9458

JUNE, 2003

ENGINE MECHANICAL SERVICE

EMTN9907B EMTI9902B

2

© 2003 Nissan North America, Inc.

All rights reserved. No part of thispublication may be reproduced in anyform without the prior written permissionof the publisher.

Printed in U.S.A.

First Printing: June, 2003

This book is designed for instructionaluse only for Nissan North America, Inc.,authorized dealers and their personnel.For additional information contact:

Nissan North America, Inc.Corporate Training OfficeTechnical Training18501 S. Figueroa St.Gardena, CA 90248-4500

This manual usespost consumerrecycled fibers

Corporate Training OfficeTechnical TrainingNissan North America, Inc. reserves the right to alter specifications or methods at any time.

3

ENGINE MECHANICAL SERVICECOURSE OBJECTIVES

Upon completion of this training program, you will be able to:

• Properly bleed all air from hydraulic valve lash adjusters.• Correctly adjust the valves of the SR20DE engine using special service tool

No. J38957-N.• Identify common engine noises and describe the most likely causes of each noise.• Use an ASIST terminal with Electronic Service Manual (ESM) to correctly identify an

engine assembly based on the Engine Identification Code and locate the properdiagnosis/repair sections, specifications and procedures applicable to the vehicle beingserviced.

• Perform a cooling system check for evidence of leaks, damage, or deterioration toassure proper cooling system performance.

• Perform an oil pressure test using a pressure gauge and interpret the results.• Use the CONSULT-II scan tool to verify proper operation of electronically-controlled,

liquid-filled engine mounts.• Use the CONSULT-II scan tool to perform basic function tests of the NCVCS on a

vehicle equipped with a VQ35DE engine.• Use a cylinder compression gauge, a cylinder leakage tester, a CONSULT-II scan tool

and the applicable Service Manual to perform an engine compression test and cylinderleakage test to determine the condition of the piston rings, valves and head gasketbased on specifications in the Service Manual.

• Remove and correctly install both left and right bank timing chains on a VK45DE engine(Infiniti technicians only).

• Remove and install the Primary and Secondary timing chains, chain guides and chaintensioners for the VQ35DE engine to assure the proper timing of the vehicle.

• Remove and install the cylinder head bolts using proper tools and procedures from theService Manual.

• Remove and install the water pump on a VQ35DE engine using proper tools andService Manual procedures.

• Correctly perform the valve inspection and adjustment on a QR25DE engine.• Review and understand the fundamentals of basic engine operation.• Perform a power balance test and use the results to determine if one or more cylinders

is misfiring.• Demonstrate the skills necessary to properly measure valve clearance, determine correct

specifications and adjust valve clearance on a QG18DE engine.• Demonstrate the skills necessary to properly remove and install the timing chains on a

QR25DE engine (Nissan technicians only).

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NOTES

SECTION

1

TEXT

1

TABLE OF CONTENTS

INTRODUCTION ....................................................................................................................3ENGINE THEORY ..................................................................................................................3

Basic Components ...................................................................................................................... 3Four-Stroke Engine Cycle .......................................................................................................... 3Lower End ...................................................................................................................................... 4Sealing the Combustion Chamber ........................................................................................... 4Upper End ...................................................................................................................................... 5Intake System ................................................................................................................................ 5Timing System............................................................................................................................... 5Lubrication System ...................................................................................................................... 6Cooling System ............................................................................................................................ 6

PRECISION TOOLS ......................................................................................................................... 7Mechanical and Electronic Micrometers ................................................................................ 7Dial Indicators................................................................................................................................ 7Vernier Calipers ............................................................................................................................ 8Dial Calipers .................................................................................................................................. 8Torque Angle Gauge ................................................................................................................... 9Bore Gauge (Cylinder Gauge/Telescoping Gauge) ............................................................ 9Straight Edge/Feeler Gauges ................................................................................................... 9Plastigage..................................................................................................................................... 10

USE OF REQUIRED TOOLS........................................................................................................ 10Belt Tension Gauge ................................................................................................................... 10Valve Shim Gauge Plate Kit ..................................................................................................... 11CONSULT-II ................................................................................................................................. 11

BLOCK INSPECTION PROCEDURES ..................................................................................... 12Block Distortion .......................................................................................................................... 12Piston-to-Bore Clearance ........................................................................................................ 12Cylinder Taper ............................................................................................................................. 13Cylinder Out-of-Round ............................................................................................................. 13Piston Ring Side Clearance..................................................................................................... 13Piston Choice in Case of Cylinder Re-boring ..................................................................... 14

CRANKSHAFT INSPECTION PROCEDURES........................................................................ 14Visual ............................................................................................................................................. 14Runout ........................................................................................................................................... 14End Play ........................................................................................................................................ 15

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Journal Out-of-Round and Taper ............................................................................................ 16CAMSHAFT INSPECTION PROCEDURES ............................................................................. 17

Runout Measurement ................................................................................................................ 17End Play Measurement ............................................................................................................. 17Sprocket Runout ........................................................................................................................ 17Cam Height & Cam Journal Clearance ................................................................................. 17Cam Journal Clearance ............................................................................................................. 18

CONNECTING ROD BEARING CLEARANCE ADJUSTMENT .......................................... 18Measuring Clearance with a Micrometer .............................................................................. 19VG30E Engine ............................................................................................................................ 19VG30DE and VE30DE Engines ............................................................................................. 19VQ30DE, KA24DE, KA24E, GA16DE, SR20DE Engines .............................................. 20Determining the Clearance Using a Plastigage Kit ............................................................ 20Connecting Rod Bushing Clearance ..................................................................................... 20

CYLINDER HEAD TORQUING .................................................................................................... 20OPERATION AND DIAGNOSIS OF ELECTRONIC LIQUID ENGINE MOUNTS.......................... 21ENGINE COOLING SYSTEM....................................................................................................... 21TESTING ENGINE COMPRESSION AND LEAKAGE .......................................................... 22

Engine Compression ................................................................................................................. 22Cylinder Leakage ........................................................................................................................ 23

LOCATING THE SOURCE OF ENGINE NOISES.................................................................. 23VG33E Piston Choice............................................................................................................... 24VQ30 Timing Chain Noise ....................................................................................................... 24SR20DE Shower Rail ................................................................................................................ 24

NISSAN CONTINUOUSLY VARIABLE TIMING CONTROL SYSTEM (NCVCS) .......................... 26System Description.................................................................................................................... 26Component Description............................................................................................................ 27New Diagnostic Trouble Codes .............................................................................................. 28Specification Data ...................................................................................................................... 28On Board Diagnostic Logic ..................................................................................................... 28

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ENGINE MECHANICAL SERVICE

INTRODUCTION

Welcome to Nissan North America’s Engine Mechanical Service Training Course. In thiscourse, you’ll learn engine theory, the type of precision tools and specific procedures you’llneed to properly diagnose and service Nissan/Ininiti engines.

ENGINE THEORY

Basic Components

A basic four-cycle engine consists of a cylinder block, cylinder head, crankshaft, connectingrod, piston, camshaft, lifter, push rod, rocker arm, valves, and valve springs.

Crankshaft rotation moves the piston up and down in the cylinder. The camshaft opens thevalves; valve springs close the valves.

Four-Stroke Engine Cycle

The intake, compression, power, and exhaust strokes define one complete four-stroke cycle. Atthe top of the intake stroke (1A), the cam and lifter arrangement opens the intake valve. As thepiston moves down, a fresh air and fuel charge is drawn into the cylinder. At the bottom of theintake stroke (1B), the valve spring closes the intake valve to seal the chamber.

The crankshaft drives the piston upward to compress the air/fuel charge (2A). Near the top ofthe compression stroke, a spark jumps the spark plug gap, igniting the compressed charge(2B).

1A 1B 2A 2B

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The fuel burns rapidly, driving the piston down the cylinder (3A). At the bottom of the powerstroke, the exhaust valve opens (3B). The upward stroke of the piston pushes spent exhaustgases from the cylinder (4). When the exhaust valve closes, the cylinder is ready for anothercycle.

3A 3B 4

Lower End

The cylinder block is the engine’s foundation, allowing the crankshaft to rotate while the pistonreciprocates. All components either move within, or attach to, the cylinder block.

The piston moves up and down in the cylinder. The connecting rod attaches to the piston andto the crank pin. Connecting rods must be light, yet very strong. The crankshaft rotates in thelowermost portion of the block, changing reciprocating piston movement into a rotationalturning force that is used by the drive train and wheels.

Some engines have a camshaft mounted in the cylinder block. The camshaft has machinedintake and exhaust lobes to move valve lifters and push rods. Push rods rotate a rocker arm toopen the valve. Springs are used to close the valve.

During the power stroke, heat from combustion quickly increases gas pressure within thecylinder. Heated, expanding gas pressure is the force that actually moves the piston down thecylinder.

Sealing the Combustion Chamber

Although expanding gas forces the piston down the cylinder, some gas does escape betweenthe piston and the cylinder wall. If enough gas escapes, a good portion of the usable pressureis no longer available to push the piston down the cylinder. The solution to this problem is toseal the chamber with compression rings. Plated rings fit in piston grooves. The edges of therings ride along on the cylinder wall.

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Combustion pressure actually pushes the ring down in its groove and out to the cylinder wall,forming the seal. Compression rings greatly reduce exhaust gas loss. An oil control ring set issimilarly used to scrape excess oil from the cylinder wall.

Upper End

The upper end of the engine consists of the cylinder head, camshaft, and the valve traincomponents. The cylinder head bolts to the cylinder block, and is sealed to the block with ahead gasket. The cylinder head holds the valve faces and the spark plug.

The top of the head holds the intake and exhaust valves and springs, and one or twocamshafts, depending on the design. A cylinder head with one camshaft is known as an OverHead Cam, or OHC, engine. OHC engines use rocker arms to operate the valves.

A cylinder head with two camshafts is known as an Dual Over Head Cam, or DOHC, engine.DOHC engines, the camshaft lobes are direct-acting on the valves. (Push rods are used onlyon engines where the camshaft is mounted in the cylinder block).

Intake System

The intake system delivers air to the cylinder in the most efficient manner. In most fuel injectedengines, air and fuel mix just before entering the combustion chamber.

Timing Systems

The purpose of the timing system is to rotate the camshaft in the proper relation to thecrankshaft so that valves open and close at the correct time. Belt-drive timing systems areused in OHC engines. The belt is usually a reinforced rubber compound that is both strong andquiet. A spring-loaded belt tensioner is used to maintain correct tension.

V8, V6 and some 4-cylinder engines use chains to drive the camshaft. Tension is maintained bychain guides and a hydraulic chain tensioner. The hydraulic tensioner adjusts tension accordingto engine speed.

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Lubrication System

Engine oil is drawn from the sump by the oil pickup. The oil is filtered before being pumped intothe engine under pressure to lubricate moving parts. Lubrication galleries are cast into thecylinder block to feed oil quickly throughout the engine.

Cross-drilled crankshaft passages run the length of the crankshaft. Oil enters at the mainbearings and exits to lubricate connecting rod bearing surfaces. The piston is lubricated bypressurized oil that sprays from a connecting rod “squirt-hole.” Oil is used to lubricates thecylinder wall and to cool the bottom of the piston.

Timing chain assemblies are lubricated by oil draining from the head, and by an oil slinger onthe crankshaft nose.

The valve train in the cylinder head also requires lubrication. Engines with block-mountedcamshafts pump oil up through valve lifters and hollow push rods so that oil flows onto therocker arms to lubricate the valve stem tip and rocker arm pivot.

Cooling System

The water pump impeller draws coolant from the radiator outlet and pumps the coolantthroughout the block. Engine temperature is regulated by the thermostat. When the engine iscold, coolant flow is directed through a bypass circuit back into the engine until operatingtemperature is reached. The wax-pellet thermostat opens at about 190 degrees Fahrenheit.

Coolant passages are cast into the block to allow circulation around each of the cylinders, upthrough the cylinder head, to the radiator for cooling and back via the water pump.

The heater circuit utilizes the heat stored in the engine coolant to warm the passengercompartment. The heater core resembles a small radiator. Coolant circulates through theheater core and back to the engine block. A blower motor fan pushes air across the heatercore. The moving air is warmed by the heater core.

7

PRECISION TOOLS

Precision measuring tools are used extensively for engine work. It is important that you bethoroughly familiar with these tools to assure accurate measurements. In the exercises you willcomplete during this class, you will practice the use of micrometers, dial indicators, verniercalipers, torque angle gauges, and feeler gauges.

Mechanical and Electronic Micrometers

The outside micrometer is used to measure thediameter of many engine parts. It is available inmany different sizes and forms and may use eitherthe English or Metric measuring system. You canalso use a digital micrometer, which is much easierto read.

A micrometer generally provides greater precisionthan a vernier caliper, but has a smaller range. Touse a micrometer, place the part in the opening.Next, turn the thimble until the spindle contacts thework. To apply a consistent pressure to the part,use the ratchet stop. Use the clamp ring to hold thethimble in place while you read the micrometer. Toread the micrometer:

• Read the exposed number on the barrel.

• Read the number of divisions past the number. One division is 0.635 mm (0.025 in).

• Read the division on the spindle. These usually read to less than 0.025 mm (onethousandth of an inch).

Dial Indicators

Dial indicators are commonly used to measure valve lift,shaft runout, and cylinder taper, among many otherthings. Dial indicator faces are calibrated in thousandthsof an inch or in millimeters. There is a wide variety ofadapters and mounting arms available so that you canuse the same indicator in many applications.

The most important point when using a dial indicator is tobe certain that the tool is firmly mounted and that theactuating rod is parallel to the plane of movementmeasured.

8

Vernier Calipers

Measuring instruments using a vernier scale havetwo engraved scales that lie alongside each other.

The longer scale on the beam of the instrument isgraduated in actual measurements, eithermillimeters or fractions of an inch. The shorter scaleslides along the beam and is called the vernierscale. Its divisions are slightly smaller than thedivisions on the beam.

The beam is a straightforward measuring rule andthe sliding vernier scale is a device for taking anaccurate reading from the rule.

A vernier caliper consists of two basic parts:

• A beam with a jaw at right angles (the beam jaw)

• A moveable jaw that slides along the beam.

There may also be a block connected to the moveable jaw by a screw. This block can be fixedin position on the beam using the clamping screw. The fine adjustment wheel can then makesmall adjustments to the position of the moveable jaw. Most calipers have separate internaljaws.

Dial Calipers

Dial calipers are similar to vernier calipers except forthe method of reading the dimension. Dial calipershave a circular scale similar to a dial indicator forthe fine reading in addition to a vernier scale withlarger divisions. Dial calipers are easier to read thanvernier calipers, but are more expensive.

9

Torque Angle Gauge

In certain cases the procedure for tighteningcylinder head bolts requires you to tighten the boltsa certain number of degrees after torquing them tospecification. A torque angle gauge helps you todo this accurately. The gauge connects to aratchet between the socket and the extension, andshows you the angle to which you are torquing thebolt.

Bore Gauge (Cylinder Gauge/TelescopingGauge)

A bore gauge is used for precision measurement ofcylinder bores. It is a T-shaped device with spring-loaded anvils that can be locked into position. You

lower the gauge into a bore, make sure the gauge shaft is vertical, unlock the anvils and readthe bore diameter on the attached dial indicator. It is best to do this at several points in thebore to check for roundness and taper. Older style bore gauges required to you lock theanvils into place, remove the gauge and determine the bore diameter by measuring the anvillength with a micrometer. Current bore gauge designs incorporate a dial indicator display thateliminates this step.

Straight Edge/Feeler Gauges

Use a heavy straightedge and a feelergauge to measure cylinder block andhead distortion. Clean the facethoroughly prior to measuring thesurface distortion. Check the flatnessat both edges and from corner tocorner in an X pattern by laying thestraightedge across the surface andslipping a feeler gauge between them.You can find specifications in theservice manual.

CHECK FOR WARPAGE OF SURFACE

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PlastigageTM

PlastigageTM is a flexible, thread-like putty used tomeasure crankshaft bearing clearances. Place astrip of PlastigageTM lengthwise in the center of ajournal, install the bearing cap and tighten the boltsto the correct specifications. When you remove thecap, you will find that the PlastigageTM has beenflattened. Compare the width of the flattenedPlastigageTM strip to the scale on the PlastigageTM

pack to read the bearing clearance.

USE OF REQUIRED TOOLS

Belt Tension Gauge

The easiest and most accurate way to check an accessory belt’stension is with a belt tension gauge. With the belt installed onthe engine, place the gauge on the belt between two pulleys.Read the gauge to measure the amount of belt deflection, andcompare the reading to the chart provided. The tighter the beltis, the less deflection there will be.

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Valve Shim Gauge Plate Kit

To correctly check and adjust the valve clearanceon the SR20DE engine, you need to use specialtool J38957-N and a dial indicator. This toolconsists of a plate that is bolted on the cylinderhead, after removing the camshafts.

Detailed instructions for using the valve shimgauge plate are in the appropriate exercise, laterin this course in Module 9.

CONSULT-II

CONSULT-II with converter is the diagnostic scan toolused exclusively with Nissan and Infiniti vehicles. It isfully OBD II compatible and has a wide range offunctions.

Special Tool:J38957-N Valve ShimGauge Plate Kit

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BLOCK INSPECTION PROCEDURES

Block Distortion

Engine block distortion is measured across the face ofthe block, where the head(s) mount, using a heavystraightedge and a feeler gauge. Clean the facethoroughly before you measure surface distortion.Check the face flatness at both edges and from cornerto corner in an X pattern, as shown.

Piston-to-Bore Clearance

During engine operation, the piston rings can gradually change the dimensions of the cylinderwalls. This in turn affects the way the pistons fit in the cylinder bores, and harms compressionand engine power. When overhauling an engine you must measure all the cylinders for taperand out-of-round with a bore gauge. You can find the specifications in the EM section of theService Manual, under Cylinder Block Inspection. If any of the cylinders are out ofspecification, you must re-bore all the cylinders. You’ll also need to replace the pistons withlarger ones. In some circumstances where the cylinders can’t be re-bored, you will need toreplace the block.

Check the piston-to-bore clearance by measuring thepiston skirt diameter at the point specified in the EMsection of the Service Manual and comparing it to thecylinder bore diameter. Subtract the skirt diameter from thebore diameter. The clearance specification is in the EMsection of the service manual under Cylinder BlockInspection, Piston-to-bore Clearance.

Cylinder Taper

As a result of cylinder pressure, temperature, and lubrication, thecylinder wears more at the top of the piston travel than at thebottom. This reduction in the wear pattern down the cylinderwall is called taper.

Measure the bottom and top of each of the cylinders at rightangles to the centerline of the crankshaft. Subtract the bottomdiameter measurement from the top diameter measurement todetermine the amount of cylinder taper.

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Cylinder Out-of-Round

As a result of the side thrust forces generated bycombustion on the piston, the cylinder walls canwear until they are no longer round. This canprevent the piston rings from properly sealing.

To determine whether the cylinders are out-of-round, use a bore gauge at the area of greatestwear at right angles to the crankshaft and in linewith the crankshaft. Subtract the smallestmeasurement from the largest measurement.

Piston Ring Side Clearance

The piston rings must fit properly in their grooves,being neither too tight nor too loose. Measure pistonring side clearance with a feeler gauge. You will findthe specifications in the EM section of the servicemanual, under Cylinder Block Inspection. Install therings in the pistons, then measure between the ringand the groove with the feeler gauge.

Ring

Feeler Gauge

NG

Feeler gauge

OK

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Piston Choice in Case of Cylinder Re-boring

You will need to replace the pistons if you have to re-bore the cylinders. Oversized pistons areavailable for service. Before re-boring the cylinders look in the Service Data and Specificationsat the rear of the EM section of the service manual to determine which oversized pistons areavailable. Be sure to check with your parts department to ensure that you can obtain thecorrect pistons before you begin boring the cylinders.

CRANKSHAFT INSPECTION PROCEDURES

Visual

When you inspect the crankshaft, pay particular attention to the journal surfaces. Excessivewear may be the result of oil passage obstructions. Be sure to examine the oil passage supply.Scoring can also result from abrasive material in the oil supply. Examine the engine oil forevidence. Uneven wear patterns can indicate bent rods or a bent crankshaft.

Runout

The crankshaft can warp in operation. You candetermine how straight the crankshaft is bymeasuring its runout. Place the crankshaft in a set ofV-blocks and mount a dial indicator with the rodperpendicular to each of the main journals. Rotatethe crankshaft in the V-blocks and read the amount ofrunout on the dial indicator, measuring at the centerof each main journal. You can find crankshaft runoutspecifications in the EM section of the service manualunder Cylinder Block Inspection, Crankshaft.

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End Play

End play is a measurement of how much the crankshaft can move back and forth in thecylinder block.

To measure crankshaft end play:

• Install the main bearings in their properpositions on the cylinder block

• Install the crankshaft

• Install the main bearing caps or bearingbeam and torque them to specifications

• Turn the crankshaft by hand to ensurethat it is properly positioned

• Mount the dial indicator on the end ofthe crankshaft, with the indicator rodparallel to the crankshaft

• Use a large screwdriver or other tool toshift the crankshaft back and forth, andmeasure the amount of end play shownon the dial indicator

Journal Out-of-Round and Taper

The crankshaft bearings maintain a film of oil between the bearing surface and the crankshaftjournal. This oil prevents actual contact between the two parts. The clearance is extremelyimportant to prevent wear and damage to the crankshaft due to insufficient lubrication.

The lubricating system of the vehicle feeds oil through oil holes to the main bearings where therotating journals distribute it to all parts of the bearings. The connecting rod bearings arelubricated through oil holes in the crankshaft. Oil moves across the face of the bearings toprevent wear and cool the bearing.

Journals wear in two ways. They may wear out-of-round or they may wear unevenly across thejournal face (taper). If the connecting rod bearing journal were out-of-round or if the journaltaper were out of specification the result could be crankshaft wear between the crank and thebearing or damage to the connecting rod.

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Journal Out-of-Round and Taper

The crankshaft bearings maintain a film of oil between the bearing surface and the crankshaftjournal. This oil prevents actual contact between the two parts. The clearance is extremelyimportant to prevent wear and damage to the crankshaft due to insufficient lubrication.

The engine lubricating system feeds oil through oil holes to the main bearings where therotating journals distribute it to all parts of the bearings. The connecting rod bearings arelubricated through oil holes in the crankshaft. Oil moves across the face of the bearings toprevent wear and cool the bearing.

Journals wear in two ways: They may wear out-of-round, or they may wear unevenly across thejournal face (taper). Crankshaft wear between the crank and the bearing or damage to theconnecting rod may occur if the connecting rod bearing journal is out-of-round or if the journaltaper is out of specification.

Check the engine block’s line bore if you see evidence of out-of-round or taper on a mainbearing journal. Send the crankshaft and/or block to a machine shop to have it checked if youfind that either out-of-round or taper are not within specifications.

Use a micrometer to check the main andconnecting rod journals for out-of-round andtaper.

• Measure out-of-round at right angles to thecenterline of the crankshaft (X and Y on theillustration).

• Measure taper in line with the crankshaftcenterline at the two outer edges of thejournal (A and B on the illustration).

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CAMSHAFT INSPECTION PROCEDURES

Cylinder head distortion or excessive heat in the cylinder head may result in warping of thecamshaft. Runout (contour) measurements provide information about the condition of thecamshaft with regard to how much bend (warpage) has occurred in the camshaft. Camshaftend play measurements provide information on how much axial movement exists in the cylinderhead.

Runout Measurement

Camshafts can warp through normal engine wear.Measuring camshaft runout provides an indicationof camshaft straightness. To measure thecamshaft, placed it on a set of V-blocks with a dialindicator. Mount the indicator rod at a 90o angle tothe center camshaft journal.

A camshaft that is out of specification must bereplaced. Excessive camshaft runout can causedamage to the cylinder head and valve train.

End Play Measurement

End play measurements provide information aboutthe condition of the camshaft with regard to howmuch camshaft movement (play) is present in thecylinder head. A dial indicator is used to measureend play.

End play is measured with the camshaft installed inthe cylinder head. To measure camshaft end play, adial indicator is mounted with the indicator rodparallel to the direction of movement to bemeasured.

In most cases, excessive end play requires that the camshaft be replaced. However, somecamshafts with excessive end play measurements may be shimmed using spacers called locateplates. The locate plates are available in different sizes to compensate for the excessive endplay to bring play within specification.

➤

➛

➛

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Sprocket Runout

Check camshaft sprocket runout prior toreinstalling the cylinder head. When measuringsprocket runout, take care not to mistake camendplay for sprocket runout. Measure the runoutusing a dial indicator.

Cam Height & Cam Journal Clearance

Proper valve operation affects engine combustion and driveability. Worn cam lobes may resultin reduced valve opening which can cause improper engine combustion and increasedemissions.

Cam height and cam journal clearance are important aspects ofcamshaft inspection and cylinder head service and can be performedwhile the cylinder head is disassembled.

Use an outside micrometer to measure cam height. The wear limitspecification is stated in the Service Manual. If the cam exceeds thelimit specification, the camshaft should be replaced.

Cam Journal Clearance

Cam journal clearance measurements may help determine if the cylinder head requires alignboring with new cam bearings or if the cylinder head must be replaced. Installing newcamshaft bearings in the cylinder head may be all that is required to repair the journalclearances.

Visual inspection of the camshaft journals may show obvious signs of scratches or excessivewear.

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Two separate measurements are necessary to calculate camshaft journal clearance. The first isto measure the diameter of the camshaft bearings in the cylinder head. The secondmeasurement is the actual camshaft journal diameter. The difference between the twomeasurements is the camshaft journal clearance.

To measure the cylinder head, a camshaft bracket must be installed and tightened to theproper torque specification. A telescopic bore gauge measures the inner diameter of each ofthe camshaft bearings. Record the measurements of each cam bearing journal.

To measure the camshaft journal, use an outsidemicrometer. Record the cam journal measurements.Subtract the outside cam journal measurement fromthe inner diameter measurement for each of thecamshaft bearings to obtain the cam journal clearance.

If any of the cam bearing measurements areexcessive, the camshaft is worn and should bereplaced.

➡

➛ ➛ ➛ ➛

➛ ➛

➛ ➛

4

A B

321

➛

➛

➛

➛

End Play

Bolt

Camshaft

Locate

Plate

Unit:

mm (in)0.02

(0.0008)0.03

(0.0012)0.06

(0.0024) Engine Rearside Identification

Mark CNo Identifica-tion Mark

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CONNECTING ROD BEARING CLEARANCE MEASUREMENT

Connecting rods provide the link between the piston and crankshaft. Connecting rods have abearing at each end; one fits to the piston pin, the other to the crankshaft connecting rodjournal. These bearings are lubricated with engine oil under pressure that prevents metal-to-metal contact, engine wear, and noise. Repairing engines requires that the connecting rods bechecked.

To check the rods, use an inside micrometer, an outside micrometer, and PlastigageTM. This ismandatory in order to select the correct size, or grade, of connecting rod bearing. Rod bearingselecting is critical to professional engine repair.

Measuring Clearance with a Micrometer

The most accurate method for measuring connecting rod bearings is with an inside and outsidemicrometer. The measurements are used to calculate the amount of clearance that is filledwith pressurized engine oil. The larger, or “big end” of the connecting rod accommodates rodbearings for attachment to the crankshaft. The “small and” of the connecting rod contains abushing for the piston wrist pin.

Use an outside micrometer to measure the crankpin journal. Use an inside micrometer tomeasure the diameter of the big end’s bearing surface. Subtract the crankpin journal diametermeasurement from the big end bearing journal diameter measurement to get the big endbearing clearance.

A similar procedure is conducted at the small end. Measure the diameter of the piston wristpin with an outside caliper. Measure the small end bore with an inside micrometer. Subtractthe wrist pin measurement from the small end bore measurement to obtain the clearance.

If the clearance is excessive at the big end, the crankshaft should be refinished or replaced anda new connecting rod bearing must be installed in the connecting rod. Before final assembly,check actual bearing clearance with PlastigageTM (as previously described) to ensure correctclearances.

If the clearance is excessive at the small end, the piston and wrist pin assembly should bereplaced and a new connecting rod bushing must be installed in the connecting rod.

Clearance can usually be adjusted within specifications using a new bearing, unless thecrankshaft journal has been damaged. In that case, either grind or replace the crankshaft,depending on the amount of damage, and replace the connecting rod.

Note:Note:Note:Note:Note: If the crankshaft is replaced with a new one, the connecting rod bearing is selected inone of three different manners dependent upon the engine serviced. Use the appropriateService Manual and pay particular attention to the engine application and the direction that thecrankshaft is read. Rod bearing selection can be read left-to-right or right-to-left, depending onapplication.

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Determining the Clearance Using a PlastigageTM Kit

PlastigageTM is a very accurate tool for determining bearing clearances. If PlastigageTM

indicates excessive bearing clearance when compared to the scale, a thicker or undersizedbearing should be selected to assure that the clearance specification is obtained.

If PlastigageTM indicates excessive bearing clearance when compared to the scale, a thicker orundersized bearing should be selected to assure that the clearance specification is obtained.

Connecting Rod Bushing Clearance

Calculating connecting rod bushing clearance (small end) is similar to calculating the clearanceat the “big end.” An inside and outside micrometer are used to make the measurements andthen clearance is calculated.

CYLINDER HEAD TORQUING

Wnemever removing or installing the cylinder head, or when cylinder head bolts are torqued, itis essential to determine whether the existing cylinder head bolts can be reused or if they mustbe replaced.

Correct bolt torquing in the correct sequence is essential to attain proper cylinder headpressure against the cylinder block. This also prevents damage to the cylinder head gasket.

Depending upon the engine, plastic zone bolts are measured either for length or diameter inorder to determine if they can be reused.

Apply a light coat of oil to the threads and seating surfaces of the cylinder head bolt beforeinstalling. Follow the Service Manual procedure to tighten the cylinder head bolts and torquethe bolts in sequence, as indicated. Loosen the bolts, then torque to specification. Use thetorque angle gauge and turn the bolts clockwise 90 to 95 degrees. This tightens the bolt to theproper torque while also stretching the bolts to provide a stronger clamping force. Stretchingthe bolts beyond specification ruins the elasticity of the bolt and least to a failed fastener.

Note:Note:Note:Note:Note: Cylinder head bolts must be tightened using a six step process. A torque wrench ANDtorque angle meter must be used. A torque wrench alone will NOT tighten the bolts to therequired specification.

22

OPERATION AND DIAGNOSIS OF ELECTRONIC LIQUID ENGINE MOUNTS

The new VQ engine mounting system reduces noise andvibration generated by the engine. The front and rearengine mounts are located on a full-floating centermember and sub frame to minimize engine vibration inthe high speed range. The front and rear engine mountsare liquid-filled to reduce noise, shake and vibrationduring idling and in the low-medium speed range.

With electronically-controlled liquid-filled engine mounts,the engine mount orifices are switched by electriccontrol, controlled by the Electronic Control Module(ECM). Electronically-controlled liquid-filled enginemounts are diagnosed with CONSULT-II Data MonitorMode and Active Test Mode.

ENGINE COOLING SYSTEM

The cooling system keeps the engine running at its most efficient operating temperature underall operating conditions. Inefficient cooling system operation results in poor engineperformance and driveability and may cause accelerated wear. Begin any cooling systemdiagnosis with a visual inspection. This includes the condition of the hoses, radiator, drive beltsand coolant. Use a pressure test to check for small leaks in the cooling system and radiatorcap.

Check the condition of radiator, engine inlet and outlet hoses and heater hoses to confirm theirintegrity. Hot engine coolant causes the rubber material to deteriorate from the inside out.When you squeeze the hose, it should be firm. If the hose feels mushy or soft in any way, youshould replace it. Check to be sure there is no evidence of damage, such as cracked rubberor obvious breakdown of the material.

The overall purpose of the cooling system is to remove heat from the engine. Water is the bestliquid for heat removal. However, water freezes at 32oF and vaporizes at 212oF. It alsopromotes corrosion. To prevent freezing and boiling and to protect metal parts, ethylene glycol(anti-freeze) is added to the water. This mixture operates in a wider temperature range, butethylene glycol transfers heat more poorly than water. To maintain the good heat removingqualities of the water in the solution while still giving adequate protection against freezing, thecoolant-to-water ratio must be maintained at 50%.

TESTING ENGINE COMPRESSION AND LEAKAGE

Engine Compression

The compression pressure test verifies the mechanical condition of the engine’s cylinders andmeasures the cylinders’ ability to hold pressure. You can check the condition of the pistonrings, valves and head gasket by testing compression and cylinder leakage.

AR ENGINE MOUNTING

ONT ENGINE MOUNTING

LEFT ENGINE MOUNT

HT ENGINE MOUNTING

CENTER MEMBER

23

The cylinder compression tester is an instrument used to measure the compression retained ineach cylinder. The needle on the face of the gauge indicates the maximum compressionpressure in each cylinder tested.

To perform the compression pressure test, disable the fuel delivery and ignition systems.Remove all spark plugs and block the throttle valve open. Installing a compression gauge into aspark plug port. Crank the engine. Record the gauge reading. Next, compare the compressionmeasurements for each cylinder against the specifications in the Service Manual. Additionalresults can be acquired by repeating the test after adding a few drops of oil to each cylinder.

Although the service manual indicates that you should record the highest gauge reading of thecompression tester when cranking the engine, it is a good idea to watch for obvious disparitiesbetween each gauge reading at each crank of the engine.

• Compression that steadily builds as you crank the engine indicates good compression.

• Low compression on the first crank that builds on subsequent cranks but does not reachspecification, may indicate worn piston rings.

• A gauge reading higher than specification may indicate carbon deposit build up in thecombustion chamber.

Cylinder Leakage

The cylinder leakage test tells you about each cylinder’s ability to hold pressure. It can helpyou identify the location and extent of a cylinder leak. To use a cylinder leakage tester, positionthe piston in the cylinder to be tested at top dead center, install the tester’s adapter in thespark plug hole and apply compressed air. The gauge on the tester indicates the totalcompression leakage expressed as a percentage. A zero percent gauge reading indicates noleakage from the cylinder, however all cylinders normally leak a small amount past the pistonrings. A 100% gauge reading indicates that the cylinder cannot hold any pressure at all.Leakage readings of 20% or more are excessive. The best method is to test every cylinder andcompare the readings. You can also listen for escaping air to help your diagnosis:

• Air escaping from the intake system indicates a leaking intake valve.

• Air escaping from the exhaust pipe indicates a leaking exhaust valve.

• Air escaping from the crankcase filler hole indicates a crankcase leak caused bybroken or worn rings, a cracked piston or worn cylinder walls.

• Air bubbles in the radiator indicates cylinder leakage into the cooling system. Thismay indicate cracks in the water jackets, block, or head gasket.

• High percentage of leakage in two adjacent cylinders indicates a head gasketproblem or an engine block crack between the cylinders.

24

LOCATING THE SOURCE OF ENGINE NOISES

You can isolate the location of knocking noises in an engine by using some simple methods:

• Connect a timing light to the engine. If the light flashes at the same frequency as thenoise, the source is associated with the crankshaft.

• Pinch off the PCV hose to increase crankcase pressure. If the noise stops or isreduced, the noise is being caused by excessive piston pin clearance.

• Isolate the knock to a particular cylinder by using CONSULT or CONSULT-II to perform acylinder balance test. If the noise stops when you disable a particular cylinder, it isassociated with that cylinder.

Special Tools

VG33E Piston Choice

Engines built before VG33-424030M(installed in the WD22, D22 and V41 series)and all VG33# engines installed in the R40series used a non-coated piston in cylinders#1, #2, #5, and #6. If it is necessary toreplace pistons in these cylinders, install non-coated pistons. Install moly-coated pistonsof the correct grade into cylinders #3, #4,and #5. The coated pistons are designedwith a tighter piston-to-bore clearance thannon-coated pistons to reduce noise andscuffing. Always check for bulletins withASIST before selecting and installingreplacement pistons.

VQ30DE Timing Chain Noise

The timing chain tensioner, tensioner gasket and guide are available for 1995-1996 Maximaand 1996 I30 VQ30DE engines if a rattle of either several seconds or continuously is heardcoming from the area of the timing chain cover when the engine is started after a cold soak.This new tensioner, tensioner gasket and guide should be installed AS A SET whenever repairsare performed on the slack-side guide.

Reference ASIST for bulletins pertaining to VQ30DE timing chain noise.

SR20DE Shower Rail

In the 2000 model year, the camshaft oil tubes (shower rails) were replaced by drilled cambearing retaining caps.

25

VQ35DE NISSAN VARIABLE INTAKE SYSTEM (NVIS)

The Nissan Variable Intake System providesoptimum intake runner length, relative tohigh and low engine speed, for torque andhorsepower. When the NVIS is OFF at lowand middle engine speeds, inlet air is routedthrough the long passages in the intakemanifold. This increases the inertial energyof the inlet air and greatly increases lowspeed torque. When the engine operates athigher speed, the NVIS system in turnedON, which opens the shorter intake manifoldrunners.

VQ30DE Dual-Stage Cooling System

The VQ30DE uses a dual thermostat cooling system with a new water control valve forimproved fuel economy and emissions performance. Coolant is routed from the water pump tothe cylinder head when the water control valve is closed. An additional path is opened so thatcoolant can also flow through passages in the cylinder block when the valve is open.

26

Nissan Continuously Variable Valve Timing Control System (NCVCS)

System DescriptionSystem DescriptionSystem DescriptionSystem DescriptionSystem Description

This system increases engine torque in low and mid rpm range. At high rpm, horsepower andfuel efficiency are both improved.

• ECM input signals are collected from crankshaft position (POS), crankshaft position(REF), camshaft position, engine speed, and engine coolant temperature.

• ECM sends a variable duty cycle to the Intake Valve Timing Control (IVTC) Solenoid valve.

• IVTC valve directs oil pressure through both intake valve timing control units(intake cam sprockets) in two possible directions, causing advance or retard of intakecam.

Front TimingChain Case

Rear TimingChain Case

CVTC (IVTC) CoverPrimary Sprocket

Secondary Sprocket

IntakeCamshaft

OilPressure Drain

IVTCValve

Piston

Drain OilPressure

TDC

IntakeValve

ExhaustValve

Advance Angle

Retension(no oil flow)

TDC

IntakeValve

ExhaustValve

Retard Angle

:Piston Movement

:Oil Flow

27

• IVTC Valve is activated by signals from the ECM.

- Longer pulse width (high duty cycle) increases pressure in the system, advancingintake cam timing

- Shorter pulse width (low duty cycle) reduces pressure in the system, retarding intakecam timing.

- Equal pulse width stops oil flow, fixing the timing at 0° advance

Component DescriptionComponent DescriptionComponent DescriptionComponent DescriptionComponent Description

• NCVCS components include:

- Intake Valve Timing Control (IVTC) Solenoid valve

- Intake Timing Sensor (senses cam advance)

- Intake Valve Timing Control Unit (intake cam sprocket)

Intake Timing Sensor Bank #2

Front Timing Chain Case

CVTC Cover

Intake Timing Sensor Bank #1

Intake Valve Timing Control Unit(Intake Cam Sprocket)

Camshaft Bracket

IVTC Valves

Rear Timing Chain Case

Cylinder Head

28

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*This represents a duty cycle in relation to the solenoid ON time.

NoteNoteNoteNoteNote: In the ESM, IVTC is also referred to as CVTC.

New Diagnostic TNew Diagnostic TNew Diagnostic TNew Diagnostic TNew Diagnostic Trouble Codesrouble Codesrouble Codesrouble Codesrouble Codes

With the NCVCS, there are diagnostic trouble codes. The following chart indicates the newcodes:

Specification DataSpecification DataSpecification DataSpecification DataSpecification Data

The following specification data are used with CONSULT-II:

On Board Diagnosis LogicOn Board Diagnosis LogicOn Board Diagnosis LogicOn Board Diagnosis LogicOn Board Diagnosis Logic

OBD malfunction is detected when:

• Malfunction A-The alignment of the intake valve timing control has been misregistered

• Malfunction B-There is a difference between angle of target and angle of phase-control

When malfunction A or B is detected, the ECM enters fail safe mode and the MIL lights up. Infail-safe mode, the IVTC valve does not function.

SECTION

2

EXERCISES

i

ENGINE MECHANICAL SERVICE SIGN-OFF SHEET

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NOTES

ii

1“Engine Fundamentals” Video

ModuleModuleModuleModuleModule11111

“ENGINE FUNDAMENTALS” VIDEO

ObjectiveObjectiveObjectiveObjectiveObjective: Given a videotape and VCR, thetechnician will be able to understandthe fundamentals of engine operation.

RelevanceRelevanceRelevanceRelevanceRelevance: All technicians should have a firmunderstanding of the four-strokeengine cycle. This video describesmany common engine types used byNissan. Engine diagnosis beginswhen the technician fully understandsengine operation.

ResourcesResourcesResourcesResourcesResources: The following items are provided:

• VCR player• “Engine Fundamentals” videotape• Text Section

Skill CheckSkill CheckSkill CheckSkill CheckSkill Check: Your understanding of the operation ofa four-cycle engine is verified bysuccessfully answering the questionsin this module.

2 “Engine Fundamentals” Video


1. One complete four-stroke engine cycleconsists of:

________________________________________

________________________________________

________________________________________

________________________________________

2. Describe the main purpose of the crankshaft.

________________________________________

________________________________________

________________________________________

3. List valve train components in order ofoperation:

________________________________________

________________________________________

________________________________________

________________________________________

4. List what moves the piston on the powerstroke?________________________________________

________________________________________

5. List three piston rings facts.

________________________________________

________________________________________

________________________________________

3“Engine Fundamentals” Video


6. What is the purpose of the oil control ring?

________________________________________

________________________________________

________________________________________

7. What is the function of the NCVCS system?

________________________________________

________________________________________

________________________________________

________________________________________

8. The timing chain expands due to centrifugalforce. How is the chain kept in place?________________________________________

________________________________________

________________________________________

9. List the order of events when referring tocoolant flow.

________________________________________

________________________________________

________________________________________

________________________________________

10. Where does coolant flow while the engine iscold?

________________________________________

________________________________________

4 “Engine Fundamentals” Video

NOTES

1NCVCS


UNDERSTANDING THE OPERATION OF VARIABLE VALVE TIMING ANDINSPECTING THE NISSAN CONTINUOUSLY VARIABLE VALVE TIMING

CONTROL SYSTEM (NCVCS) USING CONSULT-II

ObjectiveObjectiveObjectiveObjectiveObjective: Given a vehicle equipped with theVQ35DE engine and a CONSULT-II,perform basic function test of NCVCS.

RelevanceRelevanceRelevanceRelevanceRelevance: The VQ35DE is an all-new engine.Although similar to the VQ30DEengine used in Maxima, there areseveral significant differences whichmay impact diagnosis.

ResourcesResourcesResourcesResourcesResources: The following items are provided:

• Vehicle with VQ35DE engine• CONSULT-II• Electronic Service Manual (ESM)• Text Section (pages 26-28)

Skill CheckSkill CheckSkill CheckSkill CheckSkill Check: Your understanding of the operation ofthis system is verified by recordingdata with CONSULT-II and attachingprintouts into this module.

2 NCVCS


Monitoring Signals

1. Use the text section (pages 26-28) of yourStudent Guide to answer questions onethrough eight.

2. Thoroughly review this material and use it toanswer the following questions.

3. What fluid regulates intake camshaft position?

________________________________

________________________________

4. This fluid is controlled by: (Check one)

Throttle Sensor

Crank Angle Sensor

Air Flow Meter

Intake Valve Control Solenoid Valve

5. What controls the intake valve open/close timingfunction?

________________________________

________________________________

6. Under which driving conditions is valve timingactivated?

________________________________

________________________________

3NCVCS


7. When the engine is idling, what happens to thefollowing:

Intake valve open/close time:

ADVADVADVADVADVANCES / NORMAL ANCES / NORMAL ANCES / NORMAL ANCES / NORMAL ANCES / NORMAL (Circle one)

Valve overlap:

INCREASES / NORMAL INCREASES / NORMAL INCREASES / NORMAL INCREASES / NORMAL INCREASES / NORMAL (Circle one)

Control Solenoid Valve:

0% / ~40% 0% / ~40% 0% / ~40% 0% / ~40% 0% / ~40% (Circle one)

8. At low to medium speed, what happens to thefollowing:

Intake valve open/close time:

ADVADVADVADVADVANCES / NORMAL ANCES / NORMAL ANCES / NORMAL ANCES / NORMAL ANCES / NORMAL (Circle one)

Valve overlap:

INCREASES / NORMAL INCREASES / NORMAL INCREASES / NORMAL INCREASES / NORMAL INCREASES / NORMAL (Circle one)

Control Solenoid Valve:

0% / ~40% 0% / ~40% 0% / ~40% 0% / ~40% 0% / ~40% (Circle one)

4 NCVCS


9. Connect CONSULT-II to the the DLC.

10. Start the engine and warm it up to normaloperating temperature.

11. Touch STSTSTSTSTARTARTARTARTART on the CONSULT-II Main Menu.

12. Touch ENGINEENGINEENGINEENGINEENGINE. The NCVCS system is one ofthe systems controlled by the ECM for engineoperation.

13. Touch DADADADADATTTTTA MONITA MONITA MONITA MONITA MONITOR OR OR OR OR to select thediagnostic mode.

BACK LIGHT COPY

Scroll Down

DTC & SRT CONFIRMATION

DATA MONITOR (SPEC)

DATA MONITORDATA MONITORDATA MONITORDATA MONITORDATA MONITOR

SELF-DIAG RESULTS

WORK SUPPORT

SELECT DIAG MODE

ACTIVE TEST

STARTSTARTSTARTSTARTSTART

COPYLIGHT

CONSULT-II

NISSAN

AED99C

SUB MODE

SELECT SYSTEM

AIR BAG

ABS

SMART ENTRANCE

BACK LIGHT COPY

A/T

ENGINEENGINEENGINEENGINEENGINE

5NCVCS


DATA MONITOR

SELECT MONITOR ITEM

ECM INPUT SIGNALS

SELECTION FROM MENUSELECTION FROM MENUSELECTION FROM MENUSELECTION FROM MENUSELECTION FROM MENU

BACK LIGHT COPY

MAIN SIGNALS

SETTING NumericalDisplay

MODE

SELECT MONITOR ITEM

DATA MONITOR

COPYLIGHTBACKMODE

SETTINGSETTINGSETTINGSETTINGSETTINGBarchartDisplay

Page Up Page Down

ABSOL TH-P/S

MASS AIRFLOW

IACV-AAC/V

IGN TIMING

CAL/LD VALUECAL/LD VALUECAL/LD VALUECAL/LD VALUECAL/LD VALUE

START

TRIGGER POINT

SET RECORDING CONDITION

AUTO TRIG

MANU TRIGMANU TRIGMANU TRIGMANU TRIGMANU TRIG

Recording Speed

COPYLIGHTBACKBACKBACKBACKBACK

>>>>

>>>>MIN MAX

0% 20% 40% 60% 80% 100%

/64 /32 /16 /8 /4 /2 FULL

MODE

14. Touch SELECTION FROM MENUSELECTION FROM MENUSELECTION FROM MENUSELECTION FROM MENUSELECTION FROM MENU to chooseinputs to include on the display.

15. Touch each of the following inputs to highlightthem:

• ENG SPEEDENG SPEEDENG SPEEDENG SPEEDENG SPEED• THRTL POS SENTHRTL POS SENTHRTL POS SENTHRTL POS SENTHRTL POS SEN• CAL/LD VCAL/LD VCAL/LD VCAL/LD VCAL/LD VALUEALUEALUEALUEALUE• INT/V TIM (B1)INT/V TIM (B1)INT/V TIM (B1)INT/V TIM (B1)INT/V TIM (B1)• INT/V TIM (B2)INT/V TIM (B2)INT/V TIM (B2)INT/V TIM (B2)INT/V TIM (B2)• INT/V SOL (B1)INT/V SOL (B1)INT/V SOL (B1)INT/V SOL (B1)INT/V SOL (B1)• INT/V SOL (B2)INT/V SOL (B2)INT/V SOL (B2)INT/V SOL (B2)INT/V SOL (B2)

16. Touch SETTINGSETTINGSETTINGSETTINGSETTING to set up the snapshotparameters that follow.

17. Touch MANU TRIG MANU TRIG MANU TRIG MANU TRIG MANU TRIG to set the snapshotrecording condition. Leave the defaultconditions in place for both TRIGGER POINTand Recording Speed.

6 NCVCS


18. Touch BACKBACKBACKBACKBACK, then touch STSTSTSTSTARTARTARTARTART. The screenshould look similar to the image at left. Noticethat each of the inputs selected in step 8 arenow actively displayed on the CONSULT-IIscreen.

19. Touch COPYCOPYCOPYCOPYCOPY and attach printout at left.

20. Accelerate to 1,500 rpm and while holding therpm steady, touch COPYCOPYCOPYCOPYCOPY. Attach printout atleft.

21. Allow the engine to return to idle.

22. Based on the printout at left, what was thecalculated load percentage?

__________________________________

23. Shut off the engine.

Attach Printout Here


DATA MONITOR

MONITOR

ENG SPEED 763 rpm

RECORD

MODE BACK LIGHT STARTSTARTSTARTSTARTSTART

THRTL POS SENCAL/LD VALUEINT/V TIM (B1)INT/V TIM (B2)INT/V SOL (B1)INT/V SOL (B2) 0%

0%1 °CA0 °CA29%0.44 V

7NCVCS


24. Disconnect the intake timing sensor connectorfor Bank 1. See illustration at left for properlocation.

25. Start the engine.

26. Accelerate the engine to 1,500 rpm.

27. Touch COPYCOPYCOPYCOPYCOPY and attach the printout at left.

28. Allow the engine to return to idle.

29. From your printout, are both camshaft sensorsindicating the same amount of advance?

YES/ NOYES/ NOYES/ NOYES/ NOYES/ NO (Circle one)

30. Did the value of B1 sensor change?

YES/ NOYES/ NOYES/ NOYES/ NOYES/ NO (Circle one)

NoteNoteNoteNoteNote: A fixed reading indicates that the systemis not functioning properly.

31. Touch BACK BACK BACK BACK BACK and return to the SELECT DIAGMODE, then touch SELF-DIAG RESULSELF-DIAG RESULSELF-DIAG RESULSELF-DIAG RESULSELF-DIAG RESULTSTSTSTSTS.Any stored DTCs should now be displayed onthe screen.

SELF-DIAG RESULTS

DTC RESULTS TIME

INTK TIM S/CIRC-B1INTK TIM S/CIRC-B1INTK TIM S/CIRC-B1INTK TIM S/CIRC-B1INTK TIM S/CIRC-B1[P-1140][P-1140][P-1140][P-1140][P-1140] 1t

PRINT

MODEMODEMODEMODEMODE BACK LIGHT COPY

ERASE

F.F. DATA

Intake Timing Sensors

Bank #2

Bank #1

8 NCVCS


32. Touch PRINTPRINTPRINTPRINTPRINT to print all DTCs. Attach theprintouts at left.

33. Touch the box of the first DTC displayed.

34. What information is now displayed?

____________________________________

____________________________________

Note:Note:Note:Note:Note: This system uses a 2-stage fault detectionlogic. The Malfunction Indicator Light (MIL)on the instrument panel will illuminate afterthe second time the engine is started witha fault in the system.

35. Touch SCROLL DOWNSCROLL DOWNSCROLL DOWNSCROLL DOWNSCROLL DOWN to read allinformation.

36. From the information given, determine thepossible causes for this DTC and attach theprintout at left.

37. Shut off the engine and reconnect the sensorconnections.

38. Turn ignition back ON and touch ERASEERASEERASEERASEERASE toclear all DTCs, then print the screen and attachat left.

39. If you had difficulty performing the Skill Checkstated at the beginning of this module, ask yourinstructor for assistance.

40. When you have completed the Skill Check toyour satisfaction, see your instructor forverification of your work.


BACK LIGHT COPY

Scroll Down

DTC & SRT CONFIRMATION

DATA MONITOR (SPEC)

DATA MONITOR

SELF-DIAG RESULTSSELF-DIAG RESULTSSELF-DIAG RESULTSSELF-DIAG RESULTSSELF-DIAG RESULTS

WORK SUPPORT

SELECT DIAG MODE

ACTIVE TEST

9NCVCS


You have now completed this module. If youhave any doubt about your skills in completingthis module, please return to step #1 andreview your work. Once you are confident ofyour skills, have your instructor verify your workand initial your module.

Instructor’s Initials _____________________Instructor’s Initials _____________________Instructor’s Initials _____________________Instructor’s Initials _____________________Instructor’s Initials _____________________

Return the workstation to the condition in which itReturn the workstation to the condition in which itReturn the workstation to the condition in which itReturn the workstation to the condition in which itReturn the workstation to the condition in which itwas found.was found.was found.was found.was found.

10 NCVCS

NOTES

1Electronically-Controlled Engine Mounts


ELECTRONICALLY-CONTROLLED ENGINE MOUNTS

Objective: Objective: Objective: Objective: Objective: Given a vehicle with one or moreelectronically-controlled enginemounts and a CONSULT-II scan tool,verify proper operation ofelectronically-controlled, liquid-filledengine mounts using CONSULT-II.

Relevance:Relevance:Relevance:Relevance:Relevance: Understanding how to properly verifyproper operation of electronically-controlled liquid-filled engine mountsis important to complete diagnosis andrepair of noise, vibration andharshness (NVH) concerns.

Resources:Resources:Resources:Resources:Resources: The following items are provided:

• Vehicle w/Electronically-Controlled Engine Mounts

• CONSULT-II Scan Tool

Skill Check:Skill Check:Skill Check:Skill Check:Skill Check: The instructor will check yourunderstanding of electronic enginemount operation by verifying that allsteps in this module were properlyfollowed and that questions wereanswered properly.

2 Electronically-Controlled Engine Mounts


Active Test

1. Verify that the most recent diagnostic card andresident software are installed in theCONSULT-II.

2. Withe the ignition switch OFF, connect theCONSULT-II unit to the vehicle’s data linkconnector.

3. Turn the ignition ON and start the engine.

4. Touch STSTSTSTSTARTARTARTARTART on the CONSULT-II screen.

5. Touch ENGINE.ENGINE.ENGINE.ENGINE.ENGINE.

6. Touch DADADADADATTTTTA MONITA MONITA MONITA MONITA MONITOR.OR.OR.OR.OR.

7. Touch MAIN SIGNALS, MAIN SIGNALS, MAIN SIGNALS, MAIN SIGNALS, MAIN SIGNALS, then ST ST ST ST STARTARTARTARTART.....

Note:Note:Note:Note:Note: The engine must be at normal operatingtemperature before proceeding.

8. Observing the CONSULT-II screen, what is thereading from the engine coolant temperaturesensor?

________________________________________

9. Is the reading within specifications?

YES/NOYES/NOYES/NOYES/NOYES/NO (Circle one)

10. Touch BACK BACK BACK BACK BACK twice to return to the SELECTSELECTSELECTSELECTSELECTDIAG MODEDIAG MODEDIAG MODEDIAG MODEDIAG MODE screen.

11. Touch ACTIVE TESTACTIVE TESTACTIVE TESTACTIVE TESTACTIVE TEST.

12. Page DownPage DownPage DownPage DownPage Down and touch ENGINE MOUNTINGENGINE MOUNTINGENGINE MOUNTINGENGINE MOUNTINGENGINE MOUNTING.

13. Touch STSTSTSTSTARTARTARTARTART.....

REAR ENGINE MOUNTING

FRONT ENGINE MOUNTING

LEFT ENGINE MOUNTING

RIGHT ENGINE MOUNTING

CENTER MEMBER

FRONT



14. What items are monitored under MAINMAINMAINMAINMAINSIGNALSSIGNALSSIGNALSSIGNALSSIGNALS?

________________________________________

________________________________________

14a) Place vehicle in “D” with foot on brake pedal.

15. Touch TRV/IDLTRV/IDLTRV/IDLTRV/IDLTRV/IDL. This is the command for theengine mounts to switch from IDLE to TRAVELmode and back.

Note:Note:Note:Note:Note: You can verify operation by feeling a changein vibration on the hood or driver’s door.

16. What might the customer complaint be if theengine mount were not operating?

________________________________________

________________________________________

17. Repeat the same scenario as explained above,however this time instead of touchingSELECTION FROM MENU, touch MAINMAINMAINMAINMAINSIGNALSSIGNALSSIGNALSSIGNALSSIGNALS. Print your data and attach in to thespace at the left.

18. Is the engine mount operating properly?

YES / NOYES / NOYES / NOYES / NOYES / NO (Circle one)

18a) Place vehicle in Park.




Data MonitorThis exercise uses the graph feature of CONSULTor CONSULT-II.

19. With the ignition switch OFF, connect theCONSULT unit.

20. Turn the ignition ON and start the engine.

21. Touch STSTSTSTSTART ART ART ART ART on the CONSULT screen.

22. Touch ENGINEENGINEENGINEENGINEENGINE.

23. Touch DA DA DA DA DATTTTTA MONITA MONITA MONITA MONITA MONITOROROROROR.

Note:Note:Note:Note:Note: ENGINE MOUNT may be accessed usingMAIN SIGNALS or SELECTION FROMMENU in DATA MONITOR.

24. Touch SELECTION FROM MENUSELECTION FROM MENUSELECTION FROM MENUSELECTION FROM MENUSELECTION FROM MENU.

25. Page forward through the menu and touchCKPS/RPM, THROCKPS/RPM, THROCKPS/RPM, THROCKPS/RPM, THROCKPS/RPM, THROTTLE POSITIONTTLE POSITIONTTLE POSITIONTTLE POSITIONTTLE POSITIONSENSORSENSORSENSORSENSORSENSOR, and ENGINE MOUNTENGINE MOUNTENGINE MOUNTENGINE MOUNTENGINE MOUNT.....

Note: When performing the following step theengine must be revved for the test to operate.

26. Touch SETTING SETTING SETTING SETTING SETTING and choose AUTAUTAUTAUTAUTO TRIGO TRIGO TRIGO TRIGO TRIGand MAX RECORDING SPEED.MAX RECORDING SPEED.MAX RECORDING SPEED.MAX RECORDING SPEED.MAX RECORDING SPEED.

27. Touch BACKBACKBACKBACKBACK.

28. Touch STSTSTSTSTARTARTARTARTART.

29. With engine idling, touch RECORDRECORDRECORDRECORDRECORD, then revengine to travel.

30. Touch STSTSTSTSTOPOPOPOPOP, then touch STSTSTSTSTORE.ORE.ORE.ORE.ORE.

31. TTTTTouch STouch STouch STouch STouch STORE again and then touch BACK.ORE again and then touch BACK.ORE again and then touch BACK.ORE again and then touch BACK.ORE again and then touch BACK.

32. Touch DISPLADISPLADISPLADISPLADISPLAYYYYY.





33. Touch GRAPHGRAPHGRAPHGRAPHGRAPH.

34. Touch COPYCOPYCOPYCOPYCOPY.

35. Touch SCROLL DOWN.SCROLL DOWN.SCROLL DOWN.SCROLL DOWN.SCROLL DOWN.

36. Touch COPYCOPYCOPYCOPYCOPY.

37. Graph each selected item, print-out eachgraph, and attach them to the spaces at theleft.

38. Compare each graph to the other.

39. What does this comparison indicate?

________________________________________

________________________________________

________________________________________

You have now finished this module. If you have anydoubt about your skills in completing this module,please return to step #1 and review your work.Once you are confident of your skills, have yourinstructor verify your work and initial your module.

Instructor’s Initials ____________________Instructor’s Initials ____________________Instructor’s Initials ____________________Instructor’s Initials ____________________Instructor’s Initials ____________________



NOTES

1Power Balance Test Using CONSULT-II

Module 4

POWER BALANCE TEST USING CONSULT-II

Objective:Objective:Objective:Objective:Objective: Given a training vehicle andCONSULT-II scan tool, perform apower balance test and use theresults to determine if one or morecylinders is misfiring.

Relevance:Relevance:Relevance:Relevance:Relevance: The power balance test is the quickestand most efficient way to isolate amisfiring cylinder and determine if thecause of an engine noise is electricalor mechanical in nature. CONSULT-IIprovides a fast and simple way toperform the test.


• Vehicle

• CONSULT-II

Skill Check:Skill Check:Skill Check:Skill Check:Skill Check: The instructor will verify yourunderstanding of this procedure bychecking that all steps have beenproperly completed and that allquestions are correctly answered.

2 Power Balance Test Using CONSULT-II

Module 4

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1. Connect CONSULT to the Diagnostic DataLink and turn it ON.

2. Touch STSTSTSTSTARTARTARTARTART.

3. Touch ENGINEENGINEENGINEENGINEENGINE.

4. Touch ACTIVE TESTACTIVE TESTACTIVE TESTACTIVE TESTACTIVE TEST.

5. Select POWER BALANCEPOWER BALANCEPOWER BALANCEPOWER BALANCEPOWER BALANCE test. Following thedirections in the CONSULT manual, performthe power balance test. If you have anytrouble, ask your instructor for help.

3Power Balance Test Using CONSULT-II

Module 4

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1

2

3

4

5

6

6. Be sure to note the engine RPM before andduring the test for each cylinder. Note theRPM drop for each cylinder in the table below.

7. Did any cylinder fail the test (no drop in rpmwhen tested)?


8. What is indicated when all cylinders show asimilar drop in engine speed?

________________________________________

________________________________________

9. What is indicated if an engine is making a noisethat changes with RPM, and the noisedisappears while a cylinder is being testedduring the cylinder balance test?

________________________________________

________________________________________

4 Power Balance Test Using CONSULT-II

Module 4

You have now finished this module. If you have anydoubt about your skills in completing this module,please return to step #1 and review your work.Once you are confident of your skills, have yourinstructor verify your work.



1Cooling System Check


COOLING SYSTEM CHECKObjective:Objective:Objective:Objective:Objective: Given a vehicle, hydrometer, cooling

system pressure tester and applicableService Manual, perform a coolingsystem check for evidence of leaks,damage, or deterioration to assureproper cooling system performance.

Relevance:Relevance:Relevance:Relevance:Relevance: The cooling system keeps the enginerunning at its most efficient operatingtemperature under all conditions.Inefficient cooling system operationresults in poor engine performanceand driveability. This module willfamiliarize you with the essentialtechniques of cooling systemdiagnosis.


• Vehicle

• Coolant Hydrometer

• Coolant System PressureTester

• Service Manual

Skill Check:Skill Check:Skill Check:Skill Check:Skill Check: Your understanding of the tools andinformation necessary to properlyperform this procedure is verified byusing the hydrometer and pressuretester according to the ServiceManual procedure and by correctlyanswering all the questions in thismodule .

2 Cooling System Check

ModuleModuleModuleModuleModule55555 1. Visually inspect the condition of drive belts for

the vehicle at your workstation. Check thecondition of radiator, engine inlet and outlethoses and heater hoses to confirm their integrity.Heated water causes the rubber material todeteriorate from the inside out. Squeeze thehose. It should be firm. If the hose feels mushyor soft in any way, it should be replaced. Checkto be sure there is no evidence of damage suchas cracked rubber or obvious breakdown of thematerial.

2. Do any of the hoses on the vehicle at thisworkstation need replacing?


3. Note problems identified during the visualinspection here:

________________________________________

________________________________________

Note:Note:Note:Note:Note: Visual inspection of the system shouldprecede any cooling system inspection. Thisincludes the condition of the hoses, radiator,drive belts and coolant. Pressure testing thecooling system and radiator cap will identifyvery small leaks and internal leaks notdetected in the visual inspection.



4. The liquid best suited for its heat removingqualities in the cooling system is:(Check one)

Ethylene glycol

Water

5. Adding too much (over 50%) ethylene glycolantifreeze results in? (Check one)

Reduces the heat removingefficiency of the coolant solution

Raises the freezing point of the coolantsolution

Reducing inhibitors to prevent corrosion ofthe cooling system

6. It is very important to maintain a ratio ofethylene glycol to water that maximizes thecooling efficiency of the coolant whilemaintaining adequate freeze protection. Whatis the target ratio? (Check one)

50% ethylene glycol to 50% water



7. If the hydrometer reading indicated a 70%ethylene glycol (antifreeze) to 30% water ratio,this reading would be: (Check one)

Acceptable - good mix

Unacceptable - need more ethyleneglycol (anti-freeze)

Unacceptable - need more water



8. Using a hydrometer, test the coolant solutionon the vehicle at your workstation to assurethat it has the proper coolant mixture.

9. Does the vehicle at your workstation have theproper coolant mixture?

YES / NO YES / NO YES / NO YES / NO YES / NO (Circle one)

Increasing the Pressure of the Solution: Increasing the Pressure of the Solution: Increasing the Pressure of the Solution: Increasing the Pressure of the Solution: Increasing the Pressure of the Solution: Increasingthe pressure of the antifreeze solution will raise thecooling system’s boiling point.For every 1lb. increase in pressure, the boiling pointis raised 3°F.

The radiator cap functions to maintain pressure inthe cooling system. Low pressure may be causedby a defective radiator cap.A pressure tester is a hand held pump with anattached gauge which indicates applied pressure. Itmay be used to determine the condition of theradiator cap as well as to test the cooling system forleaks which are not detected during visualinspection.

PRESSURE TO TEMPERATURERATIO

• 1lb. increase = 3° boilingtemperature increase

• 6lb. increase = 18° boilingtemperature increase



Refer to the LLLLLC C C C C or CO CO CO CO CO Section of the service manualand locate Cooling System Check.Cooling System Check.Cooling System Check.Cooling System Check.Cooling System Check.

10. Perform a radiator cap pressure test on thevehicle at your workstation using the pressuretester and following service manualprocedures.

WWWWWARNING:ARNING:ARNING:ARNING:ARNING:Never remove the radiator cap when theNever remove the radiator cap when theNever remove the radiator cap when theNever remove the radiator cap when theNever remove the radiator cap when the

engine is hot. Serious burns could occur fromengine is hot. Serious burns could occur fromengine is hot. Serious burns could occur fromengine is hot. Serious burns could occur fromengine is hot. Serious burns could occur fromhigh pressure fluid escaping from the radiator.high pressure fluid escaping from the radiator.high pressure fluid escaping from the radiator.high pressure fluid escaping from the radiator.high pressure fluid escaping from the radiator.

Wrap a thick cloth around the cap. SlowlyWrap a thick cloth around the cap. SlowlyWrap a thick cloth around the cap. SlowlyWrap a thick cloth around the cap. SlowlyWrap a thick cloth around the cap. Slowlypush down and turn it a quarter-turn to allowpush down and turn it a quarter-turn to allowpush down and turn it a quarter-turn to allowpush down and turn it a quarter-turn to allowpush down and turn it a quarter-turn to allowbuilt-up pressure to escape. Carefully removebuilt-up pressure to escape. Carefully removebuilt-up pressure to escape. Carefully removebuilt-up pressure to escape. Carefully removebuilt-up pressure to escape. Carefully removethe cap by pushing down and turning it all thethe cap by pushing down and turning it all thethe cap by pushing down and turning it all thethe cap by pushing down and turning it all thethe cap by pushing down and turning it all thewaywaywaywayway.....

11. What is the radiator cap relief pressurespecifications for the vehicle at yourworkstation?

________________________________________

12. Is the radiator cap of the vehicle withinspecifications?


13. What should be done if the cap is not withinspecifications? (Check one)

Replace the gasket retainer of the cap

Replace the cap gasket

Replace the cap

EG17650001



14. Locate Checking the Cooling System forChecking the Cooling System forChecking the Cooling System forChecking the Cooling System forChecking the Cooling System forLeaks Leaks Leaks Leaks Leaks section of the Service Manual.....

15. Check for leaks in the cooling system using thepressure tester and following service manualprocedures for the vehicle at your workstation.

16. What test pressure should be applied to thesystem?

________________________________

17. Were any cooling system leaks found?


18. Exceeding the specifications could cause thefollowing problem: (Check one)

Damage to the radiator

Damage to the pressure tester gauge

Damage to the filler neck

Other Methods to Detect Internal LeaksOther Methods to Detect Internal LeaksOther Methods to Detect Internal LeaksOther Methods to Detect Internal LeaksOther Methods to Detect Internal LeaksInternal leaks may be detected in several ways. Airleaks from the water pump or exhaust leaks from thecylinder head gasket may be detected usingchemical combustion leak detectors.Exhaust leaks may also be detected using anaftermarket leak tester or an exhaust gas analyzer.



WWWWWARNING:ARNING:ARNING:ARNING:ARNING: Use caution when removing the radiator cap.

19. You may check for exhaust leaks using theaftermarket tester as described below:

• Install a sealing ring in the filler neck

• Attach the pressure tester to the radiator andopen the relief valve

• Run the engine to normal operatingtemperature

• Close the relief valve and observe the gauge

CAUTION:CAUTION:CAUTION:CAUTION:CAUTION: Do not pressurize the system above maximum specifications.

• A steady reading on the pressure gauge at ornear specifications means the system is OK.

• An excessive increase in pressure mayindicate exhaust pressure leaking into thecooling system from a head gasket leak, acrack in the cylinder block, or a crack in thecylinder head.

• A pressure decrease or a fluctuating gaugemay indicate an exhaust leak into the coolingsystem from a crack in the cylinder headexhaust port.

• A decreased fluctuation will result when theleaking cylinder is deactivated (disable sparkor injector)



20. You may check for exhaust leaks usingexhaust gas analyzer as described below:

• Run the engine to normal operatingconditions

• Carefully remove the radiator cap

• Hold the analyzer probe at the top of the fillerneck (do not immerse the probe in thecoolant)

• Accelerate to 2,000 rpm, then return to idle

• Observe the analyzer for an increase in HCand CO

CAUTION:CAUTION:CAUTION:CAUTION:CAUTION:Do not immerse the exhaust gas analyzer probein the coolant.

You have now finished this module. If you have anydoubt about your skills in completing this module,please return to step #1 and review your work.Once you are confident of your skills, have yourinstructor verify your work and initial your module.


Please return your workstation to the condition inPlease return your workstation to the condition inPlease return your workstation to the condition inPlease return your workstation to the condition inPlease return your workstation to the condition inwhich it was found.which it was found.which it was found.which it was found.which it was found.

1Oil Pressure Test


OIL PRESSURE TEST

Objective:Objective:Objective:Objective:Objective: Given a training vehicle, oil pressuregauge and the appropriate ServiceManual, you will be able to perform anoil pressure test using a pressuregauge and interpret the results.

Relevance:Relevance:Relevance:Relevance:Relevance: The pressure of the engine oil affectsvehicle operation and engine wear.Oil pressure that is too low can causeoil starvation to moving parts andincrease friction, which promoteswear. Excessive oil pressure candamage bearings, increase the risk ofcrankshaft or camshaft failure, andpromote leakage around seals.


• Vehicle

• Oil Pressure Gauge

• Service Manual

Skill Check:Skill Check:Skill Check:Skill Check:Skill Check: Your instructor will verify yourunderstanding of this procedure bychecking that the Service Manualprocedure was followed properly andthat all questions are properlyanswered.

2 Oil Pressure Test


Oil pressure is developed by the oil pump andregulated by a pressure regulating valve. Afterpassing through the oil filter the oil passes to themain oil gallery which distributes the oil throughoutthe engine.

Prior to performing any test on the engine oil system,always check the oil level to assure the engine is fullto the correct level.See the service manual for the vehicle at yourworkstation. Locate the LLLLLC C C C C or LU LU LU LU LU Section and findLubrication Circuit Lubrication Circuit Lubrication Circuit Lubrication Circuit Lubrication Circuit then answer the followingquestions. Notice that the schematic illustrates thelubrication circuit and the direction of flow.

1. What components are fed directly from themain oil gallery?

________________________________________

________________________________________

2. What vehicle conditions would lead you to usethe Lubrication Circuit ChartLubrication Circuit ChartLubrication Circuit ChartLubrication Circuit ChartLubrication Circuit Chart?

________________________________________

________________________________________

3. Locate the Oil Pressure CheckOil Pressure CheckOil Pressure CheckOil Pressure CheckOil Pressure Check procedure inthe Engine Lubrication System Engine Lubrication System Engine Lubrication System Engine Lubrication System Engine Lubrication System section of theservice manual.

Notice that there is an illustration which indicates thelocation of the oil pressure switch. It is usuallylocated on the engine block (screwed into the mainoil gallery) near the oil filter or on the oil filteradapter, depending on the vehicle.

3Oil Pressure Test


4. Where is the oil pressure switch located on thevehicle at your workstation?

________________________________________

________________________________________

When the switch is removed, an oil pressure gaugecan be installed into the tap on the main oil galleryfor measuring oil pressure.

5. Note the specifications for pressures with theengine at idle speed and at specific enginespeeds. What is the pressure specification atidle speed for the vehicle at your workstation?

________________________________________

________________________________________

6. At what engine speed should the pressure betested on the vehicle at your workstation?(Check one)

3000 rpm

3200 rpm

4000 rpm

2000 rpm

7. What is the pressure specifications for thevehicle at your workstation at the engine speedindicated above?

________________________________________

________________________________________

4 Oil Pressure Test


8. Connect the pressure gauge and perform an oilpressure test on the vehicle at your workstationfollowing the service manual procedure. Thenanswer the questions that follow.

9. In which gear position should the vehicle be into perform the oil pressure check? (Checkone)

First gear

Third gear

Neutral/Park

10. Should the vehicle be at normal operatingtemperature to conduct this test?


11. What does the service manual suggest you doif the difference between the specifications isextreme?

________________________________________

________________________________________

12. What were the results of the pressure test forthe vehicle at your workstation?

MPR erusserP

elditA ____________

_________MPRtseT ____________

5Oil Pressure Test


13. Were the pressure readings withinspecifications?


You have now completed this module and should beable to perform and interpret an oil pressure testusing a pressure gauge and following the servicemanual procedures. If you have any doubt aboutyour skills in completing this module, please return tostep #1 and review your work. Once you areconfident of your skills, have your instructor verifyyour work and initial your module.



6 Oil Pressure Test

NOTES

1Engine Compression and Leakage Test

Module 7

Objective:Objective:Objective:Objective:Objective: Given a vehicle, a cylindercompression gauge, a cylinderleakage tester, a CONSULT-II scantool and the applicable ServiceManual, perform an enginecompression test and a cylinderleakage test to determine thecondition of the piston rings,valves, and head gasket based onspecifications indicated in theService Manual.

Relevance:Relevance:Relevance:Relevance:Relevance: Compression and leakage tests arevital for determining a cylinder’sability to hold pressure.


• Vehicle

• Electronic Service Manual(ESM)

• Compression Gauge

• Cylinder Leakage Tester

• CONSULT-II

Skill Check:Skill Check:Skill Check:Skill Check:Skill Check: The instructor will check yourunderstanding of the procedures byverifying that all steps werefollowed and that all questionswere correctly answered. Theinstructor may also ask questionsregarding when these proceduresare performed, and why.

ENGINE COMPRESSION AND LEAKAGE TEST

2 Engine Compression and Leakage Test

Module 7

Compression TCompression TCompression TCompression TCompression Testestestestest

Refer to the EM EM EM EM EM section of the service manual forthe vehicle at your workstation, locate the sectionentitled Measurement of CompressionMeasurement of CompressionMeasurement of CompressionMeasurement of CompressionMeasurement of CompressionPressurePressurePressurePressurePressure and answer the following questions.

1. Should the engine be at normal operatingtemperature to conduct this test?


2. Should the ignition switch be OFF when youbegin the test?


3. Prior to performing the compressionpressure measurement, you should: (Checkone)

Disconnect distributor center cable

Remove all spark plugs

Release fuel pressure

All of the above selections

The ECECECECEC section in the service manual refers you aFuel Pressure ReleaseFuel Pressure ReleaseFuel Pressure ReleaseFuel Pressure ReleaseFuel Pressure Release procedure that you willneed to perform in order to answer the followingquestions.


Module 7

4. Refer to the procedure indicated in the ECECECECECsection of the service manual and answerthe following questions.

5. Which diagnostic mode should be usedwhen performing the procedure above usingCONSULT-II?

________________________________

________________________________

6. Should you remove the fuel pump fuse Ifperforming the fuel pressure releaseprocedure without using CONSULT-II?


7. Perform the fuel pressure release procedureaccording to the service manual on thevehicle at your workstation.

Locate Compression Pressure Measurement Compression Pressure Measurement Compression Pressure Measurement Compression Pressure Measurement Compression Pressure Measurement inthe EMEMEMEMEM section of the service manual for thevehicle at your workstation and answer thefollowing questions.

8. How many spark plugs have to be removedto ensure accurate results on the vehicle atyour workstation?

________________________________


Module 7

9. Why must the fuel injection system andignition system be disabled when performinga compression test?(Check one)

Prevents fuel from being injected into thecylinders

Prevents damage to the ignition systemduring the test

Prevents an engine fire in the shop

All of the above

10. Why does the procedure require you to“keep the throttle valve wide open” bydepressing the accelerator pedal?

_______________________________

11. Why should the vehicle’s battery be fully-charged when performing this test? (Checkone)

To generate high secondary voltage

To assure specified engine speed

To avoid damage to the ignition coil

None listed above

Note:Note:Note:Note:Note: Spark plugs should be removed duringthe compression test to prevent dragon the engine during cranking.


Module 7

12. Crank the engine a few times whileobserving the compression gauge andrecord the reading.

Reading: ___________________

13. Which gauge indication do you record?(Check one)

The gauge indication after fivecompression strokes

The gauge indication on the firstcompression stroke

The highest gauge indication

None listed above

14. What are the specifications in the servicemanual for the vehicle at your workstation?

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Module 7

If the Dry Test did not provide enoughcompression, perform a “Wet CylinderCompression Test.” This involves adding a fewdrops of engine oil into the cylinders through thespark plug holes. Repeat the compression testfor each cylinder.

15. Perform a compression test on the vehicle atyour workstation according to the servicemanual procedures.

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16. When would a wet test be necessary?

_______________________________

_______________________________

17. Were the results of the engine compressiontest within specifications for the vehicle atyour workstation?


18. What did the wet test results reveal?

_______________________________

_______________________________


Module 7

19. What might you conclude if yourcompression test indicated lowcompression in two adjacent cylindersduring both the dry and wet compressiontests? (Check one)

Leakage caused by worn cylinder walls

Leakage past the head gasket

Leakage caused by sticking valves

Leakage caused by worn cam lobes

20. What might you conclude if your drycompression test indicated lowcompression but adding oil to that cylinderduring the wet test improved compression?(Check one)

Leakage caused by worn piston rings

Leakage past the head gasket

Leakage caused by burned valves

Leakage caused by dished valve lifters

21. What might you conclude if yourcompression test indicated lowcompression during the dry test andremained low during the wet test?(Check one)

Leakage caused by worn piston rings

Leakage caused by worn cam lobes

Leakage caused by worn valves

Leakage caused by dished valve lifters


Module 7

NoteNoteNoteNoteNote: Compression readings which varybetween cylinders will have a negativeeffect on engine performance.

Leakage TLeakage TLeakage TLeakage TLeakage Testestestestest

22. Perform a cylinder leakage test on thevehicle at your workstation. Indicate yourtest results on the table on the next page.Follow the manufactur’s instructions forusing the cylinder test equipment. Be sureto observe the following procedures.

• Do not use the hose adapter for acompression gauge.

• Run the engine to bring it to normaloperating temperature.

• Disable the ignition system.

• Disable the fuel system.

• Remove all spark plugs.

• Remove the air cleaner, crankcase fillercap, dipstick, and radiator cap (be surethe coolant is at the appropriate level).

• Disconnect the PCV valve inlet hosefrom crankcase.

• Install the tester’s adapter attachment inthe spark plug hole of the cylinder atTDC on it’s compression stroke and theother tester attachment to itscompressed air source.

• Pressurize the cylinder according to themanufacturer’s directions.

• Note the gauge readings (this shows thepercentage of air leakage from thecylinder).


Module 7

• Repeat the test for each cylinder.

• If the leakage exceeds 20%, listen andlook to locate the source of the leakage.

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23. Did any cylinders fail the leakage test?


24. If so, what was the cause?

_______________________________

_______________________________

_______________________________

If you have repaired or altered the vehicle at yourworkstation to complete this module, pleaseassure that it is returned to the original condition.

You have now finished this module. If you haveany doubt about your skills in completing thismodule, please return to step #1 and review yourwork. Once you are confident of your skills, haveyour instructor verify your work.


Return the workstation to the condition inReturn the workstation to the condition inReturn the workstation to the condition inReturn the workstation to the condition inReturn the workstation to the condition inwhich it was found.which it was found.which it was found.which it was found.which it was found.

10

NONONONONOTESTESTESTESTES

1Engine Identification & Service Manual Usage

ModuleModuleModuleModuleModule 8 8 8 8 8

ENGINE IDENTIFICATION AND SERVICE MANUAL USAGE

Objective:Objective:Objective:Objective:Objective: Given an ASIST terminal withElectronic Service Manual (ESM),correctly identify an engine assemblybased on the Engine IdentificationCode and locate the proper diagnosis/repair sections, specifications andprocedures applicable to the vehiclebeing serviced.

Relevance:Relevance:Relevance:Relevance:Relevance: Before you can perform enginemaintenance or diagnosis, you need toknow where to find importantinformation. The Electronic ServiceManual (ESM) helps you find theinformation you need quickly andeasily.


• ASIST Workstation

• ASIST/ESM Disks

Skill Check:Skill Check:Skill Check:Skill Check:Skill Check: Verify that you can identify enginesand use the Electronic Service Manualby correctly answering the questionsin this module.

2 Engine Identification & Service Manual Usage


Engine Identification

1. On the ASIST Main Screen, click the ServiceManual button.

2. Select a vehicle.

3. Select Service Manual. On the QuickReference Index, click General Information (GI).

4. Using the Contents page under IdentificationInformation, locate the illustration that showsthe location of the Vehicle Identification Plate.

5. Locate the illustration of the vehicleidentification number plate. Notice thatinformation about the vehicle’s engine, date ofmanufacture, and place of manufacture isincluded in the number.

6. Where is the vehicle identification plate locatedaccording to the service manual?

________________________________________

The EM EM EM EM EM section of the service manual identifiesrepair information and specifications based upon theengine model number. Because more than oneengine may be installed in a particular vehicle model,you must apply the correct specifications andprocedures to the vehicle that you are servicing.

The engine model number is an alphanumeric(consisting of both letters and numbers) code. Thecode identifies specific properties of the engineinstalled in the vehicle. The code contains fourpieces of information about the engine.



Example: VQ35DEVQ35DEVQ35DEVQ35DEVQ35DE

VQVQVQVQVQ = Engine family: A description for a particularengine group.

35 =35 =35 =35 =35 = Displacement codes X 100: 3.5 liter(3500cc) engine.

D =D =D =D =D = Equipment codes: Double overhead cam

E =E =E =E =E = Fuel delivery type: Multipoint injection

Listed are the various equipment codes:

Answer the following questions if the Engine ModelI.D. Number were VQ35DE.

7. What is the family name designation indicatedfor this engine?

________________________________________

8. What is the engine displacement indicated?

________________________________________

9. Is this engine equipped with double overheadcams?YES / NOYES / NOYES / NOYES / NOYES / NO (Circle one)

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10. What is the fuel delivery type?

________________________________________

Answer the following questions if the Engine ModelI.D. Number were VQ30DE.

11. What is the family name designation indicatedfor this engine?

________________________________________

12. What is the engine displacement indicated?

________________________________________

13. Is this engine equipped with double overheadcams?


14. What is the fuel delivery type?

________________________________________

15. Returning to the Quick Reference Index, clickon the GENERAL INFORMA GENERAL INFORMA GENERAL INFORMA GENERAL INFORMA GENERAL INFORMATION (GI) TION (GI) TION (GI) TION (GI) TION (GI) link.

16. Use the CONTENTSCONTENTSCONTENTSCONTENTSCONTENTS in the GI GI GI GI GI section andclick on IDENTIFICA IDENTIFICA IDENTIFICA IDENTIFICA IDENTIFICATION INFORMATION INFORMATION INFORMATION INFORMATION INFORMATIONTIONTIONTIONTION.

17. Can you determine what engine is installed inthe vehicle from the Vehicle IdentificationNumber (VIN)?


18. Where is the engine serial number located onthe engine(s) for the vehicle selected?

________________________________________

________________________________________



19. Return to the GENERAL INFORMAGENERAL INFORMAGENERAL INFORMAGENERAL INFORMAGENERAL INFORMATION (GI)TION (GI)TION (GI)TION (GI)TION (GI)section. Refer to the CONTENTSCONTENTSCONTENTSCONTENTSCONTENTS in the GI GI GI GI GIsection.

20. Can you find tightening torque specificationsfor standard bolts in this section of the servicemanual?

________________________________________

21. What mark is embossed on the bolt head of agrade 7T 7T 7T 7T 7T bolt?

________________________________________

22. On a M6 M6 M6 M6 M6 bolt, what does the M M M M M stand for?

________________________________________

23. Return to the Quick Reference Index. Click onthe MAINTENANCE SECTION (MA) MAINTENANCE SECTION (MA) MAINTENANCE SECTION (MA) MAINTENANCE SECTION (MA) MAINTENANCE SECTION (MA) link.

24. Refer to the CONTENTS CONTENTS CONTENTS CONTENTS CONTENTS in the MA MA MA MA MA sectionand locate the table indicating recommendedfluids and lubricants.

25. What is the recommended capacity of engineoil (in quarts) with changing the oil and oilfilter?

________________________________________

26. In your experience, what may result if theengine oil level is too high?

________________________________________

________________________________________

________________________________________



CAUTION:CAUTION:CAUTION:CAUTION:CAUTION:Do not overfill beyond the recommended level.Doing so can result in a buildup of deposits inthe combustion chamber and intake manifold.A buildup of deposits around the throttle platesand AAC Valves may result in poor idle quality.

27. Find the SAE Viscosity Number chart.

28. What weight of engine oil is preferred for allambient temperatures?

________________________________________

29. Go back to the Quick Reference Index. Clickon the ENGINE MECHANICAL (EM) ENGINE MECHANICAL (EM) ENGINE MECHANICAL (EM) ENGINE MECHANICAL (EM) ENGINE MECHANICAL (EM) link.

30. On the CONTENTS CONTENTS CONTENTS CONTENTS CONTENTS page of the EM EM EM EM EM section,locate the PRECAUTIONS PRECAUTIONS PRECAUTIONS PRECAUTIONS PRECAUTIONS sub sectionindicating parts that require angular tightening.

31. Do cylinder head bolts require angulartightening?


32. Do connecting rod cap nuts require angulartightening?


33. In what sub section of the EMEMEMEMEM section of theservice manual can you find a blow-upillustration of the engine with indicated torquespecifications for component parts?

________________________________________



34. Where in the EM EM EM EM EM section of the service manualcan you find the engine firing order?

________________________________________

________________________________________

The Service Data and Specifications (SDS)Service Data and Specifications (SDS)Service Data and Specifications (SDS)Service Data and Specifications (SDS)Service Data and Specifications (SDS)subsection of the service manual contains valuableinformation regarding inspection and adjustment ofengine components. Every section of the servicemanual has an SDS subsection.

Refer to the SDS sub section in the EM EM EM EM EM section ofthe service manual and answer the questions thatfollow.

35. How many grades of pistons are available?

________________________________________

Note:Note:Note:Note:Note: If more than one engine is available for thevehicle, specify the engine application.

36. How many grades of main bearings areavailable?

________________________________________

Note:Note:Note:Note:Note: If more than one engine is available for thevehicle, specify the engine application.



37. What is the main bearing clearance limitspecification?

________________________________________

38. What is the connecting rod bearing clearancestandard specification?

________________________________________

39. Return to the Quick Reference Index. Click onENGINE LUBRICAENGINE LUBRICAENGINE LUBRICAENGINE LUBRICAENGINE LUBRICATION & COOLINGTION & COOLINGTION & COOLINGTION & COOLINGTION & COOLINGSSSSSYYYYYSTEMS (LSTEMS (LSTEMS (LSTEMS (LSTEMS (LC) C) C) C) C) link.

40. On the CONTENTS CONTENTS CONTENTS CONTENTS CONTENTS page of the L L L L LC C C C C section,find the Engine Lubrication Circuit Engine Lubrication Circuit Engine Lubrication Circuit Engine Lubrication Circuit Engine Lubrication Circuit subsectionand click on Lubrication Circuit.Lubrication Circuit.Lubrication Circuit.Lubrication Circuit.Lubrication Circuit.

Notice that the lubrication circuit diagram indicatesthe direction of oil passage through the engine.

41. Is there a similar circuit diagram whichindicates the direction of water though theengine?


42. Where in the service manual can you findinformation regarding cooling fan operation?

________________________________________

Why?

________________________________________

________________________________________

________________________________________



You have now completed this module and should beable to identify the engine assembly based on theEngine Identification Code and locate the properdiagnosis/repair sections in the service manual toassure that the correct specifications andprocedures are applied to the serviced vehicle. If youhave any doubt about your skills in completing thismodule, please return to step #2 and review yourwork. Once you are confident of your skills, haveyour instructor verify your work and initial yourmodule.




NOTES

1SR20DE Valve Adjustment


SR20DE VALVE ADJUSTMENT

Objective:Objective:Objective:Objective:Objective: Given a SR20DE engine and aService Manual, correctly adjust thevalves of the SR20DE Engine usingspecial service tool No. J38957-N.

Relevance:Relevance:Relevance:Relevance:Relevance: Correctly checking and adjusting valveclearance on the SR20DE enginerequires special tool No. J38957-N.This procedure synchronizes the twovalves to the single rocker arm whilemaintaining proper contact betweenthe rocker arm and cam lobe.


• SR20DE engine

• Special Tool J38957-N

• Service Manual

Skill Check:Skill Check:Skill Check:Skill Check:Skill Check: Verify that you can perform thetechnique by correctly answering thequestions, which demonstrateunderstanding of each step listed inthe Service Manual. Your instructorwill verify that the valves are properlyadjusted and that all questions arecorrectly answered.

2 SR20DE Valve Adjustment


1. Valve adjustment is necessary following thereplacement of what parts or serviceprocedures? (Indicate in the space providedbelow):

________________________________________

________________________________________

Note: Note: Note: Note: Note: Keep parts in order so that they can beinstalled in their original positions duringassembly.

2. Remove rocker arms, shims, guides, and bothcamshafts using the procedure described inthe service manual EM EM EM EM EM section.

3. Make sure the rocker arm guides are installedin their proper place (centered in the valvespring retainers).

4. Install the special tool plate into the cylinderhead over the No. 1 and No. 2 cylinders.

5. Align the tool plate holes with the mating camjournal holes in the cylinder head and securethe plate with two furnished bolts. Center thetool plate and tighten the bolts securely.

6. Working on the No. 1 cylinder intake valves,insert the dial indicator through the hole directlyabove the valve equipped with the rocker armguide (see the illustration at the left).

Special Tool:J38957-N Valve ShimGauge Plate Kit



7. Move the dial indicator back and forth in theplate hole until it is centered directly over therocker arm guide. Slowly move it around untilthere is no fluctuation in the dial indicatorneedle. The rocker arm guide will tip back andforth on the valve stem therefore the dialindicator must be correctly centered or theindicated reading will be incorrect.

8. Record the dial reading and note the cylindernumber and valve.

Cylinder #: _______ Valve: _________

Measurement: ___________

9. What is the most important operation whenmeasuring the distance on the rocker armguide?

________________________________________

________________________________________

________________________________________

10. Withdraw the dial indicator and insert it into theadjacent hole for the intake valve of thatcylinder. After removing the shim, align thepointer with the center of the valve stem.

11. Move the dial indicator back and forth in theplate hole until it is centered directly over thevalve stem. Slowly move it around until there isno fluctuation in the dial indicator needle (seethe illustration at left).

Rocker Arm Guide

Valve

Valve Spring Retainer



Shim

T

IndicatesT= 2.800 (0.1102 in)

Shim

Rocker ArmGuide

Rocker Arm

12. Record the dial reading and note the cylindernumber and valve.Cylinder #: ____ Valve: ____________Measurement: ___________

13. Select a shim that is equal to the differencebetween the two measurements. Subtract themeasurement taken in step 8 (rocker armguide) from the measurement taken in step 12(valve stem). (see the illustration at left). Thisdimension (T1) will indicate the thicknessrequired to synchronize the two valves to theirsingle rocker arm.

Step 12 Measurement ______

Step 8 Measurement - ______

Thickness required = ______

Notice in the illustration at the left that one side ofthe rocker arm is machined to accommocate thegroove in one shim.

Shims are available in 17 different thicknesses,ranging from 2.800 mm (0.1102 in.) to 3.200 mm(0.126 in.) in increments of 0.025 mm (0.0010 in.).



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)2011.0(008.28200

)1911.0(520.30352

)2111.0(528.28252

)1021.0(050.30305

)2211.0(058.28205

)1121.0(570.30357

)2311.0(578.29257

)0221.0(001.31300

)2411.0(009.29200

)0321.0(521.31352

)2511.0(529.29252

)0421.0(051.31305

)1611.0(059.29205

)0521.0(571.31357

)1711.0(579.29257

)0621.0(002.32300

)1811.0(000.30300

14. What would be the symptom if the shim heightis not even? (Check one)

Rough idle or engine misfire

Burnt Valve

Rocker arm wear

Cam lobe wear

All

You have now completed this module and should beable to correctly adjust the valves of the SR20DEengine using special service tool No. J38957-N. Ifyou have any doubt about your skills in completingthis worksheet, please return to step #1 and reviewyour work. Once you are confident of your skills,have your instructor verify your work.

Instructor’sInstructor’sInstructor’sInstructor’sInstructor’s I I I I Initialsnitialsnitialsnitialsnitials_____________________



NOTES

1Hydraulic Valve Lash Adjusters

Module 10

Objective:Objective:Objective:Objective:Objective: Given an SR20DE engine and aservice manual, properly bleed air fromhydraulic valve lash adjusters.

Relevance:Relevance:Relevance:Relevance:Relevance: Understanding how to bleed valve lashadjusters is essential to proper engineoverhaul.


• SR20DE Engine

• Service Manual

Skill Check:Skill Check:Skill Check:Skill Check:Skill Check: Verify that you can properly bleed theadjusters following the instructions inthe Service Manual and by correctlyanswering all questions in the module.

HYDRAULIC VALVE LASH ADJUSTERS

2 Hydraulic Valve Lash Adjusters


1. Begin this module with the hydraulic valveadjuster removed from the cylinder head, acontainer of clean engine oil, and a piece ofaluminum welding rod or other suitable tool ofthe appropriate diameter, with the end finishedoff so it will not damage the check valve ball.

2. On which page in the service manual is thehydraulic valve lash adjuster bleedingprocedure listed?

________________________________________

3. Follow the valve hydraulic lash adjusterbleeding procedure listed in the servicemanual as Illustrated. Be careful not to scratchor damage the check valve with the rod.

4. Can you disassemble the hydraulic lashadjuster for service?


5. Can you bleed the air in the valve hydraulic lashadjuster high pressure chambers by runningthe engine?


6. Can the hydraulic valve lash adjuster plungerbe compressed with your fingers once it hasbeen properly bled?

YES / NOYES / NOYES / NOYES / NOYES / NO (Circle one):

If YESYESYESYESYES, what is the problem?

________________________________________

________________________________________

Welding RodEngine Oil

3Hydraulic Valve Lash Adjusters

Module 10

7. What is the proper procedure if the hydrauliclash adjuster cannot be bled properly?

________________________________________

________________________________________

8. What would the symptom be if the valvehydraulic lash adjuster has not been bledproperly?

________________________________________

________________________________________

9. Review the objective of this module. If you areunclear about any aspect of the objective,request assistance from your instructor.

You have now completed this module. If you haveany doubt about your skills in completing thismodule, please return to step #1 and review yourwork. Once you are confident of your skills, haveyour instructor verify your work.

Instructor’s Initialsnstructor’s Initialsnstructor’s Initialsnstructor’s Initialsnstructor’s Initials____________________


4 Hydraulic Valve Lash Adjusters

NOTES

1QR25DE Valve Clearance and Adjustment


QR25DE VALVE CLEARANCE INSPECTION AND ADJUSTMENT

Objective:Objective:Objective:Objective:Objective: Given a QR25DE engine, correctlyperform the valve clearance inspectionand adjustment.

Relevance:Relevance:Relevance:Relevance:Relevance: The procedure is new because shimsare no longer used. Knowing thisprocedure will help you better servicethis engine in your dealership.

Resources:Resources:Resources:Resources:Resources: · ESM Section EM

Skill Check:Skill Check:Skill Check:Skill Check:Skill Check: Perform valve clearance inspection,identify proper valve lifter selectionand identify proper camshaft removaland installation procedure.

2 QR25DE Valve Clearance and Adjustment


1. Locate the valve clearance and adjustmentprocedure in the ESM. Print these pages to usefor reference at the workstation.

2. When should the valve clearance be inspected?

________________________________________

________________________________________

________________________________________

________________________________________

3. What are the valve clearancespecifications for the QR25DE engine?

HOHOHOHOHOTTTTT

Intake ___________________.....

___________________

Exhaust ___________________

___________________.....

COLDCOLDCOLDCOLDCOLD

Intake ___________________

___________________

Exhaust ___________________.

___________________.....

4. Follow the service manual procedure and pre-pare the engine to check intake and exhaustclearance on cylinder #4.

5. Cylinder #4 must be at TDC of the_______________ stroke before checkingvalve clearance.



6. Measure and record intakeintakeintakeintakeintake valve clearance forcylinder #4 in the following chart. Circle theoutcome of measurement below.

MEASUREMENT

(front)

. OK / NG

(rear)

. OK / NG

7. Measure and record exhaustexhaustexhaustexhaustexhaust valve clearance forcylinder #4 in the following chart. Circle theoutcome of measurement below.

MEASUREMENT

(front)

. OK / NG

(rear)

. OK / NG

8. If a valve clearance is out ofspecification, what component must bereplaced to correct the clearance?

________________________________________

9. What component(s) must be removed in order toaccess this part?

________________________________________

10.According to the service manual, what othervalve clearances can beinspected at the same time withcylinder #4?________________________________________

________________________________________

________________________________________



11. According to the service manual, should thespecs for a cold engine or hot engine be usedfor adjustment?

COLDCOLDCOLDCOLDCOLD / HO / HO / HO / HO / HOTTTTT (Circle One)

12. What is the equation for calculating the correctthickness for the replacement valve lifter?

________________________________________

________________________________________

________________________________________

NONONONONOTE:TE:TE:TE:TE: Measurement accuracy of the valveclearance and removed lifter is criticalsince you can’t confirm your resultsuntil the camshafts are installed!

IMPORTMPORTMPORTMPORTMPORTANTANTANTANTANT: You will NOT be removing the cam-shafts during this exercise. See your instructor fordimension “t1” (thickness of the removed lifter).Record the dimensions “t1” below.

INTAKE

Front .

Rear .

EXHAUST

Front .

Rear .



13. Using the equation from step #12 list thereplacement valve lifter(s) needed to correctthe valve clearance for the intake valves youidentified as NG in step #6.

REPLACEMENT LIFTER

Thickness ID Mark

Front . .

Rear . .

14. Using the equation from step #12 list thereplacement valve lifter(s) needed to correctvalve clearance for the exhaust valves identifiedas NG in #7.

REPLACEMENT LIFTER

Thickness ID Mark

Front . .

Rear . .

15. What page in the service manual does thecamshaft removal and installation instructionsbegin?

________________________________________

16. According to the service manual cylinder #1must be at ___ ___ ___ ___ ___ on its

____________________stroke prior to removingthe camshafts.

17. When following the service manual procedurefor camshaft removal, will the timing chaindisengage from the crankshaft sprocket whilethe front cover is attached to the block?

YES /YES /YES /YES /YES / NO NO NO NO NO (Circle one)



18. Visually, how can you differentiate the intakecamshaft from the exhaust camshaft when theyare removed from the engine?

________________________________________

________________________________________

________________________________________

19. When installing the camshafts, the intakecamshaft dowel pin must be at _____ o’clockand the exhaust camshaft dowel pin must be at______ o’clock.

20. The marks that identify the intakeintakeintakeintakeintake camshaftbrackets are:

NUMBERS / LETTERS NUMBERS / LETTERS NUMBERS / LETTERS NUMBERS / LETTERS NUMBERS / LETTERS (Circle One)

21. The marks that identify the exhaustexhaustexhaustexhaustexhaust camshaftbrackets are:

NUMBERS / LETTERSNUMBERS / LETTERSNUMBERS / LETTERSNUMBERS / LETTERSNUMBERS / LETTERS (Circle One)

22. Locate the procedure for tightening thecamshaft brackets. Read this procedure andexplain why it is a 4-step torque/tighteningsequence.

________________________________________

________________________________________

________________________________________

23. According to the service manual, if thecamshaft endplay is out of specification, whatmust be replaced first?

________________________________________



You have successfully completed this worksheet.You should now be able to inspect and adjust valveclearance on the QR25DE engine.

If you have any doubts about the skills you haveacquired, please return to Step 1 and review yourwork. When you are confident of your skills, contactyour instructor and have him verify your work.

Instructor’s Initials:Instructor’s Initials:Instructor’s Initials:Instructor’s Initials:Instructor’s Initials: ________________

Please return this workstation to the condition inPlease return this workstation to the condition inPlease return this workstation to the condition inPlease return this workstation to the condition inPlease return this workstation to the condition inwhich you found it.which you found it.which you found it.which you found it.which you found it.


NOTES

1Engine Noise Diagnosis


ENGINE NOISE DIAGNOSIS

Objective:Objective:Objective:Objective:Objective: Given an engine noise audio tape/CDand this module, identify commonengine noises and describe the mostlikely causes of each noise.

Relevance:Relevance:Relevance:Relevance:Relevance: Understanding and interpretingengine noises is an important part ofengine diagnosis. This module willhelp you to understand the meaning ofdifferent engine noises.


• Engine Noise Diagnosis AudioTape/CD

Skill Check:Skill Check:Skill Check:Skill Check:Skill Check: Your understanding of engine noisesand how to identify them will bedetermined by successfully answeringthe questions in this module.

2 Engine Noise Diagnosis


ENGINE NOISE DIAGNOSIS AUDIOTAPE/CD

This module includes an audio tape/CD. Followingthe instructions in the module, you will listen to theaudio then work through the module. After you havecompleted all the activities in the module, have theinstructor sign off the module and sign-off sheet.

The tape, “Engine Noise Diagnosis,” is recorded ontwo sides. One side contains a collection ofexamples of common engine noises with adescriptive narration. The other side of the tapegives the same noises, without narration. You will beasked to identify the sounds on that side of the tapeat the end of this module.

The audio tape/CD is also a job aid. Keep it as aresource and listen to it when you are faced with anengine-noise repair.

1. Listen to the audio tape/CD now. Put a checkmark by each noise as you listen to it: (Checkone)

Timing belt tension too tight

Timing belt tension too loose

Drive belt tension too loose (squeak)

Drive belt tension too loose (shriek)

Piston pin knock

Piston slap

Bearing noise

Hydraulic lifter noise

Valve stem noise



Using the audio tape/CD as a reference, identify thefollowing noises by their description. Please markthe correct response.

2. A whining noise near the front of a hot engine:(Check one)

Timing belt too tight

Timing belt too loose

Drive belt too tight

Drive belt too loose

3. A flapping sound near the front of the engine:(Check one)




Drive belt too loose

4. An intermittent shrieking noise at the front ofthe engine when the air conditionercompressor cycles on: (Check one)


Timing belt slipping


Drive belt slipping



5. A shrieking sound when the wheels are turnedhard: (Check one)




Drive belt tension too loose

6. A knock at the crankshaft pulley, noticeable asthe engine warms up: (Check one)

Rod bearing

Main bearing

Piston pin

Piston slap

7. A knock at the side of the engine which islouder when the engine is cold: (Check one)

Rod bearing

Main bearing

Piston pin

Piston slap

8. A thumping noise at the side of the block whichis louder when the engine is hot and diminisheswhen one cylinder is shorted out:(Check one)

Connecting rod bearing

Main bearing

Piston pin

Piston slap



9. A thumping noise at the side of the block whichis louder when the engine is hot and doesn’t goaway when any cylinder is shorted out:

(Check one)

Rod bearing

Main bearing

Piston pin

Piston slap

10. A clicking noise which originates near thecylinder head or rocker cover: (Check one)

Hydraulic lifter

Valve stem

Piston pin

Rod bearing

11. A squeaky-hissing sound which gets louder asthe engine warms up: (Check one)

Hydraulic lifter

Valve stem

Piston pin

Rod bearing



Return your workstation to the condition in whichReturn your workstation to the condition in whichReturn your workstation to the condition in whichReturn your workstation to the condition in whichReturn your workstation to the condition in whichit was found.it was found.it was found.it was found.it was found.


NOTES


1VQ35DE Timing Chain Installation

Objective:Objective:Objective:Objective:Objective: You will be able to performtiming chain installation on theVQ35DE engine.

Relevance:Relevance:Relevance:Relevance:Relevance: The timing chain installationprocedure needs to beperformed properly to avoidengine damage.

Resources:Resources:Resources:Resources:Resources: · ESM Section EM

· ESM Job Aid

Skill Check:Skill Check:Skill Check:Skill Check:Skill Check: Perform timing chain installationand ensure timing chain andsprockets are aligned correctly.

VQ35DE TIMING CHAIN INSTALLATION


2 VQ35DE Timing Chain Installation

1. Locate and print the timing chaininstallation procedure in the ESM.

2. Position the crankshaft where the ESMspecifies. The crankshaft key should beat: Circle one:

9:00 10:00 11:00 12:00

3. Can you locate a mark to help with thealignment?

____________________________________

4. Install the crankshaft sprocket. How canyou tell if the sprocket is installedcorrectly?

____________________________________

____________________________________

____________________________________

5. Make sure the dowel pin on the bank 1exhaust cam is positioned as illustratedon the left.

6. Position the Bank 2 camshafts in theposition indicated in the diagram on theleft.

7. On the intake cam, what size hole mustbe facing up?LARGE / SMALL LARGE / SMALL LARGE / SMALL LARGE / SMALL LARGE / SMALL (Circle one)

8. Follow the service manual procedure toinstall Bank 2 secondary chain andsprockets.


3VQ35DE Timing Chain Installation

9. Which marks on the exhaust camsprocket must be lined up with thedouble gold links and which mark on theintake sprocket must line up with thesingle gold link?

ROUND / OVROUND / OVROUND / OVROUND / OVROUND / OVALALALALAL (Circle one)

10. Tighten the camshaft sprocket mountingbolt by hand.

11. Remove the stopper pin from thesecondary chain tensioner.

12. Install the primary chain by aligning theyellow links with the mating marks on theintake sprockets and the orange link withthe mating mark on the crank.

13. Install the internal (upper) chain guide.

14. Install the primary chain tensioner.

Service Tip:Service Tip:Service Tip:Service Tip:Service Tip:

Check timing chain alignment and verify thatthe chain properly engages all sprockets andthat the chain guides have been installed inthe proper direction.

This completes the timing chain installation forthis workstation. Please notify your instructorfor verification of your work.

Instructor Signoff:Instructor Signoff:Instructor Signoff:Instructor Signoff:Instructor Signoff: .....

Please return the workstation to its originalPlease return the workstation to its originalPlease return the workstation to its originalPlease return the workstation to its originalPlease return the workstation to its originalcondition.condition.condition.condition.condition.

NOTES

4 VQ35DE Timing Chain Installation

1VK45DE Timing Chain Replacement

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Module14

VK45DE TIMING CHAIN REPLACEMENTVK45DE TIMING CHAIN REPLACEMENTVK45DE TIMING CHAIN REPLACEMENTVK45DE TIMING CHAIN REPLACEMENTVK45DE TIMING CHAIN REPLACEMENT

ObjectiveObjectiveObjectiveObjectiveObjective: Given a VK45DE engine and ServiceManual, you will demonstrate the skillsnecessary to properly remove andreplace the timing chain on theVK45DE engine.

RelevanceRelevanceRelevanceRelevanceRelevance: Knowing how to properly remove andreplace the timing chain on a VK45DEengine is essenial to properly andaccurately service this engine.

ResourcesResourcesResourcesResourcesResources: The following are provided:

• VK45DE engine

• Service Manual

• Hand tools

• Puller (steering wheel)

Skill CheckSkill CheckSkill CheckSkill CheckSkill Check: Your instructor will check yourunderstanding of this procedure byinspecting your work and verifying thatall questions are answered correctly. Inparticular, proper cam timing will bechecked.

2 VK45DE Timing Chain Replacement

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Module14

TDC

1. Open the Service Manual to the timing chainsection or refer to the copy provided.

2. Set number 1 piston on TDC on itscompression stroke. Do this by removing thecam position sensor. Rotate the crankshaftwhile looking through the sensor opening in thetiming cover. When the group of 3 sensor marksjust begin to pass the opening, stop. Then alignthe balancer (crank pulley) to the TDC timingmark.

3. Remove the oil pan.

4. Remove the crankshaft damper.

Note:Note:Note:Note:Note: Do not remove the balance weights (left andright hexagon bolts) at the front of thecrankshaft pulley. These are installed at theengine plant to dynamically balance theengine.

5. Remove the left and right CVTC actuator coversfrom the timing cover.

6. Remove the timing cover.

Note:Note:Note:Note:Note: There is an o-ring and filter screen assemblyin the timing cover for bank 1 and bank 2CVTC oil passages. The o-ring and screencan easily fall out of the passage duringtiming cover removal. Verify that they are inthe proper locations after removing the timingcover and when reinstalling the timing cover.

7. Remove the oil pump assembly. You will need touse a puller or slide hammer to remove the oilpump drive as it is an interference fit on thecrankshaft.

BalanceWeight


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Module14

8. Remove left and right rocker covers. With theengine at TDC for cylinder number 1, the leftbank camshafts should be in the position shown(see illustration at left).

9. Using a 24mm open-end wrench to hold eachcamshaft, break loose the sprocket retainingbolts.

10. Remove the left and right chain tensioners.

11. Remove the exhaust camshaft sprocket retainingbolts, then remove the exhaust sprockets.

12. Remove the intake camshaft sprockets, timingchains and crankshaft sprockets.

13. Are the timing chains the same for the left andright bank?

YES / NOYES / NOYES / NOYES / NOYES / NO (circle one)

14. Are the exhaust camshaft sprocketsinterchangeable left to right?


15. Are the intake camshaft sprockets/CVTCactuators interchangeable left to right?



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Module14

R

16. Why?

_____________________________________

_____________________________________

_____________________________________

Instructor Sign Off Instructor Sign Off Instructor Sign Off Instructor Sign Off Instructor Sign Off ________________________

Note:Note:Note:Note:Note: The guides are marked to indicate left orright bank to insure correct installation.

Timing Chain InstallationTiming Chain InstallationTiming Chain InstallationTiming Chain InstallationTiming Chain Installation

Note:Note:Note:Note:Note: Completely install the right timing chain first,followed by the left. Right crankshaft timinggear marks cannot be seen when the leftsprocket is installed on the crankshaft.

17. Install the right crankshaft sprocket.

18. Install the right bank intake camshaft sprocket/CVTC actuator. The camshaft dowels should beat the 12:00 position relative to the top of thecylinder head (see illustration at left).

19. Using a wrench to hold the intake camshaft inplace, torque the intake sprocket bolt.

Note:Note:Note:Note:Note: The intake camshaft sprocket/CVTC actuatorcan be installed in two different positions.Use the index slot that places the “R” atapproximately the 12 o’clock position inrelation to the top of the cylinder head.

20. Install the timing chain around the crankshaftand intake camshaft sprockets.


GITN

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Module14

Orange orBlue Links

Note:Note:Note:Note:Note: The orange or blue link must line up with thecrankshaft index mark and the yellow or goldlinks must line up with each camshaft indexmark. Make sure the chain is properly routedaround the timing chain oil jet.

21. Install the right bank exhaust camshaft sprocket.You may have to position the camshaft correctlyto line up the index marks. Use the 24 mm.Open-end wrench to rotate the camshaft ifrequired.

Note:Note:Note:Note:Note: Hold the exhaust cam shaft firmly with thewrench when torquing the sprocket toisolate the timing chain from the torqueapplied to the bolt.

22. Compress the right bank tensioner and use asuitable pin to hold the piston in the retractedposition.

Note:Note:Note:Note:Note: The right bank tensioner has an oil hole atthe top of the piston. Do not cover the holewhile compressing the piston as oil needs toescape through the hole as you compressthe piston.

23. Install the tensioner and release the pin. This willkeep the right bank chain in the correct positionduring installation of the left bank.

24. Properly torque the right intake and exhaustsprocket bolts then recheck timing markalignment.

25. Install the left bank crankshaft sprocket andintake camshaft sprocket/CVTC actuator. Use awrench to hold the camshaft while torquing thebolt.


GITN

0028A

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0005AModule14

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L

Orange andBlue Links

Note:Note:Note:Note:Note: The left bank intake sprocket/CVTCactuator must be installed with the letter “L”in the 12 o’clock position with respect tothe top of the cylinder head. Make sure thechain guide is in its proper position wheninstalling the intake sprocket. If it is out ofposition, the sprocket or guide must beremoved to install in the correct position.

26. Install the left bank timing chain. The orange orblue link must line up with the index mark on thecrankshaft, and the yellow or gold link with theindex mark on the intake camshaft sprocket.

Note:Note:Note:Note:Note: Make sure the chain is properly routedaround the timing chain oil jet.

27. Install the left bank exhaust camshaft sprocketusing the left bank index mark. If necessary, usethe 24mm. open-ended wrench to rotate thecamshaft(s) for proper alignment.

28. Compress the left bank chain tensioner and usea suitable pin to hold the piston in the retractedposition.

29. Install the tensioner on the engine and removethe pin.

30. Properly torque the left intake and exhaustsprocket bolts then recheck timing markalignment.


GITN

0028A

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Module14

31. Are all the index marks and timing chain coloredlinks in proper position?


If No, repeat the installation procedure tocorrect the problem.

Instructor Sign Off:Instructor Sign Off:Instructor Sign Off:Instructor Sign Off:Instructor Sign Off: _______________________

32. Rotate the engine two to three times.

33. Reinstall the other components as directed byyour instructor.

34. If you had difficulty performing the Skill Checkstated at the beginning of this module, ask yourinstructor for assistance.

35. When you have completed the Skill Check toyour satisfaction, see your instructor forverification of your work.

Instructor’s InitialsInstructor’s InitialsInstructor’s InitialsInstructor’s InitialsInstructor’s Initials ________________________

Return the workstation to the condition in whichReturn the workstation to the condition in whichReturn the workstation to the condition in whichReturn the workstation to the condition in whichReturn the workstation to the condition in whichit was found.it was found.it was found.it was found.it was found.

8

NONONONONOTESTESTESTESTES

1VQ35DE Water Pump Removal and Installation


VQ35DE WATER PUMP REMOVAL AND INSTALLATION

Objective:Objective:Objective:Objective:Objective: At the end of this work session youwill be able to remove and install thewater pump for the VQ35DE engine toassure the proper circulation ofcoolant to the engine.

Relevance:Relevance:Relevance:Relevance:Relevance: Understanding how to properlyremove and replace the water pump ina VQ35DE engine is essential toproperly and accurately service thisengine.

Resources:Resources:Resources:Resources:Resources: The following items are provided:• VQ35DE engine on stand• Applicable Service Manual• Basic tools

Skill Check:Skill Check:Skill Check:Skill Check:Skill Check: The instructor will check yourunderstanding of this procedure byinspecting your work and verifying thatall questions are answered correctly.

2 VQ35DE Water Pump Removal and Installation


1. The water pump for the new VQ engine ischain driven (from the outer side of the timingchain) rather than belt driven to simplify theauxiliary equipment drive system and to shortenthe overall length of the engine.

2. The water pump is small and built into the(rear) timing case subassembly of the engine.



3. Water pump removal is complicated due to therestricted space between the engine and thebody side member of the vehicle. To facilitatethe servicing of the water pump:

• The side member is slightly modified tomake water pump removal easier.

• Two special covers have been installed inthe timing chain case for easier access tothe pump and chain tensioner.

4. Locate water drains on engine block.



5. When you perform this service on a vehicle, besure to drain the coolant to below the level ofthe water pump, or coolant will enter the enginecrankcase.

• Drain the water from the radiator byopening the radiator drain cock.

• Do not forget to drain the coolant throughthe drain opening at the location wherethe alternator would attach to the timingchain case.

6. Confirm that the # 1 cylinder is positioned atT.D.C. on its compression stroke.

TIMING CHAIN TENSIONER REMOVAL

7. See Service Manual first. Remove the coverinstalled in the timing chain case to allowaccess to the timing chain tensioner. (Do notremove water pump at this time).



PUSH

Hole

8. Use caution when removing the cover from thetiming case. The case is made of aluminumand can easily be damaged.

9. Remove any sealing material from the tensionercover and the outside of the timing chain case.

10. The timing chain must be relaxed to disengagethe water pump. The timing chain tensionermust be removed to allow slack in the timingchain.

11. The space between the engine front cover andthe side member is restricted making it difficultto see the two bolts which secure the chaintensioner to the (rear) chain case subassembly.Therefore, the tensioner removal proceduremust be performed by feel. Take care not todrop the bolts into the case.

Note:Note:Note:Note:Note: Failure to follow this procedure may resultin the internal parts of the tensioner(sleeve, spring bar, etc.) to be forced outby the reaction of the built-in spring anddrop into the case.

12. Retract the tensioner plunger by pulling the leverdown to release the plunger stop tab.

Note:Note:Note:Note:Note: Insert a stopper pin (2.5 mm or 0.98 in.Allen wrench) into the tensioner body holeto hold the lever while retracting theplunger.

13. While holding the slack guide by hand, asillustrated, remove the tensioner.




WATER PUMP REMOVAL

Note: See Service Manual prior to water pumpremoval.

14. To disengage the water pump from the chain,rotate the crankshaft approximately 20 degrees(2nd timing mark on crank pulley) counter-clockwise. This will relax the timing chaintension.

15. Remove the water pump access cover,installed in the timing chain case. Be carefulwhen removing the cover to the timing chaincase. The case is made of aluminum and canbe easily damaged.

16. Remove any sealing material from the waterpump cover and the outside of the timing chaincase.



17. Water pump input pressure is high. This highpressure prevents easy removal of the waterpump. To overcome this problem, perform thefollowing procedure to remove the water pump.

18. Remove the three M8 bolts from the waterpump flange.

19. Two of the holes on the water pump flange aretapped holes. Install two M8 bolts in the twoM8 tapped holes on the water pump flange andtighten them until they contact the counterbores on the timing case.

20. Alternately turn the two M8 bolts one-halfrotation each time to drive the water pump out.

Note:Note:Note:Note:Note: Failure to follow this procedure may resultin damage to the pump or timing chain.

21. As a result of the restricted space between theengine and the body side member, there is adefinite water pump removal and installationdirection.



22. Failure to follow the directional procedure forremoval and installation may result in damageto the water pump.

23. When the O-ring surface and the water pumpare free to move by hand, pull the O-ringsection straight out. Remove the water pumpfrom the timing chain case. Be careful not tobump the O-ring sealing surface or the microfinished section of the timing chain case duringremoval.

24. Move the water pump in the direction indicatedby the letter “A” (in the illustration at the left)until it touches the side member.

25. Lift the water pump in the direction indicatedby the letter “B” in the illustration.


26. Before reinstalling the water pump into thetiming case, ensure that the mating surfaces forthe O-rings are clean, free of scratches andlubricated.

27. Reinstall the water pump in the reverse order ofremoval. Be sure to follow the procedureoutlined above regarding the direction ofremoval and installation of the pump. Torque allbolts to Service Manual specifications.

BBBBB

AAAAA



28. After the water pump is installed and the timingchain has been positioned on the pump, rotatethe crankshaft back 20 degrees in a clockwisedirection to move the chain slack back to thetiming chain tensioner.

29. Pull the slack guide back to permit reinstallationof the chain tensioner. Reinstall the tensioner.Torque all bolts to Service Manualspecifications.

30. Remove the stopper pin from the tensioner bodyso that the tensioner may contact the slackguide.

O-rings

Mechanical SealMechanical Seal

O-rings

Mechanical SealMechanical Seal

Vane



31. When performing this operation on a vehicle:

• Be certain that the sealant is properlyapplied to the tensioner and water pumpcovers of the timing chain case, it mustcompletely cover the mating surfaces.

• Be sure to apply the coat of sealant to theshaded areas illustrated below and tightenthe bolts to Service Manual specifications.



32. If performing this procedure on a vehicle, afterinstalling the tensioner, run the engine at about3000 rpm under no load to purge air from thehigh pressure chamber.

33. Lubricating oil will not reach the tensionerimmediately following installation. A rattlingnoise will be heard for approximately 10seconds of tensioner operation. This indicatesthat air still remains in the chamber. This isnormal and will not affect the other areas ofoperation.




12

NOTES

VQ35DE Water Pump Removal and Installation

1Cylinder Head Torquing


CYLINDER HEAD TORQUING

Objective:Objective:Objective:Objective:Objective: Given a training engine, a torquewrench , torque angle meter and aService Manual you will demonstratethe skills necessary to properlymeasure head bolts to determinewhether they can be reused, andproperly torque the cylinder head boltsto specifications.

Relevance:Relevance:Relevance:Relevance:Relevance: Any time you remove and reinstall acylinder head or retorque cylinderhead bolts it is essential to determinewhether the existing head bolts can bereused or must be replaced. Also,correct bolt torquing is essential tomaintain cylinder head pressure andprevent damage to the head gasket.


• Engine

• Torque Wrench

• Torque Angle Meter

• Service Manual

Skill Check:Skill Check:Skill Check:Skill Check:Skill Check: The instructor will check yourunderstanding of these skills byverifying the accuracy of your workand checking that all questions areanswered correctly. Also, yourunderstanding of plastic zone boltsand using the torque angle meter willbe checked.

2 Cylinder Head Torquing


Note:Note:Note:Note:Note: Depending upon the engine, plastic zonebolts are measured either for length ordiameter to determine if they can be reused.Verify the procedure using the applicableService Manual.

1. On what page in the Service Manual can youfind the instructions for cylinder head boltmeasuring?

________________________________

2. Remove one half of the cylinder head bolts.

3. According to the Service Manual, can thesebolts be reused?

________________________________

Note:Note:Note:Note:Note: The cylinder head does not need to beremoved during this workshop exercise. Theobjective is for you to perform the correcttorquing procedure.

5. On what page in the Service Manual is thesequence for tightening cylinder head boltslocated?

________________________________

6. Apply a light coat of oil to the threads andseating surfaces of the cylinder head boltbefore installing.

3Cylinder Head Torquing


7. Follow the Service Manual procedure to tightenthe cylinder head bolts.

8. Torque the bolts as indicated.

9. Loosen the bolts, then torque to specification.

10. Use the torque angle gauge and turn the boltsto the specified amount. This tightens the boltto the proper torque and keeps the bolt fromstretching beyond specification.

Note:Note:Note:Note:Note: Cylinder head bolts must be tightenedusing a multi-step process. A torquewrench AND torque angle meter must beused. A torque wrench alone will NOTtighten the bolts to the requiredspecification!




NOTES

4 Cylinder Head Torquing

1QG18DE Valve Adjustment


Objective:Objective:Objective:Objective:Objective: Use Special tools, feeler gauges anda Service Manual to properly measurevalve clearance, determine correctspecifications and adjust valveclearance on a QG18DE engine.

Relevance:Relevance:Relevance:Relevance:Relevance: The QG18DE engine has a uniquevalve train configuration. Knowinghow to properly inspect, adjust andservice the valve train is critical totimely and accurate repair.


• QG18DE Engine

• Service Manual

• Feeler Gauge

• Special Tool J-38972-1

• Special Tool J-38972-2

Skill Check:Skill Check:Skill Check:Skill Check:Skill Check: The instructor will check yourunderstanding of these skills byverifying the accuracy of your workand checking that all questions areanswered correctly.

QG18DE VALVE ADJUSTMENT

2 QG18DE Valve Adjustment


1. What is the clearancespecification for INTAKE valves on theQG18DE engine?

________________________________________

2. What is the clearance specification forEXHAUST valves on the QG18DE engine?

________________________________________

3. Should the measurement be taken with thecylinder head Hot or Cold?

________________________________________

4. Record INTAKE valve clearance measurementsin the following chart for the cylinder you areassigned to work on.

5. Record EXHAUST valve clearancemeasurements in the following chart for thecylinder you are assigned to work on.

TNEMERUSAEM .K.O .G.N

TNEMERUSAEM .K.O .G.N

3QG18DE Valve Adjustment


6. If any clearances are out ofspecification, adjust them according to theprocedure found in the Service Manual.

7. Recheck the valve clearances.

8. What is the maintenance service interval forchecking and adjusting valve clearance?

_________________________________________

9. What other service conditions may require avalve adjustment?

_________________________________________

_________________________________________


Instructor’s Initials _________________________Instructor’s Initials _________________________Instructor’s Initials _________________________Instructor’s Initials _________________________Instructor’s Initials _________________________


TOOL (A)TOOL (B)

Lifter Plate (Shim) ThicknessAvailable at intervals of 0.02 mm(0.0008 im) thickness

NOTES

4 QG18DE Valve Adjustment

1


QR25DE Timing Chain and Balancer Unit

Objective:Objective:Objective:Objective:Objective: You will be able to remove and installthe timing chain on the QR25DEengine.

Relevance:Relevance:Relevance:Relevance:Relevance: The QR25DE engine is new and usesa narrow-pitch, silent-type timingchain, hydraulic tensioners and acompact balancer.

This worksheet will help you becomefamiliar with this procedure so you canbetter service this engine in yourdealership.

Resources:Resources:Resources:Resources:Resources: · ESM Section EM· ESM Job Aid· QR25DE engine on stand

Skill Check:Skill Check:Skill Check:Skill Check:Skill Check: Correctly perform the timingchainremoval and installation procedure(includes balancer unit), per ESMprocedures.

QR25DE TIMING CHAIN AND BALANCER UNIT

2 QR25DE Timing Chain and Balancer Unit


1. Locate the timing chain removal and installationprocedures in the ESM, Section EM. Printthese pages for reference at the workstation.

2. Following the ESM, prepare the engine fortiming chain removal by setting the #1 cylinderat TDC on the compression stroke. Thecrankshaft pulley and camshaft sprocketsshould look like the illustrations on the left.

3. Continue with the ESM procedure to removethe front cover, timing chain, tensioner andcamshaft sprockets.

4. Note the CAUTION in the ESM. Is this afreewheeling engine?YES / NOYES / NOYES / NOYES / NOYES / NO (Circle one)

5. Continue with the ESM procedure to removethe timing chain for the balancer unit. What keyservice point should be observed here?

________________________________________

________________________________________

________________________________________

6. At this point, both timing chains, thetensioners, the camshaft sprockets and thecrankshaft sprocket should be removed.

NoteNoteNoteNoteNote: DO NODO NODO NODO NODO NOTTTTT remove the balancer unit.

7. According to the ESM, can the balancer unit bedisassembled for service?


3



The balancer unit has been disassembled in thephoto at the left for reference only. Note thatthe unit has two counter-rotating shafts thatmust be in time with each other and with thecamshaft.

8. Rotate the balancer unit drive sprockets byhand. What do you notice as you rotate thebalancer unit?

________________________________________

________________________________________

________________________________________

9. When removing/installing the balancer unit, canthe mounting bolts be reused?

YESYESYESYESYES / NONONONONO / IT DEPENDS IT DEPENDS IT DEPENDS IT DEPENDS IT DEPENDS (Circle one)

Explain:

________________________________________

________________________________________

________________________________________

10. What customer concerns could be caused bythe balancer unit?

________________________________________

________________________________________

________________________________________



11. Follow the ESM procedure to install thebalancer unit, timing chain, crankshaft sprocketand tensioner assembly.Which direction should the crankshaft keypoint? (Circle one)

12:0012:0012:0012:0012:00 / 3:00 / 6:00 / 9:00 3:00 / 6:00 / 9:00 3:00 / 6:00 / 9:00 3:00 / 6:00 / 9:00 3:00 / 6:00 / 9:00

Note:Note:Note:Note:Note: There may be two link colors on the timingchain. There are 26 links between the gold/yellow mating marks on the timing chain.There are 64 links between the camshaftsprocket gold/yellow link and the crankshaftsprocket orange/blue link on the timing chainside without the tensioner.

12. When referencing this engine, what colortiming chain link must be lined up with themating mark on the crankshaft sprocket?

________________________________________

13. In relation to crankshaft speed, at what speeddo the balancer unit shafts rotate? (Checkone)

Same (1 to 1)

Half (0.5 to 1)

Twice (2 to 1)

Four times (4 to 1)

Why do you think the balancer unit must rotateat this speed?

________________________________________

________________________________________

________________________________________

5



14. Continue with the ESM procedure to install thecamshaft sprockets, timing chain and tensioner.

15. According to the ESM, is it safe to turn thecrankshaft after installing the timing chain butbefore installing the front cover?

YESYESYESYESYES / NONONONONO (Circle one)

Why or why not?Why or why not?Why or why not?Why or why not?Why or why not?

________________________________________

________________________________________

16. Before installing the front cover, locate thetiming chain oil jet, CVTC solenoid oil screenand crank sprocket chain guides in the frontcover assembly. (Refer to the photos at theleft.) The oil jet or CVTC oil screen maybecome clogged. Additionally, the CVTC oilscreen may fall out during service.

Oil jetCrankshaft sprocketchain guides

PTN182

CVTC oil screen

PTN183



Service TipService TipService TipService TipService Tip: Refer to the illustration at the left forspecified areas to install RTV siliconesealant on the front cover sealingsurface. Notice the sealant applied toposition “A,” which is a bolt holethrough the center of the cover.

17. Locate the CVTC oil passage on the illustrationto the left, and circle the location.

18. How many O-rings are used with the frontcover?

________________________________________

Where are the O-rings located?

________________________________________

________________________________________

________________________________________

SSSSSTTTTTOPOPOPOPOP. See instructor prior to installing the. See instructor prior to installing the. See instructor prior to installing the. See instructor prior to installing the. See instructor prior to installing thefront cover and upper oil pan.front cover and upper oil pan.front cover and upper oil pan.front cover and upper oil pan.front cover and upper oil pan.

You have successfully completed this worksheet.You should now be able to remove and install thetiming chain on the QR25DE engine and properlytime the engine.

If you have any doubts about the skills you haveacquired, please return to Step 1 and review yourwork. When you are confident of your skills, haveyour instructor verify your work.

Instructor’s Initials: ________________Instructor’s Initials: ________________Instructor’s Initials: ________________Instructor’s Initials: ________________Instructor’s Initials: ________________

Please return this workstation to the condition inPlease return this workstation to the condition inPlease return this workstation to the condition inPlease return this workstation to the condition inPlease return this workstation to the condition inwhich you found it.which you found it.which you found it.which you found it.which you found it.

SECTION

3

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