Transcript
Classification:
Reference:
EM98-006
Date:
NTB98-094
November 15, 1998
FRONTIER TIMING CHAIN/FRONT COVER REVISED SERVICE PROCEDURE APPLIED ENGINE:
KA24DE
SERVICE INFORMATION A revised service procedure for the engine front cover/timing chain has been adopted for the KA24DE. It is no longer recommended to remove the cylinder head when removing the timing chain/front cover(s). Utilize the following steps when servicing the front cover, timing chain, guides or tensioner(s). SERVICE PROCEDURE CAUTION: • • • • •
After removing the timing chain, do not turn the crankshaft and camshaft separately or the valves will strike the piston heads. When installing chain tensioners or other sliding parts, lubricate contacting surfaces with new engine oil. Apply new engine oil to bolt threads and seat surfaces when installing the camshaft sprockets and the crankshaft pulley. Do not spill engine coolant on the drive belts. Please refer to the Service Manual for the correct tightening torque.
Removal of Upper Timing Chain: 1. 2. 3. 4. 5. 6.
Remove the air cleaner assembly, Remove the spark plug wires. Set #1 piston at TDC on its compression stroke. Remove vacuum hoses, electrical harness, connectors, and harness clamps. Remove the power steering belt. Remove the power steering pump and position it to the side. Remove the idler pulley and bracket as well. 7. Remove the rocker cover. 8. Remove camshaft sprocket cover.
1/8
9. Wipe off the links of the timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with the timing marks on the cam sprockets and idler sprocket (see Figure 1).
Figure 1 10. Remove cam sprocket bolts, cam sprockets and upper timing chain. 11. Support lower timing chain by using a suitable tool as shown in Figure 2 to avoid chain tensioner spring from coming out. NOTE: This step is only to be applied when the lower cover is not being removed.
Figure 2 12. Remove the idler sprocket.
2/8
Removal of Lower Timing Chain: 1. Drain coolant by removing the cylinder block drain plug and opening the radiator drain cock (Refer to MA section of the Service Manual). 2. Drain engine oil. 3. Remove the following parts: • Alternator & A/C compressor drive belts. • Cooling fan with coupling. • Radiator shroud. 4. Remove the A/C compressor and position it to the side. Remove the idler pulley and bracket as well. 5. Set #1 piston at TDC on its compression stroke. 6. Remove the distributor. 7. Remove the crankshaft pulley. 8. Remove the oil pan (Refer to "Removal" under "Oil Pan" in the Service Manual). 9. Remove the oil pump and distributor drive shaft, then the oil pickup strainer. 10. Remove the front cover. CAUTION: Be careful not to tear or damage the cylinder head gasket. 11. Remove the following parts: • Lower timing chain tensioner (push tensioner piston in and insert a suitable pin into the hole to retain the tensioner piston in the tensioner body). • Chain tension arm. • Lower timing chain guide. 12. Remove the upper timing chain (refer to "Removal of Upper Timing Chain" in this bulletin). 13. Wipe off the links of the timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with the timing marks on the crankshaft sprocket and idler sprocket (see Figure 3).
Figure 3 14. Remove the lower timing chain and sprocket.
3/8
Installation of Lower Timing Chain: 1. Install the crankshaft sprocket, making sure the mating marks face the front of the engine. 2. Install the idler sprocket and lower timing chain using the mating marks and the paint marks made during the removal process. CAUTION: Be careful not to tear or damage the cylinder head gasket. 3. Install chain guide and chain tension arm. 4. Install lower chain tensioner and remove the pin securing the piston into the tensioner body. 5. Front cover installation: a. Using a scraper or other suitable tool remove all traces of liquid gasket from the cylinder block and front cover mating surfaces. b. Install new crankshaft seal in front cover (see Figure 4).
Figure 4
4/8
c. Apply a continuous bead of RTV sealant to the front cover (see Figure 5). NOTE: Use Genuine Nissan RTV silicone sealant P/N 999MP-A7007, Three Bond P/N TB1207D or equivalent.
Figure 5 c. Also place RTV sealant on the head gasket surface. d. Install the front cover to the engine. 6. Install oil strainer and oil pan, referring to "Installation" in the "OIL PAN" section of the Service Manual. 7. Install the oil pump and distributor drive shaft. NOTE: Make sure the flat side of the distributor drive shaft is facing the engine (see Figure 6). Failure to do so will result in the distributor being out of time.
Figure 6 8. Install the following parts: a. Crankshaft pulley. b. A/C compressor and idler pulley bracket. c. Radiator shroud and cooling fan with coupling. d. A/C compressor, alternator and power steering pump drive belts. e. Air duct.
5/8
Installation of Upper Timing Chain: 1. Install the lower timing chain (refer to "Installation of Lower Timing Chain" in this bulletin). 2. Install upper timing chain and sprockets, using the painted reference marks made during removal. 3. Install chain tensioner. Remove the pin holding the tensioner piston in the bore of the tensioner. 4. Install camshaft sprocket cover: a. Use a scraper to remove all traces of liquid gasket from the mating surfaces of the engine block and camshaft sprocket cover. b. Apply a continuous bead of RTV sealant to the cover as shown in Figure 7. NOTE: Use Genuine Nissan RTV silicone sealant P/N 999MP-A7007, Three Bond P/N TB1207D or equivalent.
Figure 7 c. Also place RTV sealant on the head gasket surface. CAUTION: Be careful not to tear or damage the cylinder head gasket. CAUTION: Be careful upper timing chain does not slip or jump when installing the camshaft sprocket cover.
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d. Install camshaft sprocket cover. 5. Install rubber plugs into cylinder head after applying RTV sealant (see Figure 8).
Figure 8 6. Install rocker cover, tightening the bolts as shown in Figure 9.
Figure 9
7/8
7. Install distributor, aligning as shown in Figure 10.
Figure 10 8. Install vacuum hoses, electrical harnesses and connectors.
PARTS INFORMATION DESCRIPTION Genuine Nissan RTV sealant
PART #/PFP 999MP-A7007*
QUANTITY as needed
* Claim quantity/portion used with Expense Code 009. DO NOT put the sealant P/N on the claim.
CLAIMS INFORMATION Please reference the Revision B pages of the Nissan 1992-1999 Warranty Flat Rate Information Manual, Section AG, Op Codes AG14AA, AG143A, AG144A, AG22AA, and AG24AA. You will note that the descriptions and Flat Rate Times applicable to the D22 vehicle for these Op Codes have been revised to reflect this new procedure. Also note that Op Codes AG50AA and AG504A have been deleted.
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TIMING CHAIN
KA24DE
Components
Components
NEEM0091
AEM464
1. 2. 3. 4. 5. 6.
Upper timing chain tensioner Cam sprocket Upper timing chain Water pump Water pump pulley Crankshaft pulley
7. 8. 9. 10. 11. 12.
Front oil seal Front cover Camshaft sprocket cover Oil slinger Oil pump drive gear Lower timing chain
EM-20
13. 14. 15. 16. 17.
Crankshaft sprocket Chain guide Idler sprocket Chain tension arm Lower timing chain tensioner
TIMING CHAIN
KA24DE Components (Contd)
GI MA
LC EC FE
LIQUID GASKET APPLICATION PLACES
AEM470
CL
NEEM0091S01
MT AT TF PD AX SU BR ST RS BT HA
AEM479
SC EL
EM-21
IDX
TIMING CHAIN
KA24DE
Removal
Removal
NEEM0092
CAUTION: I After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads. I When installing chain tensioners or other sliding parts, lubricate contacting surfaces with new engine oil. I Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprockets and crankshaft pulley. I Do not spill engine coolant on drive belts.
UPPER TIMING CHAIN
NEEM0092S01
1. 2.
Remove the air cleaner assembly. Remove the spark plug wires.
3. 4.
Set No.1 piston at TDC on its compression stroke. Remove vacuum hoses, electrical harness connectors, and harness clamps. Remove the power steering belt. Remove the power steering pump and position it to one side. Remove the idler pulley and bracket as well.
5. 6.
WEM067
7. I
Remove the rocker cover. Remove in numerical order as shown.
8.
Remove the camshaft sprocket cover.
AEM356
AEM374
EM-22
TIMING CHAIN
KA24DE Removal (Contd)
9.
Wipe off the links of the timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with the timing marks on the cam sprockets and idler sprocket. 10. Remove cam sprocket bolts, cam sprockets and upper timing chain.
GI MA
LC
JEM547G
IDLER SPROCKET
NEEM0092S02
1.
Remove upper timing chain. Refer to UPPER TIMING CHAIN, Removal EM-22. 2. Support lower timing chain by using a suitable tool to prevent chain tensioner spring from coming out. NOTE: This step is only to be applied when the lower cover is not being removed. 3. Remove the idler sprocket.
EC
LOWER TIMING CHAIN
MT
1.
2. 3. I I I I 4. AEM480
5. 6.
CL
NEEM0092S03
Drain coolant by removing the cylinder block drain plug and opening the radiator drain cock. Refer to MA section of the Service Manual. Drain engine oil from drain plug of oil pan. Remove the following parts. Alternator drive belt. A/C compressor drive belt. Cooling fan with coupling. Radiator shroud. Remove A/C compressor and position it to the side. Remove the idler pulley and bracket as well. Set No. 1 piston to TDC on its compression stroke. Remove the distributor.
FE
AT TF PD AX SU BR ST RS
WEM067
BT HA SC EL
EM-23
IDX
TIMING CHAIN
KA24DE
Removal (Contd)
7. 8.
Remove the crankshaft pulley with suitable puller. Remove oil pan. Refer to Removal in OIL PAN (EM-18). 9. Remove the oil pump and distributor drive shaft, then the oil pickup strainer. 10. Remove the front cover. CAUTION: Be careful not to tear or damage the cylinder head gasket.
LEM115
11. Remove the following parts. I Lower timing chain tensioner (Push piston and insert a suitable pin into pin hole.) I Chain tension arm I Lower timing chain guide 12. Remove the upper timing chain and idler sprocket. Refer to UPPER TIMING CHAIN in Removal(EM-22) and IDLER SPROCKET (EM-23).
SEM796E
13. Wipe off the links of the timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with the timing marks on the crankshaft sprocket and idler sprocket. 14. Remove the lower timing chain and sprocket.
AEM482
Inspection
NEEM0093
Check for cracks and excessive wear at roller links. Replace chain if necessary.
AEM403
EM-24
TIMING CHAIN
KA24DE Installation
Installation LOWER TIMING CHAIN
NEEM0094 NEEM0094S01
1. I
SEM205C
Install crankshaft sprocket. Make sure that mating marks of crankshaft sprocket face front of engine. 2. Install the idler sprocket and lower timing chain using the mating marks and the paint marks made during the removal process. CAUTION: Be careful not to tear or damage the cylinder head gasket. 3. Install chain guide and chain tension arm. 4. Install lower chain tensioner and remove the pin securing the piston into the tensioner body.
GI MA
LC EC FE CL MT
5. I
SEM715A
Front cover installation: Using a scraper or other suitable tool remove all traces of liquid gasket from the cylinder block and front cover mating surfaces. I Install new crankshaft seal in front cover. I Apply a continuous bead of liquid gasket to front cover (Refer to EM-21). NOTE: Use Genuine Nissan RTV Silicone Sealant P/N 999MP-A7007 or equivalent. I Be sure to install new front oil seal. Refer to EM-28. I Also place RTV sealant on the head gasket surface. I Install the front cover to the engine. 6. Install oil strainer and oil pan. Refer to Installation in OIL PAN, EM-19.
AT TF PD AX SU BR ST RS
SEM292D
AEM391
7. Install the oil pump and distributor drive shaft. NOTE: Make sure the flat side of the distributor drive shaft is facing the engine. Failure to do so will result in the distributor being out of time. 8. Install the following parts: I Crankshaft pulley. I A/C compressor and idler pulley bracket. I Radiator shroud and cooling fan with coupling. I A/C compressor, alternator and power steering pump drive belts.
EM-25
BT HA SC EL IDX
TIMING CHAIN
KA24DE
Installation (Contd)
I
Air duct.
IDLER SPROCKET 1. 2.
UPPER TIMING CHAIN 1.
NEEM0094S02
Install lower timing chain. Refer to LOWER TIMING CHAIN, Installation. Install idler sprocket and bolt.
NEEM0094S03
Install lower timing chain and idler sprocket. Refer to LOWER TIMING CHAIN (EM-25) and IDLER SPROCKET ( EM-26) in Installation.
SEM548G
2.
SEM549G
Install upper timing chain and sprockets, referring to the painted marks made during removal. 3. Install chain tensioner. Remove the pin holding the tensioner piston in the bore of the tensioner. 4. Install camshaft sprocket cover: I Use a scraper to remove all traces of liquid gasket from mating surfaces of the engine block and camshaft sprocket cover. I Apply a continuous bead of RTV sealant to the cover. Refer to EM-21. I Also place RTV sealant on the head gasket surface. NOTE: Use Nissan Genuine RTV Silicone Sealant, Part No. 999 MP-A7007 or equivalent. CAUTION: I Be careful not to tear or damage the cylinder head gasket. I Be careful upper timing chain does not slip or jump when installing camshaft sprocket cover.
JEM547G
5. I
Install rubber plugs into cylinder head after applying RTV sealant. Refer to EM-21. Rubber plugs should be installed flush with the cylinder head surface.
SEM234EA
EM-26
TIMING CHAIN
KA24DE Installation (Contd)
6.
Install rocker cover. Tighten bolts in numerical order. : 8 - 11 N·m (0.8 - 1.1 kg-m, 69 - 95 in-lb).
GI MA
LC
AEM357
7. 8.
Install distributor, aligning as shown. Install vacuum hoses, electrical harnesses, connectors, and harness clamps.
EC FE CL MT
WEM067
AT TF PD AX SU BR ST RS BT HA SC EL
EM-27
IDX
TIMING CHAIN GI MA EM LC EC FE CL MT AT TF PD FA RA BR ST AEM464
1 s 2 s 3 s 4 s 5 s 6 s
Upper timing chain tensioner Cam sprocket Upper timing chain Water pump Water pump pulley Crankshaft pulley
7 s 8 s 9 s 10 s 11 s 12 s
Front oil seal Front cover Camshaft sprocket cover Oil slinger Oil pump drive gear Lower timing chain
13 s 14 s 15 s 16 s 17 s
Crankshaft sprocket Chain guide Idler sprocket Chain tension arm Lower timing chain tensioner
RS BT HA EL IDX
EM-17
TIMING CHAIN
AEM435
Liquid gasket application places
AEM377
AEM378
AEM486
EM-18
TIMING CHAIN Removal
GI
CAUTION: ● After removing timing chain, do not turn crankshaft and MA camshaft separately, or valves will strike piston heads. ● When installing chain tensioners or other sliding parts, lubricate contacting surfaces with new engine oil. EM ● Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprockets and crankshaft pulley. ● Do not spill engine coolant on drive belts.
LC
UPPER TIMING CHAIN 1. 2.
Remove the air cleaner assembly. Remove the spark plug wires.
EC FE CL MT
3. 4. 5. 6.
AT Set No.1 piston at TDC on its compression stroke. Remove vacuum hoses, electrical harness connectors, and harness clamps. TF Remove the power steering belt. Remove the power steering pump and position it to one side. Remove the idler pulley and bracket as well.
PD FA
WEM067
7. ●
Remove the rocker cover. Remove in numerical order as shown.
RA BR ST RS
AEM356
8.
Remove the camshaft sprocket cover.
BT HA EL IDX
AEM374
EM-19
TIMING CHAIN Removal (Contd) 9.
Wipe off the links of timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with the timing marks on the cam sprockets and idler sprocket. 10. Remove cam sprocket bolts, cam sprockets and upper timing chain.
JEM547G
IDLER SPROCKET 1.
Remove upper timing chain. Refer to Removal, Upper Timing Chain EM-19. 2. Support lower timing chain by using a suitable tool to avoid chain tensioner spring from coming out. NOTE: This step is only to be applied when the lower cover is not being removed. 3. Remove the idler sprocket.
LOWER TIMING CHAIN 1. 2. 3. ● ● ● ●
4.
Drain coolant by removing the cylinder block drain plug and opening the radiator drain cock. Refer to MA section of the Service Manual. Drain engine oil from drain plug of oil pan. Remove the following parts. Alternator drive belt. A/C compressor drive belt. Cooling fan with coupling. Radiator shroud. Remove A/C compressor and postion it to the side. Remove the idler pulley and bracket as well.
AEM480
5. 6. 7.
Set No. 1 piston to TDC on its compression stroke. Remove the distributor. Remove the crankshaft pulley.
WEM067
EM-20
TIMING CHAIN Removal (Contd) GI Remove oil pan. Refer to Removal in OIL PAN (EM-15). 9. Remove the oil pump and distributor drive shaft, the the oil MA pickup strainer. 10. Remove the front cover. CAUTION: EM Be careful not to tear or damage the cylinder head gasket. 8.
LC LEM115
EC 11. Remove the following parts. ● Lower timing chain tensioner (Push piston and insert a suitable pin into pin hole.) FE ● Chain tension arm ● Lower timing chain guide 12. Remove the upper timing chain and idler sprocket. Refer to Removal UPPER TIMING CHAIN (EM-19) and IDLER CL SPROCKET (EM-20). MT SEM796E
13. Wipe off the links of the timing chain next to the timing marks AT on the sprockets. Put paint marks on the timing chain, matching them with the timing marks on the crankshaft sprocket and TF idler sprocket. 14. Remove the lower timing chain and sprocket.
PD FA RA BR ST RS AEM482
Inspection
BT
Check for cracks and excessive wear at roller links. Replace chain if necesary. HA
EL IDX AEM403
EM-21
TIMING CHAIN Installation LOWER TIMING CHAIN 1.
Install crankshaft sprocket. Make sure that mating marks of crankshaft sprocket face front of engine. 2. Install the idler sprocket and lower timing chain using the mating marks and the paint marks made during the removal process. CAUTION: Be careful not to tear or damage the cylinder head gasket. 3. Install chain guide and chain tension arm. 4. Install lower chain tensioner and remove the pin securing the piston into the tensioner body.
●
SEM205C
5.
Front cover installation: Using a scraper or other suitable tool remove all traces of liquid gasket from the cylinder block and front cover mating surfaces. ● Install new crankshaft seal in front cover. ● Apply a continuous bead of liquid gasket to front cover (Refer to EM-25). NOTE: Use Genuine Nissan RTV Silicone Sealant P/N 999MP-A7007 or equivalent. ● Be sure to install new front oil seal. Refer to (EM-25). ● Also place RTV sealant on the head gasket surface. ● Install the front cover to the engine. 6. Install oil strainer and oil pan. Refer to Installation, OIL PAN (EM-16). ●
SEM715A
SEM292D
AEM391
7. Install the oil pump and distributor drive shaft. NOTE: Make sure the flat side of the distributor drive shaft is facing the engine. Failure to do so will result in the distributor being out of time. 8. Install the following parts: ● Crankshaft pulley. ● A/C compressor and idler pulley bracket. ● Radiator shroud and cooling fan with coupling. ● A/C compressor, alternator and power steering pump drive belts.
EM-22
TIMING CHAIN Installation (Contd) ●
Air duct
IDLER SPROCKET 1. 2.
Install lower timing chain. Refer to Installation, Lower Timing Chain. Install idler sprocket and bolt.
GI MA EM LC
UPPER TIMING CHAIN 1.
EC
Install lower timing chain and idler sprocket. Refer to Installation LOWER TIMING CHAIN (EM-22) FE andIDLER SPROCKET (EM-23).
CL MT SEM548G
2. 3. 4. ●
●
●
Install upper timing chain and sprockets, the painted reference marks made during removal. Install chain tensioner. Remove the pin holding the tensioner piston in the bore of the tensioner. Install camshaft sprocket cover: Use a scraper to remove all traces of liquid gasket from mating surfaces of the engine block and camshaft sprocket cover. Apply a continuous bead of RTV sealant to the cover. Refer to EM-18. Also place RTV sealant on the head gasket surface.
AT TF PD FA
SEM549G
RA
NOTE: Use Nissan Genuine RTV Silicone Sealant, Part No. 999 MP-A7007 or equivalent. BR CAUTION: ● Be careful not to tear or damage the cylinder head gasket. ● Be careful upper timing chain does not slip or jump when ST installing camshaft sprocket cover.
RS JEM547G
5. ●
Install rocker cover gasket. Apply liquid gasket to cylinder head and camshaft sprocket cover. Refer to EM-18.
BT HA EL IDX
EM-23
TIMING CHAIN Installation (Contd) 6.
Install rocker cover. Tighten bolts in numerical order. : 8 - 11 Nzm (0.8 - 1.1 kg-m, 69 - 95 in-lb).
7. 8.
Install distributor, aligning as shown. Install vacuum hoses, electrical harnesses, connectors and harness clamps.
AEM357
WEM067
EM-24
