Removal and Installation" . Remove Remo ve the the spark spark plug plug with with a suitab suitable le spark spark plug wrench. wrench. Temperature range
NGK
Standard type
PLFR5A-11
Hot type
PLFR4A-11
Cold type
PLFR6A-11
SEM294A
INSPECTION AFTER REMOVAL REMOVAL Use standard type spark plug for normal conditions. The hot type spark plug is suitable when fouling occurs with the standard type spark plug under conditions such as: q Frequent engine starts. q Low ambient temperatures. The cold type spark plug is suitable when spark plug knock occurs with the standard type spark plug under conditions such as: q Extended highway driving. q Frequent high engine revolution. q
Revision: May 2004
EM-30
2003 Altima
SPARK PLUG [QR25DE] Do not use a wire brush for cleaning the spark plugs. Replace as necessary.
A
EM
C SMA773C
D
If plug is covered with carbon, a spark plug cleaner may be used. Cleane Cle anerr air pres pressur sure e
: less less than than 588 kPa kPa (6 (6 kg/cm kg/cm2 , 85 psi)
Cleaning time
: less than 20 seconds
E
Checking and adjusting plug gap is not required between change intervals. Gap Ga p
F
: 1.0 1.0 - 1.1 1.1 mm (0 (0.0 .003 039 9 - 0. 0.04 043 3 in) in) G
H
SMA806CA
I
INSTALLATION q
Installation is in the reverse order of removal. J
K
L
M
Revision: May 2004
EM-31
2003 Altima
FUEL INJECTOR AND FUEL TUBE [QR25DE]
FUEL INJECTOR AND FUEL TUBE Removal and Installation
PFP:16600 EBS00DUB
WBIA0147E
1.
Fuel hose
2.
Intake manifold
3.
Sub-harness
4.
Fuel tube
5.
Clip
6.
O-ring
7.
Fuel injector
8.
Insulator
CAUTION: q Apply new engine oil to parts before installing the parts, as shown above. q Do not remove or disassemble parts unless instructed as shown in the figure.
REMOVAL 1. 2. 3.
Releas Release e the the fue fuell pres pressur sure. e. Ref Refer er to EC-50, "FUEL PRESSURE RELEASE" . Remove Rem ove the intake intake air duct. duct. Ref Refer er to to EM-16, "Removal and Installation" . Disconnect Disconnect the fuel fuel hose hose quick quick connector connector at the fuel tube tube side. side. Refer Refer to to EM-18, "INTAKE MANIFOLD" . CAUTION: q Prepare a container and cloth for catching any spilled fuel. q This operation should be performed in a place that is free from any open flames.
Revision: May 2004
EM-32
2003 Altima
FUEL INJECTOR AND FUEL TUBE [QR25DE] While hoses are disconnected seal their openings with vinyl bag or similar material to prevent foreign material from entering them. Remove Rem ove the intake intake collect collector or.. Refe Referr to EM-18, "INTAKE MANIFOLD" . Disconnect Disconnect sub-harn sub-harness ess for for injector injector at engine engine front front side, side, and and remove remove it from bracket. bracket. Loosen the m mounti ounting ng bolts bolts in the the order order as shown, then remove remove fuel tube and fuel injectors as an a n assembly. assembly. Remove Rem ove the ffuel uel injec injector tors s from from tthe he fuel fuel tube tube.. q Release the clip and remove the fuel injector. q Pull fuel injector straight out of the fuel tube. q Be careful not to damage the nozzle. q Avoid any impact, such as dropping the fuel injector. injector. q Do not disassemble or adjust the fuel injector. i njector. q
4. 5. 6. 7.
KBIA0239E
A
EM
C
D
E
INSTALLATION 1.
2.
3.
4. a.
Insta Installll new new O-rin O-rings gs on on the the fuel fuel inject injector or.. q Lubricate the O-rings lightly with new engine oil. q Be careful not to scratch it during installation. Also be careful not to twist or stretch the O-ring. If the O-ring was stretched while it is attached, do not insert it into the fuel tube immediately. Install Install the the fuel injector injector into into the fuel tube tube with with the following following proceprocedure: q Do not reuse the clip,replace it with a new one. q Insert the new clip into the clip mounting groove on fuel injector. q Insert the clip so that projection "A" of fuel injector matches notch "A" of the clip. Insert Insert fuel fuel injec injector tor into into fu fuel el tube tube with clip clip atta attache ched. d. q Insert it while matching it to the axial center. q Insert fuel injector so that projection "B" of fuel injector matches notch "B" of the clip. q Make sure that fuel tube flange is securely fixed in flange fixing groove on the clip. q Make sure that installation is complete by checking that fuel injector does not rotate or come off. Inst Instal alll fu fuel el ttub ube e asse assemb mbly ly.. Insert Insert the the tip tip of each fuel injector injector into intake intake ma manifold nifold..
F
G
H
I
J
K
L
M
KBIA0240E
b.
Tighten Tighten the the mounting mounting bolts in two two steps steps in in the numerical numerical order order shown.
KBIA0239E
Revision: May 2004
EM-33
2003 Altima
FUEL INJECTOR AND FUEL TUBE [QR25DE] Fuell tube Fue tube bolt bolt tig tight hteni ening ng 1st 1st step step
: 9.3 9.3 - 10.8 10.8 N·m N·m (0.9 (0.95 5 - 1.1 1.1 kg-m, kg-m, 83 - 95 95 in-lb in-lb))
Fuell tube Fue tube bolt bolt tig tight hteni ening ng 2nd 2nd step step
: 20.6 20.6 - 26.5 26.5 N·m N·m (2.1 (2.1 - 2.7 kg-m kg-m,, 16 - 19 19 ft-lb ft-lb))
CAUTION: q After properly connecting fuel tube assembly to injector and fuel hose, check connection for fuel leakage. 5. Instal Installl the the intake intake collec collector tor.. Refer Refer to EM-18, "INTAKE MANIFOLD" . 6. Con Connec nectt the fuel fuel hose hose quic quick k connec connector tor.. Refer Refer to EM-18, "INTAKE MANIFOLD" . 7. Installatio Installation n of the remaining remaining component components s is in the the reverse reverse order order of remova removal. l.
INSPECTION AFTER INSTALLATION Make sure there is no fuel leakage l eakage at connections as follows: 1. Apply fuel fuel pressure pressure to fuel fuel lines by turning turning ignition ignition switch switch ON (with (with engine engine stopped). stopped). Then check check for fuel fuel leaks at connections. 2. Start Start the the engine engine and and rev itit up and and check check for for fuel leaks at connecti connections. ons. NOTE: Use mirrors for checking on connections out of the direct line of sight. CAUTION: Do not touch engine immediately after stopping as engine is extremely hot. q Perform procedures for “Throttle Valve Closed Position Learning” Learning” after finishing repairs. Refer to EC48, "Throttle Valve Closed Position Learning" . q If electric throttle control actuator is replaced, perform procedures for “Idle Air Volume Learning” Learning” after finishing repairs. Refer to EC-48, "Idle Air Volume Learning" .
Revision: May 2004
EM-34
2003 Altima
ROCKER COVER [QR25DE]
ROCKER COVER Removal and Installation
PFP:13264
A EBS00DUC
EM
C
D
E
F
WBIA0153E
1.
PCV valve
4.
Rock Rocker er cove coverr gas gaske kett
2.
Oil filler cap
3.
G
Rocker cover
H
REMOVAL 1. 2. 3. 4.
Remove Remo ve the the ign ignit itio ion n coils coils.. Refe Referr to EM-29, "Removal and Installation" . Disconnect Disconnect the the PCV hose and and breather breather hose from from the the rocker rocker cover cover.. Loosen the bolts bolts in th the e numerica numericall order order as shown using power tool. Remove Remove the rocker cover. cover. Remove Remove the the oil oil filler filler cap cap and PCV valve if necessary, to transfer to the new rocker cover.
I
J
K
L WBIA0025E
M
INSTALLATION 1.
Apply RTV RTV Silicone Silicone Sealant Sealant to the the joint part part of the cylinder cylinder head head and camshaft camshaft bracket bracket following following the the steps below:
Revision: May 2004
EM-35
2003 Altima
ROCKER COVER [QR25DE] Use Genuine Silicone RTV Sealant, or equivalent. Refer to GI-43, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . Refe Re ferr to to ill illus ustr trat atio ion n “a” to apply sealant to joint part of No.1 camshaft bracket and cylinder head. Refe Re ferr tto o ill illus ustr trat atio ion n “b” to apply sealant in a 90° degree angle to the illustration “a”. Inst Instal alll the the rock rocker er cove coverr. q The rocker cover gasket must be securely installed in the groove in the rocker cover. q
a. b. 2.
WBIA0164E
3.
Tighten Tighten the rocker rocker cover bolts in two steps, steps, in the numeric numerical al order as shown. Rocker cover bolt tightening 1st step
: 1.0 - 2.9 N·m (0.1 - 0.3 0 .3 kg-m, 9 - 26 in-lb)
Rocker cover bolt tightening 2nd step
: 7.4 - 9.3 N·m (0.75 - 0.95 kg-m, 65 - 82 in-lb)
WBIA0071E
4. 5.
Connect Connect the PCV hose hose and breather breather hose to the the rocker cover cover.. If necessary necessary,, install install the oil filler filler cap and PCV valve and lubricate the PCV valve O-ring with new engine oil. Instal Installl the the ignit ignition ion coils. coils. Ref Refer er to EM-29, "Removal and Installation" .
Revision: May 2004
EM-36
2003 Altima
CAMSHAFT [QR25DE]
CAMSHAFT Removal and Installation
PFP:13001
A EBS00DUD
EM
C
D
E
F
G
H
I
J
WBIA0026E
K 1.
Camshaft brackets (1 - 5)
2.
Washer
3.
Front cover (partial view)
4.
Chain guide
5.
Chain tensioner
6.
O-ring(s)
7.
Chain tensioner spring
8.
Chain tensioner plunger
9.
IVT control solenoid valve
10. IVT control cover
11. Camshaft sprocket (EXH)
12. Camshaft sprocket (INT)
13. Valve lifter
14. Camshaft (EXH)
15. Camshaft (INT)
16. Cam Camsha shaft ft positi position on sensor sensor (PHAS (PHASE) E)
M
REMOVAL 1. 2. 3. 4. 5. 6.
Remove the rocker Remove rocker cover cover.. Refe Referr tto o EM-35, "Removal and Installation" . Remove Rem ove the the front front right right side side tire tire and wheel wheel using using power power tool. tool. Remove Rem ove the R RH H splas splash h shiel shield d using using pow power er tool. tool. Remo Re move ve the the dri drive ve belt belt.. Remove Rem ove the cool coolant ant overfl overflow ow reser reservoi voirr tank. tank. Disconnect Disconnect variable variable timing timing control control solenoid solenoid harness harness connect connector or..
Revision: May 2004
L
EM-37
2003 Altima
CAMSHAFT [QR25DE] 7.
Remove Remo ve the the IV IVT T control control cover by cutting cutting the sealant sealant us using ing the the Tool. q Loosen the bolts in the order shown.
WBIA0027E
8. a. b.
Set the the No.1 No.1 cylinder cylinder at at TDC on its its compress compression ion stroke stroke with the the following procedure: Open Open the the splas splash h cover cover on on RH unde underr cover cover.. Rotate Rota te cranks crankshaft haft pulley clockwise, clockwise, and align mating mating marks marks for TDC with timing indicator on front cover, as shown.
KBIA0190E
c.
At tthe he same same time, time, make sure that the mating mating marks on camshaf camshaftt sprockets are lined up with the yellow links in the timing chain, as shown. q If not, rotate crankshaft pulley one more turn to line up the mating marks to the yellow links, as shown.
KBIA0115E
9.
Pull the the timing chain chain guide guide out between between the camshaf camshaftt sprocket sprockets s through through front front cover. cover.
10. Remove Remove camshaft camshaft sprockets sprockets with the following procedure procedure.. CAUTION: q Do not rotate the crankshaft or camshaft while the timing chain is removed. It causes interference between valve and piston. NOTE: q Chain tension holding work is not necessary. Crankshaft sprocket and timing chain do not disconnect structurally while front cover is attached. a. Line up up the the mating mating marks marks on camshaf camshaftt sprocket sprockets s with with the yellow links in the timing chain, and paint an indelible mating mark on the sprocket and timing chain link plate.
Revision: May 2004
EM-38
KBIA0049E
2003 Altima
CAMSHAFT [QR25DE] b.
c.
Push in th the e ten tensioner sioner plunger plunger and hold. Insert Insert a stoppe stopperr pin into the hole on tensioner body to hold the chain tensioner. Remove the timing chain tensioner. q Use a wire with 0.5 mm (0.02 in) diameter for a stopper pin. Secure Secure the the hexagon hexagonal al part part of cams camshaf haftt with with a suitabl suitable e tool. tool. Loosen the camshaft sprocket mounting bolts and remove the camshaft sprockets.
A
EM
C KBIA0048E
D
11. Loosen the the camshaft camshaft bracket bracket bolts in the order order shown, and and remove the camshaft brackets and camshafts. q Remove No.1 camshaft bracket by slightly tapping it with a rubber mallet. 12. Rem Remove ove the the valve valve lifters lifters.. q Check mounting positions, and set them aside in the order removed.
E
F
G WBIA0028E
INSPECTION AFTER REMOVAL Camshaft Runout
H
1.
Put the camsha camshaft ft on on a V-block V-block supporting supporting the No.2 and No.5 No.5 journals. 2. Set the the dial dial gauge gauge vert vertica ically lly on on th the e No. No.3 3 journa journal. l. 3. Turn Turn camshaf camshaftt in one direct direction ion by by hand, hand, and and me measure asure the camcamshaft runout on the dial gauge total indicator reading. Standard
I
J
: Less than 0.04 mm (0.0016 in) K PBIC0038E
L
Camshaft Cam Height 1.
2.
Meas Me asur ure e the the camsh camshaf aftt cam cam heigh height. t. Stan anda dard rd in inttak ake e cam cam he heig ight ht
: 45. 45.66 665 5 - 45 45.8 .855 55 mm (1.7978 - 1.8053 in)
Stand St andard ard exh exhaus austt cam cam heig height ht
: 43.97 43.975 5 - 44.1 44.165 65 mm mm (1.7313 - 1.7388 in)
M
If wear wear is is beyond beyond the the limit limit,, replace replace the cams camshaf haft. t.
PBIC0039E
Camshaft Journal Clearance Outer Diameter of Camshaft Journal
Revision: May 2004
EM-39
2003 Altima
CAMSHAFT [QR25DE] q
Measure the outer diameter of the camshaft journal. Standard No.1 outer diameter
: 27.935 - 27.955 mm (1.0998 - 1.1006 in)
Standard No.2, 3, 4, 5, Standard outer diameter
: 23.435 - 23.455 mm (0.9226 - 0.9234 in)
PBIC0040E
Inner Diameter of Camshaft Bracket q Tighten the camshaft bracket bolts to the specified torque following the tightening pattern as shown. Refer to Step 4 of EM-42, "INSTALLATION" , of "CAMSHAFT" for the specified torque sequence.
SBIA0255E
q
Using inside micrometer, measure inner diameter of camshaft bracket. Standard No.1
: 28.000 - 28.021 mm (1.1024 - 1.1032 in)
Standard No.2, 3, 4, 5
: 23.500 - 23.521 mm (0.9252 - 0.9260 in)
PBIC0041E
Calculation of Camshaft Journal Clearance q (Journal clearance) = (inner diameter of camshaft bracket) – bracket) – (outer (outer diameter of camshaft journal) Stan St anda dard rd q
: 0. 0.04 045 5 - 0. 0.08 086 6 mm mm (0 (0.0 .001 018 8 - 0. 0.00 0034 34 in in))
When out of the specified range above, replace either or both b oth the camshaft and the cylinder head assembly. NOTE: Inner diameter of the camshaft bracket is manufactured together with the cylinder head. If the camshaft bracket is out of specification, replace the whole cylinder head assembly.
Revision: May 2004
EM-40
2003 Altima
CAMSHAFT [QR25DE] Camshaft End Play 1.
Standard end play 2. 3.
A
Install Install a dial dial gauge gauge in the the thrust thrust directi direction on on the the front front end of the camshaft. Measure the end play with the dial gauge while moving the camshaft forward and backward (in direction to axis).
EM
: 0.115 - 0.188 mm (0.0045 - 0.0074 in)
If out out of the specif specified ied range, range, replace replace with with new camshaft camshaft and measure again. If out out of the specifi specified ed range range again, again, replace replace with with new cylinder cylinder head assembly.
C
PBIC0042E
D
Camshaft Sprocket Runout 1. 2. 3.
Insta Installll the the camsh camshaft aft in the the cylin cylinder der hea head. d. Insta Installll the cams camshaf haftt sprock sprocket et on the the camsha camshaft. ft. Measure Measure camsha camshaft ft sprock sprocket et runout runout while turning turning tthe he camsha camshaft ft by hand. Run Ru nou outt
4.
E
F
: Les Less s th than 0. 0.15 15 mm (0. 0.00 0059 59 in)
If it exceeds exceeds the specificat specification, ion, replace replace camshaf camshaftt sprocke sprocket. t.
G
H KBIA0181J
I
Valve Lifter q
Check if the surface of the valve lifter l ifter has any excessive wear or cracks, replace as necessary. necessary. J
K
L KBIA0182E
Valve Lifter Clearance
M
Outer Diameter of Valve Lifter q Measure the outer diameter of o f the valve lifter. lifter. Valve lifter outer ou ter diam diamete eterr q
: 33.965 33.965 - 33.9 33.980 80 mm (1.3 (1.3372 372 - 1.33 1.3378 78 in) in)
If out of the specified range, replace the valve lifter.
JEM798G
Revision: May 2004
EM-41
2003 Altima
CAMSHAFT [QR25DE] Valve Lifter Bore Inner Diameter q Using inside micrometer, measure diameter of valve lifter bore of cylinder head. Stan St anda dard rd q
: 34. 34.00 000 0 - 34. 34.02 021 1 mm mm (1. (1.33 3386 86 - 1.3 1.339 394 4 in) in)
If out of the specified range, replace the cylinder head assembly. assembly.
PBIC0043E
Calculation of Valve Lifter Clearance q (Valve (Valve lifter clearance) = (hole diameter for valve lifter) – lifter) – (outer (outer diameter of valve lifter) Standard q
: 0.020 - 0.056 mm (0.0008 - 0.0022 in)
If out of specified range, replace either or both valve lifter and cylinder head assembly.
INSTALLATION 1. 2.
Inst Instal alll the the valv valve e lif lifte terr. q Install them in the same position from which they were removed. Inst Instal alll the the cams camsha haft fts. s. q The distinction between the intake and exhaust camshafts is in a difference of shapes of the back end: Intake: Signal plate for the camshaft position sensor (PHASE) Exhaust: Cone end shape
KBIA0246E
q
Install camshafts so that the dowel pins on the front side are positioned as shown.
KBIA0051E
3.
Inst Instal alll cams camsha haft ft bra brack cket ets. s. q Install by referring to identification mark on upper surface mark. q Install so that identification mark can be correctly read when viewed from the exhaust side.
SBIA0256E
Revision: May 2004
EM-42
2003 Altima
CAMSHAFT [QR25DE] Install No. 1 camshaft bracket as follows. – Apply sealant to No.1 camshaft bracket as shown. q Use Genuine Silicone RTV Sealant, or equivalent. Refer to GI-43, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . CAUTION: q After installation, be sure to wipe off any excessive sealant leaking from part “A” (both on right and left sides). q
A
EM
C SBIA0257E
D q
q
Apply sealant to camshaft bracket contact surface on the front cover backside. Apply sealant to the outside of bolt hole on front cover.
E
F
G SBIA0258E
q
H
Position the No.1 camshaft bracket near the mounting position, and install it without disturbing the sealant applied to the surfaces.
I
J
SBIA0259E
4.
Tighten Tighten camsha camshaft ft bracket bracket bolts bolts in four four steps steps in in the order order shown. shown. Step 1 (bolt (bolts s 9 - 11 11))
: 2.0 N·m (0.2 (0.2 kg-m, kg-m, 17 in-l in-lb) b)
Step 2 (bol (bolts ts 1 - 8)
: 2.0 2.0 N·m N·m (0.2 (0.2 kgkg-m, m, 17 17 in-l in-lb) b)
Step 3 (bolt (bolts s 1 - 11 11))
: 5.9 N·m (0.6 (0.6 kg-m, kg-m, 52 in-l in-lb) b)
L
M
Step 4 (bolt (bolts s 1 - 11) : 9.0 9.0 - 11.8 11.8 N·m N·m (0.92 (0.92 - 1.2 kg-m, 80 - 104 in-lb) CAUTION: After tightening camshaft bracket bolts, be sure to wipe off excessive sealant from the parts listed below. q Mating surface of rocker cover. q Mating surface of front cover, when installed without the front cover.
Revision: May 2004
EM-43
K
SBIA0255E
2003 Altima
CAMSHAFT [QR25DE] 5.
Inst Instal alll cams camsha haft ft spr sproc ocke kets ts.. q Install them by lining up the mating marks on each camshaft sprocket with the ones painted on the timing chain during removal. q Before installation of chain tensioner, it is possible to re-match the marks on timing chain with the ones on each sprocket. CAUTION: q Aligned mating marks could slip. Therefore, after matching them, hold the timing chain in place by hand. q Before and after installing installing chain tensioner, check again to make sure that mating marks have not slipped. Camshaft sprocket mounting bolts
6.
7. 8. a. b. c.
KBIA0115E
: 128 - 156 N·m (13 - 16 kg-m, 94 - 115 ft-lb)
Inst Instal alll cha chain in tens tensio ione nerr. CAUTION: q After installation, pull the stopper pin off completely, and make sure that the tensioner is fully released. Inst Instal alll cha chain in guid guide. e. Install Install IVT IVT control control cover cover with the following following proced procedure. ure. Install Install IVT IVT control control solenoid solenoid valve valve to intake intake valve valve timing timing control control cover. Instal Installl O-ri O-ring ng to front front cover cover side. side. Apply Genuine Genuine Silicon Silicone e RTV RTV Sealant Sealant to the positions positions shown in the figure. Refer to GI-43, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .
SBIA0260E
d.
Inst Instal alll IVT IVT cont contro roll cov cover er.. q Tighten the bolts in the numerical order as shown. 9. Che Check ck and and adju adjust st valv valve e clear clearanc ances. es. Ref Refer er to to EM-44, "Valve Clearance" . 10. Installation of the remaining components components is in the reverse order of removal.
KBIA0085E
Valve Clearance
EBS00DUE
INSPECTION q
1. 2. 3.
Perform this inspection as follows after removal, installation, or replacement of the camshaft or any valverelated parts, or if there are any unusual engine conditions due to changes in valve clearance over time (starting, idling, and/or noise). Warm arm up the the eng engin ine, e, the then n stop stop it. it. Remove Rem ove fron frontt RH engin engine e under under cover cover usin using g power power tool. tool. Remove Rem ove the rocker rocker cover cover using using powe powerr tool. tool. Refer to EM-35, "Removal and Installation" .
Revision: May 2004
EM-44
2003 Altima
CAMSHAFT [QR25DE] 4.
Turn Turn cranksh crankshaft aft pulley pulley in normal normal direction direction (clock (clockwise wise when viewed from front) to align TDC identification mark (without paint mark) with timing indicator.
A
EM
C KBIA0190E
D
5.
At this this time, time, check that the both both intake intake and exhaust exhaust cam lobes lobes of No. 1 cylinder face outside. q If they do not face outside, turn crankshaft pulley once more.
E
F
G KBIA0400J
6.
H
By referr referring ing to to the the figure figure (locati (locations ons indicat indicated ed with with black black arrow) arrow),, measure valve clearances with a feeler gauge at locations marked X as shown in the table below. b elow. q No.1 cylinder compression TDC. Cylinder Valve Measurable
No.1 INT ×
No.2
EX H
INT
×
×
EXH
No.3 INT
I
No.4
EX H
INT
EXH
J
x
KBIA0248E
q
Use a feeler gauge to measure the clearance between valve and camshaft.
K
L
Valve clearance standard: Hot Cold*
7.
Intake
: 0.32 - 0.40 mm (0.013 - 0.016 in)
Exha Ex haus ustt
: 0.3 0.33 3 - 0. 0.41 41 mm (0 (0.0 .013 13 - 0.0 0.016 16 in in))
Intake
: 0.24 - 0.32 mm (0.009 - 0.013 in)
Exha Ex haus ustt
: 0.2 0.26 6 - 0. 0.34 34 mm (0 (0.0 .010 10 - 0.0 0.013 13 in in))
M
*Reference data at approximately 20°C (68°F) CAUTION: If inspection was carried out with cold engine, check that values with fully warmed up engine are still s till within specifications. Turn Turn crank cranksha shaft ft one one compl complete ete revo revolut lution ion (360 (360°) and align mark on crankshaft pulley with pointer.
Revision: May 2004
EM-45
KBIA0185E
2003 Altima
CAMSHAFT [QR25DE] 8.
By referr referring ing to to the figure figure (locatio (locations ns indicat indicated ed with with black black arrow), arrow), measure valve clearances with a feeler gauge at locations marked X as shown in the table below . q No.4 cylinder compression TDC. Cylinder Valve
No.1 INT
Measurable
EXH
No.2 INT
EX H x
No.3 INT ×
No.4
EXH
INT
EXH
x
×
KBIA0249E
9.
If out out of specif specifica icatio tions, ns, adju adjust st as follow follows. s.
ADJUSTMENT NOTE: q Perform adjustment depending on selected head thickness of valve lifter. q The specified valve lifter thickness is the dimension at normal temperatures. Ignore dimensional differences caused by temperature. Use the specifications for hot engine condition to adjust. 1. Re Remo move ve cams camsha haft ft.. Re Refe ferr tto o EM-37, "Removal and Installation" . 2. Remo Remove ve the valve lifters lifters at the locatio locations ns that that are outside outside the the standard. standard. 3. Measure Measure the the center center thickne thickness ss of of the removed removed valve valve lifters lifters with with a micrometer.
KBIA0057E
4.
Use the the equation equation below below to to calculate calculate valve lifter lifter thickness thickness for replace replacement. ment. q Valve lifter thickness calculation. t = t1 + (C1 - C2) t = Thickness of replacement valve lifter. t1 = Thickness of removed valve lifter. C1 = Measured valve clearance. C2 = Standard valve clearance. q Thickness of a new valve lifter can be identified by stamp marks on the reverse side (inside the cylinder). Stamp Stamp mark 696 indicates a thickness of 6.96 6 .96 mm (0.2740 in) Available thickness of valve lifter: 26 sizes with a range of 6.96 to 7.46 mm (0.2740 (0 .2740 to 0.2937 in), in steps of 0.02 mm (0.0008 in), when assembled at the factory.
KBIA0119E
5. 6. 7. 8.
Insta Installll the the select selected ed valve valve lifter lifter.. Inst Instal alll cams camsha haft ft.. Manuall Man ually y turn turn cranks crankshaf haftt pu pulle lley y a few turns. turns. Check that that valve clearance clearances s for cold engine engine are within within specificatio specifications, ns, by referring referring to the specifie specified d values.
Revision: May 2004
EM-46
2003 Altima
CAMSHAFT [QR25DE] 9.
After comple completing ting the repair repair,, check valve valve clearances clearances again again with the specific specification ations s for warmed warmed engine. engine. Use a feeler gauge to measure the clearance between the valve and camshaft. Make sure the values are within specifications.
A
Valve clearance standard: Hot Cold*
Intake
: 0.32 - 0.40 mm (0.013 - 0.016 in)
Exha Ex haus ustt
: 0.3 0.33 3 - 0. 0.41 41 mm (0 (0.0 .013 13 - 0.0 0.016 16 in in))
Intake
: 0.24 - 0.32 mm (0.009 - 0.013 in)
Exha Ex haus ustt
: 0.2 0.26 6 - 0. 0.34 34 mm (0 (0.0 .010 10 - 0.0 0.013 13 in in))
EM
C
*: Reference data at approximately 20 °C (68°F) D
E
F
G
H
I
J
K
L
M
Revision: May 2004
EM-47
2003 Altima
TIMING CHAIN [QR25DE]
TIMING CHAIN Removal and Installation
PFP:13028 EBS00DUF
WBIA0031E
1.
Oil rings
2.
Camshaft sprocket (INT)
3.
Camshaft sprocket (EXH)
4.
Chain tensioner
5.
Spring
6.
Chain tensioner plunger
7.
Timing chain slack guide
8.
Timing chain
9.
Front cover
10. Chain guide
11. IVT solenoid valve
12. IVT cover
13. Engine mounting bracket
14. Crankshaft pulley bolt
15. Crankshaft pulley
16. Front oil seal
17. Balancer unit timing chain tensioner
18. Oil pump drive spacer
19. Crankshaft sprocket
20. Timing chain tension guide
21. Balancer unit timing chain
22. 22. Bala Balanc ncer er unit unit
CAUTION: Apply new engine oil to parts parts marked in illustration before installation. Revision: May 2004
EM-48
2003 Altima
TIMING CHAIN [QR25DE] REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. a. b. 12.
A
Support Support the the engine engine and transaxle transaxle assembly assembly with suitab suitable le tools. tools. Remo Re move ve RH spl splas ash h shie shield ld.. Remove Remove the the upper upper and lower oil pan, pan, and and oil strainer strainer.. Refer Refer to to EM-25, "Removal and Installation" . Remo Re move ve gene generat rator or.. Ref Refer er to SC-33, "Removal" . Remo Re move ve engi engine ne cove coverr. Disconnect Disconnect variable variable timing timing control control solenoid solenoid harness harness connect connector or.. Remo Re move ve engi engine ne grou ground nd.. Remove Rem ove the cool coolant ant overfl overflow ow reser reservoi voirr tank. tank. Position Position the the RH engine engine compart compartment ment fuse and relay relay box aside. aside. Remove Remove the RH engine engine mount mount and bracket. bracket. Refer Refer to EM-72, "Removal and Installation" . Remove Remove the IVT (intake (intake valve timing) timing) control control cover. cover. Loosen Loo sen bolts bolts in in the the numer numerica icall order order as as shown shown.. Remove Rem ove the the cover cover with with suit suitabl able e tool tool to cut the seal sealant ant.. Pull chain guide guide between camshaf camshaftt sprockets sprockets out through through front cover.
EM
C
D
E
F
G WBIA0027E
H
13. Set the No.1 cylinder at TDC on the compression stroke with the following procedure: a. Rota Rotate te the the cranks crankshaft haft pulley clockwise clockwise and align align the mating mating marks to the timing indicator on the front cover.
I
J
K KBIA0190E
b.
At tthe he same same time, time, make make sure sure that that the the mating mating marks on the the camcamshaft sprockets are lined up as shown. q If not lined up, rotate the crankshaft pulley one more turn to line up the mating marks to the positions as shown.
L
M
KBIA0115E
Revision: May 2004
EM-49
2003 Altima
TIMING CHAIN [QR25DE] 14. Remove Remove crankshaft crankshaft pulley with with the following following procedure: procedure: a. Hold the cranks crankshaft haft pulley with a suitable suitable tool, then loosen loosen the crankshaft pulley mounting bolt, and pull the pulley out about 10 mm (0.39 in).
KBIA0077E
b.
Attach Attach a pulley puller in the the M 6 (0.24 in diameter diameter)) thread thread hole on crankshaft pulley, and remove crankshaft pulley.
KBIA0078E
15. Remove Remove the front cover cover with the followin following g procedure: procedure: a. Loosen Loosen the mounting mounting bolts bolts in the revers reverse e order order shown shown in the the figfigure, and remove them. b. Re Remo move ve the the fron frontt cove coverr. CAUTION: q Be careful not to damage the mounting surface. 16. If the front front oil seal needs to be replaced, lift it out with a screwdriver to remove it.
WBIA0032E
17. Remove Remove timing chain chain with the followin following g procedure: procedure: a. Push in the tensioner tensioner plunger. plunger. Insert Insert a stopper stopper pin into the the hole hole on the tensioner body to hold the chain tensioner. q Use a wire of 0.5 mm (0.02 in) diameter as a stopper pin. b. Re Remo move ve the the cha chain in tten ensi sion oner er..
KBIA0048E
Revision: May 2004
EM-50
2003 Altima
TIMING CHAIN [QR25DE] c.
Secure Secure hexa hexagona gonall part part of th the e camsha camshaft ft wi with th a wrench wrench and and loosen the camshaft sprocket mounting bolt and remove the camshaft sprocket for both camshafts. CAUTION: q Do not rotate the crankshaft or camshafts while the timing chain is removed. It can cause damage to the valve and piston.
A
EM
C
KBIA0049E
D
18. Remove the chain slack guide, tension tension guide, timing chain, and oil pump pump drive spacer. spacer. E
19. Remove Remove the timing chain chain tensioner tensioner for the balancer balancer unit with the the following procedure: a. Lift the tensioner tensioner lever lever up, a and nd release release the ratch ratchet et claw claw for for installation. b. Push Push tens tensione ionerr sleev sleeve e in, in, and and hold hold it. it. c. Matching Matching the the hole hole on lever with the one one on body, body, insert insert a stopper stopper pin to secure tensioner sleeve. d. Remove Remove the the timing timing chain chain tensioner tensioner for the balancer balancer unit. unit. 20. Remove Remove timing chain chain for balancer unit unit and crankshaft crankshaft sprocket. sprocket.
F
G
KBIA0121E
21. Loosen mounting mounting bolts bolts in reverse reverse order shown shown in the figure, and remove balancer unit. q Use Torx socket (size E14) CAUTION: q Do not disassemble balancer unit.
H
I
J
K KBIA0122E
L
INSPECTION AFTER REMOVAL Timing Chain Check the timing chain for cracks or serious wear. If a defect is detected, replace it.
M
PBIC0282E
Revision: May 2004
EM-51
2003 Altima
TIMING CHAIN [QR25DE] Balancer Unit Mounting Bolt Outer Diameter q
q q
Measure outer diameters (d1, d2) at the two positions shown in the figure. Measure d2 within the range A. If the value difference (d1 - d2) exceeds the limit (a dimension difference is large), replace it with a new one. Limit
: 0.15 mm (0. 0059 in) or more
KBIA0126E
INSTALLATION NOTE: q There may be two color variations of the link l ink marks (link colors) on the timing chain. q There are 26 links between the gold/yellow mating marks on the timing chain; and 64 links between the camshaft sprocket gold/yellow link and the crankshaft sprocket orange/blue link, on the timing chain side without the tensioner. tensioner. 1. Make Make sure sure the cran cranksh kshaft aft key key point points s straig straight ht up. up. 2. Install Install the the balancer balancer unit and tighten tighten the mountin mounting g bolts bolts in the numerical order shown with the following procedure: CAUTION: q When reusing a mounting bolt, check its outer diameter before installation. Refer to EM-52, "Balancer Unit Mounting Bolt Outer Diameter" .
KBIA0122E
Balancer unit mounting bolts Step 1
: 45.2 - 51.0 N·m (4.6 - 5.2 kg-m, 34 - 37 ft-lb)
Step 2
: 90° - 95° degrees rotation (Target: 90° degrees)
Step 3 (Loosen in reverse order or tightening)
: 0 N·m (0 kg-m, 0 ft-lb)
Step 4
: 45.2 - 51.0 N·m (4.6 - 5.2 kg-m, 34 - 37 ft-lb)
Step 5
WBIA0154E
: 90° - 95° degrees rotation (Target: 90° degrees)
Apply new engine oil to threads and seating surfaces of mounting bolts. CAUTION: q Check tightening angle with an angle wrench or a protractor. Do not make judgment by visual check alone. q
Revision: May 2004
EM-52
2003 Altima
