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Removal and Installation: Removal

WARNING: This page is about a different car, the 2005 Nissan Xterra. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove engine room cover with power tool. Refer to "REMOVAL ".
  2. Release the fuel pressure. Refer to FUEL PRESSURE RELEASE .
  3. Drain engine oil. Refer to "CHANGING ENGINE OIL ".
    CAUTION:
    • Perform this step when engine is cold.
    • Do not spill engine oil on drive belts.
  4. Drain engine coolant from radiator. Refer to "DRAINING ENGINE COOLANT ".
    CAUTION:
    • Perform this step when engine is cold.
    • Do not spill engine coolant on drive belts.
  5. Remove radiator cooling fan assembly. Refer to "ENGINE COOLING FAN ".
  6. Separate engine harnesses removing their brackets from front timing chain case.
  7. Remove drive belts. Refer to "REMOVAL ".
  8. Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside. Refer to "REMOVAL ".
  9. Remove power steering oil pump bracket. Refer to "REMOVAL ".
  10. Remove alternator. Refer to "REMOVAL ".
  11. Remove water bypass hose, water hose clamp and idler pulley bracket from front timing chain case.
  12. Remove right and left intake valve timing control covers.
    • Loosen bolts in reverse order as shown below.
    • Cut liquid gasket for removal using Tool.

      Tool number: KV10111100 (J-37228) 

    CAUTION: Shaft is internally jointed with camshaft sprocket (INT) center hole. When removing, keep it horizontal until it is completely disconnected.
    Fig 1: Right And Left Intake Valve Timing Control Covers Bolts (With Tightening Sequence)
    G03606340Courtesy of NISSAN MOTOR CO., U.S.A.
  13. Remove collared O-rings from front timing chain case (left and right side).
    Fig 2: Locating O Ring
    G03606341Courtesy of NISSAN MOTOR CO., U.S.A.
  14. Remove rocker covers (right and left banks). Refer to "REMOVAL AND INSTALLATION ".
    NOTE: When only timing chain (primary) is removed, rocker cover does not need to be removed.
  15. Obtain No. 1 cylinder at TDC of its compression stroke as follows:
    NOTE: When timing chain is not removed/installed, this step is not required.
    1. Rotate crankshaft pulley clockwise to align timing mark (A) (grooved line without color) with timing indicator (B).
      Fig 3: Aligning Crankshaft Pulley Timing Mark (A) (Grooved Line Without Color) With Timing Indicator (B)
      G05880611Courtesy of NISSAN MOTOR CO., U.S.A.
    2. Make sure that intake and exhaust cam noses on No. 1 cylinder (engine front side of right bank) are located as shown below.
      • If not, turn crankshaft one revolution (360°) and align as shown below.
        NOTE: When only timing chain (primary) is removed, rocker cover does not need to be removed. To make sure that No. 1 cylinder is at its compression TDC, remove front timing chain case first. Then check mating marks on camshaft sprockets. Refer to "INSTALLATION ".
        Fig 4: Locating Intake And Exhaust Cam Noses On No. 1 Cylinder (Engine Front Side Of RH Bank)
        G03592407Courtesy of NISSAN MOTOR CO., U.S.A.
  16. Remove crankshaft pulley as follows:
    1. Remove starter motor and set Tool. Refer to "REMOVAL ".

      Tool number: KV10117700 (J-44716) 

      Fig 5: Setting Tool
      G03606344Courtesy of NISSAN MOTOR CO., U.S.A.
    2. Loosen crankshaft pulley bolt and locate bolt seating surface as 10 mm (0.39 in) from its original position.
      CAUTION: Do not remove crankshaft pulley bolt. Keep loosened crankshaft pulley bolt in place protect removed crankshaft pulley from dropping.
      Fig 6: Locating Crankshaft Pulley Bolt
      G03606345Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Pull crankshaft pulley with both hands to remove it.
  17. Loosen two bolts in front of oil pan (upper) in reverse order as shown below.
    Fig 7: Upper Oil Pan Bolts (With Tightening Sequence)
    G03592410Courtesy of NISSAN MOTOR CO., U.S.A.
  18. Remove front timing chain case as follows:
    1. Loosen bolts with power tool in reverse order as shown below.
      Fig 8: Front Timing Chain Case Bolts (With Tightening Sequence)
      G05880616Courtesy of NISSAN MOTOR CO., U.S.A.
    2. Insert suitable tool into the notch at the top of the front timing chain case as shown below (1).
    3. Pry off case by moving tool as shown below (2).
    • Cut liquid gasket for removal using Tool.

      Tool number : KV10111100 (J-37228) 

    Fig 9: Prying Off Case By Moving Tool
    G05880617Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION:
    • Do not use screwdriver or something similar.
    • After removal, handle front timing chain case carefully so it does not twist, bend, or warp under a load.
  19. Remove O-rings from rear timing chain case.
    Fig 10: Identifying Rear Timing Chain Case O-Rings
    G05880618Courtesy of NISSAN MOTOR CO., U.S.A.
  20. Remove water pump cover and chain tensioner cover from front timing chain case, if necessary.
    • Cut liquid gasket for removal using Tool.
  21. Remove front oil seal from front timing chain case using suitable tool.
    CAUTION: Be careful not to damage front timing chain case.
    Fig 11: Removing Front Oil Seal From Front Timing Chain Case
    G05880619Courtesy of NISSAN MOTOR CO., U.S.A.
  22. Use a scraper to remove all traces of old liquid gasket from front and rear timing chain cases and oil pan (upper), and liquid gasket mating surfaces.
    CAUTION: Be careful not to allow gasket fragments to enter oil pan.
    Fig 12: Removing All Traces Of Old Liquid Gasket From Front And Rear Timing Chain Cases
    G05880620Courtesy of NISSAN MOTOR CO., U.S.A.
    • Remove old liquid gasket from bolt hole and thread.
    Fig 13: Removing Old Liquid Gasket From Bolt Hole And Thread
    G05880621Courtesy of NISSAN MOTOR CO., U.S.A.
  23. Use a scraper to remove all traces of old liquid gasket from water pump cover, chain tensioner cover and intake valve timing control covers.
    Fig 14: Removing All Traces Of Old Liquid Gasket From Water Pump Cover
    G05880622Courtesy of NISSAN MOTOR CO., U.S.A.
  24. Remove timing chain tensioner (primary) as follows:
    1. Loosen clip of timing chain tensioner (primary), and release plunger stopper (1).
    2. Insert plunger into tensioner body by pressing slack guide (2).
    3. Keep slack guide pressed and hold plunger in by pushing stopper pin through the tensioner body hole and plunger groove (3).
      Fig 15: Locating Plunger Stopper, Slack Guide And Plunger Groove
      G05880623Courtesy of NISSAN MOTOR CO., U.S.A.
    4. Remove bolts and remove timing chain tensioner (primary).
  25. Remove internal chain guide, tension guide and slack guide.
    NOTE: Tension guide can be removed after removing timing chain (primary).
    Fig 16: Identifying Internal Chain Guide, Tension Guide And Slack Guide
    G05880624Courtesy of NISSAN MOTOR CO., U.S.A.
  26. Remove timing chain (primary) and crankshaft sprocket.
    CAUTION: After removing timing chain (primary), do not turn crankshaft and camshaft separately, or valves will strike the piston heads.
  27. Remove timing chain (secondary) and camshaft sprockets as follows:
    1. Attach suitable stopper pin to the right and left timing chain tensioners (secondary).
      NOTE:
      • Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a stopper pin.
      • For removal of timing chain tensioner (secondary), refer to "CAMSHAFT " [Removing camshaft bracket (No. 1) is required.]
      Fig 17: Attaching Stopper Pin To Right And Left Timing Chain Tensioners (Secondary)
      G03606356Courtesy of NISSAN MOTOR CO., U.S.A.
    2. Remove camshaft sprocket (INT and EXH) bolts.
      • Secure the hexagonal portion of camshaft using wrench to loosen bolts.
      CAUTION: Do not loosen bolts with securing anything other than the camshaft hexagonal portion or with tensioning the timing chain.
      Fig 18: Removing Camshaft Sprocket (INT And EXH) Bolts
      G03606357Courtesy of NISSAN MOTOR CO., U.S.A.
    3. Remove timing chain (secondary) together with camshaft sprockets.
      • Turn camshaft slightly to secure slackness of timing chain on timing chain tensioner (secondary) side.
      • Insert 0.5 mm (0.020 in)-thick metal or resin plate between timing chain and timing chain tensioner plunger (guide). Remove timing chain (secondary) together with camshaft sprockets with timing chain loose from guide groove.
        CAUTION: Be careful of plunger coming off when removing timing chain (secondary). This is because plunger of timing chain tensioner (secondary) moves during operation, leading to coming off of fixed stopper pin.
        Fig 19: Removing Timing Chain (Secondary) Together With Camshaft Sprockets
        G03606358Courtesy of NISSAN MOTOR CO., U.S.A.
        NOTE: Camshaft sprocket (INT) is a one piece integrated design sprockets for timing chain (primary) and for timing chain (secondary).
      • When handling camshaft sprocket (INT), be careful of the following:
        CAUTION:
        • Handle carefully to avoid any shock to camshaft sprocket.
        • Do not disassemble. (Do not loosen bolts "A" as shown).
        Fig 20: Identifying Bolt "A"
        G03606359Courtesy of NISSAN MOTOR CO., U.S.A.
  28. Remove water pump. Refer to "REMOVAL ".
  29. Remove rear timing chain case as follows:
    1. Loosen and remove bolts using power tool in reverse order as shown below.
    2. Cut liquid gasket using Tool and remove rear timing chain case.

      Tool number : KV10111100 (J-37228) 

    Fig 21: Rear Timing Chain Case Bolts (With Tightening Sequence)
    G04894086Courtesy of NISSAN MOTOR CO., U.S.A.
    CAUTION:
    • Do not remove plate metal cover of oil passage.
    • After removal, handle rear timing chain case carefully so it does not twist, bend, or warp under a load.
    Fig 22: Identifying Plate Metal Cover Of Oil Passage
    G04894087Courtesy of NISSAN MOTOR CO., U.S.A.
  30. Remove O-rings from cylinder head and camshaft bracket (No. 1).
    Fig 23: Identifying O-Rings Of Cylinder Head And Camshaft Bracket (No. 1)
    G04894088Courtesy of NISSAN MOTOR CO., U.S.A.
  31. Remove O-rings from cylinder block.
    Fig 24: Identifying O-Rings Of Cylinder Block
    G04878332Courtesy of NISSAN MOTOR CO., U.S.A.
  32. Remove timing chain tensioners (secondary) from cylinder head if necessary.
    1. Remove camshaft brackets (No. 1). Refer to "REMOVAL ".
    2. Remove timing chain tensioners (secondary) with stopper pin attached.
  33. Use scraper to remove all traces of old liquid gasket from front and rear timing chain cases, and opposite mating surfaces.
    Fig 25: Removing Traces Of Old Liquid Gasket
    G03592428Courtesy of NISSAN MOTOR CO., U.S.A.
    • Remove old liquid gasket from bolt hole and thread.
      Fig 26: Removing Old Liquid Gasket From Bolt Hole And Thread
      G03592429Courtesy of NISSAN MOTOR CO., U.S.A.
  34. Use scraper to remove all traces of liquid gasket from water pump cover, chain tensioner cover and intake valve timing control covers.
    Fig 27: Removing Traces Of Liquid Gasket
    G03592430Courtesy of NISSAN MOTOR CO., U.S.A.
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