1999 NISSAN PRIMERA height

Assembly
Apply high-temperature grease to lubricate the bearing, gears
and frictional surface when assembling the starter.
Carefully observe the following instructions.
PINION PROTRUSION LENGTH ADJUSTMENT
Clearance“l”
With pinion driven out by magnetic switch, push pinion back to
remove slack and measure clearance“l”between the front edge
of the pinion and the pinion stopper.
Clearance“l”:
Refer to SDS (EL-52).
Movement“
”
Compare movement“
”in height of pinion when it is pushed out
with magnetic switch energized and when it is pulled out by hand
until it touches stopper.
Movement“
”
Refer to SDS (EL-52).

Not in the specified value ... Adjust by selecting the correct
adjusting plate.
SEL026Z Pinion stopper
Clearance“l”
SEL497D
NEL305 Adjusting plate
STARTING SYSTEM
EL-51

Service Data and Specifications (SDS)
STARTER
TypeM70R M2T62071 0 001 116 006
MAGNETI MARELLI MITSUBISHI BOSCH
Reduction gear type Reduction gear type Non-Reduction
Applied model SR20 CD20TQG18
QG16
System voltage V 12
No load
Terminal voltage V 11.5 11.0 11.5
Current A 115 Less than 105 Less than 48
Revolution rev/min More than 4500 More than 4,030 More than 5,800
Min. commutator dia. mm (in) 28.8 (1.134) 31.4 (1.236) 33.5 (1.319)
Min. brush of length mm (in) 5.0 (0.197) 11.5 (0.453) 3.5 (0.138)
Brush spring tension N (kg, lb)14.3 - 25.2
(1.46 - 2.57,
3.22 - 5.69)13.7 - 25.5
(1.4 - 2.6,
3.1-5.7)5.2 (0.53, 1.17)
at 7.5 mm (0.295 in) brush
length
Movement“
”in height of pinion
assembly mm (in)———
Clearance“I”between pinion front
edge & pinion stopper
mm (in)0-3.0(0-0.118)—0.0 - 3.9 (0 - 0.154)
Ty p eS114-806A S114-871 S13-305 S13-531 S114-800B
HITACHI
Reduction gear type
Applied model SR20SR20
with CVT modelsCD20TCD20T
cold areaQG18⋅QG16
cold area
System voltage V 12
No load
Terminal voltage V 11.0
Current A Less than 90 Less than 140 Less than 90
Revolution rev/min More than 2,700 More than 2,300 More than 3900 More than 2750
Min. commutator dia. mm (in) 28.0 (1.102) 35.5 (1.398) 28.0 (1.102)
Min. brush length mm (in) 10.5 (0.413) 11.0 (0.433) 10.5 (0.413)
Brush spring tension N (kg, lb) 16.2 (1.65, 3.64)12.7 - 17.7 (1.29 -
1.80, 2.84, 3.97)28.4 - 34.3 (2.90 - 3.50, 6.39 - 7.72)12.7 - 17.7
(1.29 - 1.80,
2.84 - 3.97)
Clearance between bearing &
armature shaft mm (in)Less than 0.2 (0.008)
Clearance“I”between pinion front
edge & pinion stopper
mm (in)0.3-2.5
(0.012 - 0.098)0.3-2.0
(0.012 - 0.079)0.3-0.8
(0.012 - 0.031)0.3 - 2.5
(0.012 - 0.098)
STARTING SYSTEM
EL-52

System Description
The auto level control unit is designed to adjust the beam angle of the headlamp in response to the load-
ing conditions of the vehicle. It is not designed to compensate for the dynamic handling of the vehicle.
The vehicle’s front and rear height is measured by sensors attached to the front stabilizer bar and the rear
suspension lateral link arm. The sensors provide a signal to the auto level control unit, which calculates the
correct headlamp aiming position and sends a signal to the aiming motors.
Initialisation
After the replacement or adjustment of any suspension sensor, the system must be self calibrated. This is
achieved as follows.
The vehicle must be empty, since any load will result in an invalid calibration. From outside of the vehicle
turn ignition on and then within 7 seconds the light switch must be turned from off to side lights on position,
5 times, finishing with the lamps in the on position.
The headlamps will then move to the highest, then the lowest then the normal position to indicate that the
calibration is successful, as can be seen by the moving beam pattern.
After successful calibration the headlamps must then be aimed in the conventional manner. Refer to EL-70.
HEADLAMP—Headlamp Aiming Control (Auto)—
EL-91

Aiming Adjustment
Before performing aiming adjustment, make sure of the follow-
ing.
a. Keep all tires inflated to correct pressure.
b. Place vehicle on level ground.
c. Check that vehicle is unloaded (except for full levels of
coolant, engine oil and fuel, and spare tire, jack, and tools).
Have the driver or equivalent weight placed in driver’s seat.
1. Set the distance between the screen and the center of the
fog lamp lens as shown at left.
2. Turn front fog lamps ON.
3. Adjust front fog lamps so that the top edge of the high inten-
sity zone is 100 mm (4 in) below the height of the fog lamp
centers as shown at left.

When performing adjustment, if necessary, cover the head-
lamps and opposite fog lamp.
Bulb Specifications
Item Wattage (W)
Front fog lamp 55
NEL553 Aiming adjusting screw
MEL327G
7.6 m (25 ft)
Screen
Main axis of light
MEL328G Vertical centerline
ahead of left fog lamp
Car
axis Top edge of high
intensity zoneVertical centerline
ahead of right
fog lamp
Floor to center
of foglamp lens
(height of fog
lamp centers)
.100 (4).100 (4)
High-intensity areas
Unit: mm (in)
FRONT FOG LAMP
EL-111

ENGINE MECHANICAL
SECTION
EM
CONTENTS
PRECAUTIONS...............................................................5
Parts Requiring Angular Tightening .............................5
Liquid Gasket Application Procedure ..........................5
PREPARATION................................................................6
Special Service Tools ..................................................6
Commercial Service Tools .........................................10
QG
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING................................................... 11
NVH Troubleshooting - Engine Noise ....................... 11
OUTER COMPONENT PARTS.....................................13
Removal and Installation ...........................................13
MEASUREMENT OF COMPRESSION PRESSURE....16
OIL PAN.........................................................................17
Components...............................................................17
Removal .....................................................................17
Installation ..................................................................18
TIMING CHAIN..............................................................19
Components...............................................................19
Removal .....................................................................20
Inspection...................................................................24
Installation ..................................................................24
OIL SEAL.......................................................................29
Replacement ..............................................................29
VALVE OIL SEAL.....................................................29
FRONT OIL SEAL....................................................29
REAR OIL SEAL......................................................30
CYLINDER HEAD..........................................................31
Components...............................................................31
Removal .....................................................................32
Disassembly...............................................................34
Inspection...................................................................34
CYLINDER HEAD DISTORTION...............................34
CAMSHAFT VISUAL CHECK....................................34
CAMSHAFT RUNOUT..............................................35
CAMSHAFT CAM HEIGHT.......................................35
CAMSHAFT JOURNAL CLEARANCE........................35
CAMSHAFT END PLAY............................................36
CAMSHAFT SPROCKET RUNOUT...........................36
VALVE GUIDE CLEARANCE....................................36
VALVE GUIDE REPLACEMENT................................37
VALVE SEATS.........................................................38
REPLACING VALVE SEAT FOR SERVICE PARTS.....38
VALVE DIMENSIONS...............................................39
VALVE SPRING.......................................................39
VALVE LIFTER AND VALVE SHIM.............................40
Valve Clearance.........................................................40
CHECKING.............................................................40
ADJUSTING............................................................41
Assembly ...................................................................43
Installation ..................................................................43
ENGINE REMOVAL.......................................................48
Removal and Installation ...........................................48
REMOVAL...............................................................49
INSTALLATION........................................................51
CYLINDER BLOCK.......................................................52
Components...............................................................52
Removal and Installation ...........................................53
Disassembly...............................................................53
PISTON AND CRANKSHAFT....................................53
Inspection...................................................................54
PISTON AND PISTON PIN CLEARANCE...................54
PISTON RING SIDE CLEARANCE............................54
PISTON RING END GAP..........................................54
CONNECTING ROD BEND AND TORSION...............55
CYLINDER BLOCK DISTORTION AND WEAR...........55
PISTON-TO-BORE CLEARANCE..............................56
CRANKSHAFT.........................................................57
BEARING CLEARANCE...........................................57
CONNECTING ROD BUSHING CLEARANCE
(Small end)
..............................................................59
REPLACEMENT OF CONNECTING ROD
BUSHING (Small end)
..............................................60
FLYWHEEL/DRIVE PLATE RUNOUT.........................60
EM

Assembly ...................................................................60
PISTON..................................................................60
CRANKSHAFT.........................................................61
SR20DE
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING........................................64
NVH Troubleshooting - Engine Noise .......................65
OUTER COMPONENT PARTS.....................................66
COMPRESSION PRESSURE........................................69
Measurement of Compression Pressure ...................69
OIL PAN.........................................................................70
Removal .....................................................................70
Installation ..................................................................73
TIMING CHAIN..............................................................75
Components...............................................................75
Removal .....................................................................76
Inspection...................................................................79
Installation ..................................................................79
OIL SEAL REPLACEMENT..........................................84
VALVE OIL SEAL.....................................................84
FRONT OIL SEAL....................................................84
REAR OIL SEAL......................................................85
CYLINDER HEAD..........................................................86
Components...............................................................86
Removal .....................................................................87
Disassembly...............................................................89
Inspection...................................................................91
CYLINDER HEAD DISTORTION...............................91
CAMSHAFT VISUAL CHECK....................................91
CAMSHAFT RUNOUT..............................................92
CAMSHAFT CAM HEIGHT.......................................92
CAMSHAFT JOURNAL CLEARANCE........................92
CAMSHAFT END PLAY............................................93
CAMSHAFT SPROCKET RUNOUT...........................93
VALVE GUIDE CLEARANCE....................................93
VALVE GUIDE REPLACEMENT................................94
VALVE SEATS.........................................................95
REPLACING VALVE SEAT FOR SERVICE PARTS.....95
VALVE DIMENSIONS...............................................95
VALVE SPRING.......................................................96
HYDRAULIC LASH ADJUSTER................................96
ROCKER ARM, SHIM AND ROCKER ARM GUIDE.....97
Assembly ...................................................................97
Installation ..................................................................99
ENGINE REMOVAL.....................................................106
Components.............................................................106
Removal ...................................................................107
Installation ................................................................108
CYLINDER BLOCK.....................................................109
Components.............................................................109
Disassembly............................................................. 110
PISTON AND CRANKSHAFT.................................. 110Inspection................................................................. 110
PISTON AND PISTON PIN CLEARANCE................. 110
PISTON RING SIDE CLEARANCE.......................... 111
PISTON RING END GAP........................................ 111
CONNECTING ROD BEND AND TORSION............. 111
CYLINDER BLOCK DISTORTION AND WEAR......... 112
PISTON-TO-BORE CLEARANCE............................ 112
CRANKSHAFT....................................................... 113
BEARING CLEARANCE......................................... 114
CONNECTING ROD BUSHING CLEARANCE
(Small end)
............................................................ 116
REPLACEMENT OF CONNECTING ROD
BUSHING (Small end)
............................................ 117
REPLACEMENT OF PILOT BUSHING (M/T) OR
PILOT CONVERTER (CVT)
.................................... 117
FLYWHEEL/DRIVE PLATE RUNOUT....................... 117
Assembly ................................................................. 117
PISTON................................................................ 117
CRANKSHAFT....................................................... 118
CD20T
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING.....................................121
NVH Troubleshooting Chart - Engine Noise ...........122
OUTER COMPONENT PARTS...................................123
COMPRESSION PRESSURE......................................126
OIL PAN.......................................................................129
Removal ...................................................................129
Installation ................................................................129
TIMING BELT...............................................................131
Camshaft Timing Belt ..............................................131
REMOVAL.............................................................131
Inspection.................................................................133
Installation ................................................................134
Injection Pump Timing Belt ......................................135
REMOVAL.............................................................135
INSTALLATION......................................................136
OIL SEAL REPLACEMENT........................................138
VALVE OIL SEAL...................................................138
CAMSHAFT AND CRANKSHAFT OIL SEAL
INSTALLING DIRECTION AND MANNER
................138
CAMSHAFT OIL SEALS.........................................138
CRANKSHAFT FRONT OIL SEAL...........................139
CRANKSHAFT REAR OIL SEAL.............................139
CYLINDER HEAD........................................................140
Components.............................................................140
Removal ...................................................................141
Disassembly.............................................................141
Inspection.................................................................142
CYLINDER HEAD DISTORTION.............................142
VALVE GUIDE CLEARANCE..................................142
VALVE GUIDE REPLACEMENT..............................142
VALVE SEATS.......................................................143
VALVE SEAT REPLACEMENT................................143
CONTENTS(Cont'd)
EM-2

VALVE DIMENSIONS.............................................144
VALVE SPRING SQUARENESS..............................145
VALVE SPRING PRESSURE LOAD........................145
VALVE LIFTER......................................................145
COMBUSTION CHAMBER REPLACEMENT............146
CAMSHAFT VISUAL CHECK..................................147
CAMSHAFT END PLAY..........................................147
CAMSHAFT RUNOUT............................................147
CAMSHAFT CAM HEIGHT.....................................147
CAMSHAFT JOURNAL CLEARANCE......................147
Valve clearance .......................................................148
Checking ..................................................................148
Adjusting ..................................................................149
Assembly .................................................................151
Installation ................................................................151
TURBOCHARGER.......................................................156
Removal ...................................................................156
Disassembly.............................................................157
Inspection.................................................................158
OIL AND WATER TUBES........................................158
ROTOR SHAFT.....................................................158
TURBINE WHEEL..................................................159
COMPRESSOR WHEEL.........................................159
WASTEGATE VALVE..............................................160
WASTEGATE VALVE ACTUATOR...........................160
Assembly .................................................................160
Installation ................................................................160
ENGINE REMOVAL.....................................................162
CYLINDER BLOCK.....................................................166
Components.............................................................166
Preparation ..............................................................167
Disassembly.............................................................167
PISTON AND CRANKSHAFT..................................167
Inspection.................................................................168
PISTON AND PISTON PIN CLEARANCE.................168
PISTON RING SIDE CLEARANCE..........................168
PISTON RING END GAP........................................169
MAIN BEARING CLEARANCE................................169
CONNECTING ROD BEARING CLEARANCE (Big
end)
......................................................................170
CONNECTING ROD AND PISTON PIN
CLEARANCE (Small end)
.......................................171
CONNECTING ROD BEND AND TORSION.............172
CRANKSHAFT.......................................................172
CYLINDER BLOCK DISTORTION...........................173
CYLINDER BORE..................................................173
PISTON-TO-BORE CLEARANCE............................174
Assembly .................................................................175
PISTON................................................................175
CRANKSHAFT.......................................................175
PISTON WITH CONNECTING ROD........................176
FLYWHEEL RUNOUT.............................................177QG
SERVICE DATA AND SPECIFICATIONS (SDS)........178
General Specifications .............................................178
Compression Pressure ............................................178
Cylinder Head ..........................................................178
Valve ........................................................................179
VA LV E...................................................................179
VALVE SPRING.....................................................179
VALVE LIFTER......................................................179
VALVE CLEARANCE..............................................179
VALVE GUIDE.......................................................180
AVAILABLE SHIMS................................................180
VA LV E S E AT.........................................................182
VALVE SEAT RESURFACE LIMIT...........................183
Camshaft and Camshaft Bearing ............................183
Cylinder Block ..........................................................184
Piston, Piston Ring and Piston Pin .........................185
PISTON................................................................185
PISTON RING.......................................................185
PISTON PIN..........................................................185
Connecting Rod .......................................................186
Crankshaft................................................................186
Main Bearing............................................................186
STANDARD...........................................................186
UNDERSIZE..........................................................186
Connecting Rod Bearing .........................................187
STANDARD SIZE...................................................187
UNDERSIZE..........................................................187
Bearing Clearance ...................................................187
Miscellaneous Components.....................................187
SR20DE
SERVICE DATA AND SPECIFICATIONS (SDS)........188
General Specifications .............................................188
Inspection and Adjustment ......................................188
COMPRESSION PRESSURE.................................188
CYLINDER HEAD..................................................188
VA LV E...................................................................189
CAMSHAFT AND CAMSHAFT BEARING.................192
CYLINDER BLOCK................................................192
PISTON, PISTON RING AND PISTON PIN..............193
CONNECTING ROD...............................................193
CRANKSHAFT.......................................................194
AVAILABLE MAIN BEARING...................................194
AVAILABLE CONNECTING ROD BEARING.............195
MISCELLANEOUS COMPONENTS.........................195
CD20T
SERVICE DATA AND SPECIFICATIONS (SDS)........196
General Specifications .............................................196
Inspection and Adjustment ......................................196
COMPRESSION PRESSURE.................................196
CYLINDER HEAD..................................................196
CONTENTS(Cont'd)
EM-3

20. Remove cylinder head bolts.
21. Remove cylinder head with manifolds.
IHead warpage or cracking could result from removing in
incorrect order.
ICylinder head bolts should be loosened in two or three
steps.
DisassemblyNCEM00181. Remove valve components with Tool.
2. Remove valve oil seal with a suitable tool.
InspectionNCEM0019CYLINDER HEAD DISTORTIONNCEM0019S01IClean surface of cylinder head.
IUse a reliable straightedge and feeler gauge to check the flat-
ness of cylinder head mating surface.
ICheck along six positions shown in figure.
Head surface flatness:
Standard: Less than 0.03 mm (0.0012 in)
Limit: 0.1 mm (0.004 in)
If beyond the specified limit, replace or resurface it.
Resurfacing limit:
The limit for cylinder head resurfacing is determined by the
amount of cylinder block resurfacing.
Amount of cylinder head resurfacing is ªAº.
Amount of cylinder block resurfacing is ªBº.
The maximum limit is as follows:
A + B = 0.2 mm (0.008 in)
After resurfacing cylinder head, check that camshaft rotates freely
by hand. If resistance is felt, replace cylinder head.
Nominal cylinder head height:
117.8 - 118.0 mm (4.638 - 4.646 in)
CAMSHAFT VISUAL CHECKNCEM0019S02Check camshaft for scratches, seizure and wear.
SEM878F Loosen in numerical order.Engine front
SEM914F KV10109220
KV10116200
SEM915F Straightedge
Feeler gauge
CYLINDER HEADQG
Removal (Cont'd)
EM-34