9458

EMTN9907B EMTI9902B
ENGINE MECHANICAL SERVICE
JUNE, 2003
This book is designed for instructional use only for Nissan North America, Inc., authorized dealers and their personnel. For additional information contact: Nissan North America, Inc. Corporate Training Office Technical Training 18501 S. Figueroa St. Gardena, CA 90248-4500
2003 Nissan North America, Inc. All rights reserved. No part of this publication may be reproduced in any form without the prior written permission of the publisher. Printed in U.S.A. First Printing: June, 2003
This manual uses post consumer recycled fibers
Corporate Training Office Technical Training Nissan North America, Inc. reserves the right to alter specifications or methods at any time.
ENGINE MECHANICAL SERVICE COURSE 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 proper diagnosis/repair sections, specifications and procedures applicable to the vehicle being serviced. Perform a cooling system check for evidence of leaks, damage, or deterioration to assure 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 cylinder leakage test to determine the condition of the piston rings, valves and head gasket based 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 chain tensioners 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 the Service Manual. Remove and install the water pump on a VQ35DE engine using proper tools and Service 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).
NOTES
S E C T I O N 1
T E X T
TABLE OF CONTENTS INTRODUCTION ....................................................................................................................3 ENGINE THEORY ..................................................................................................................3

Basic Components ...................................................................................................................... 3 Four-Stroke Engine Cycle .......................................................................................................... 3 Lower End ...................................................................................................................................... 4 Sealing the Combustion Chamber ........................................................................................... 4 Upper End ...................................................................................................................................... 5 Intake System ................................................................................................................................ 5 Timing System............................................................................................................................... 5 Lubrication System ...................................................................................................................... 6 Cooling System ............................................................................................................................ 6 PRECISION TOOLS ......................................................................................................................... 7 Mechanical and Electronic Micrometers ................................................................................ 7 Dial Indicators................................................................................................................................ 7 Vernier Calipers ............................................................................................................................ 8 Dial Calipers .................................................................................................................................. 8 Torque Angle Gauge ................................................................................................................... 9 Bore Gauge (Cylinder Gauge/Telescoping Gauge) ............................................................ 9 Straight Edge/Feeler Gauges ................................................................................................... 9 Plastigage..................................................................................................................................... 10 USE OF REQUIRED TOOLS........................................................................................................ 10 Belt Tension Gauge ................................................................................................................... 10 Valve Shim Gauge Plate Kit ..................................................................................................... 11 CONSULT-II................................................................................................................................. 11 BLOCK INSPECTION PROCEDURES ..................................................................................... 12 Block Distortion .......................................................................................................................... 12 Piston-to-Bore Clearance ........................................................................................................ 12 Cylinder Taper ............................................................................................................................. 13 Cylinder Out-of-Round ............................................................................................................. 13 Piston Ring Side Clearance..................................................................................................... 13 Piston Choice in Case of Cylinder Re-boring ..................................................................... 14 CRANKSHAFT INSPECTION PROCEDURES ........................................................................ 14 Visual ............................................................................................................................................. 14 Runout ........................................................................................................................................... 14 End Play ........................................................................................................................................ 15
Journal Out-of-Round and Taper ............................................................................................ 16 CAMSHAFT INSPECTION PROCEDURES ............................................................................. 17 Runout Measurement ................................................................................................................ 17 End Play Measurement ............................................................................................................. 17 Sprocket Runout ........................................................................................................................ 17 Cam Height & Cam Journal Clearance ................................................................................. 17 Cam Journal Clearance ............................................................................................................. 18 CONNECTING ROD BEARING CLEARANCE ADJUSTMENT .......................................... 18 Measuring Clearance with a Micrometer .............................................................................. 19 VG30E Engine ............................................................................................................................ 19 VG30DE and VE30DE Engines ............................................................................................. 19 VQ30DE, KA24DE, KA24E, GA16DE, SR20DE Engines .............................................. 20 Determining the Clearance Using a Plastigage Kit ............................................................ 20 Connecting Rod Bushing Clearance ..................................................................................... 20 CYLINDER HEAD TORQUING .................................................................................................... 20 OPERATION AND DIAGNOSIS OF ELECTRONIC LIQUID ENGINE MOUNTS .......................... 21 ENGINE COOLING SYSTEM....................................................................................................... 21 TESTING ENGINE COMPRESSION AND LEAKAGE .......................................................... 22 Engine Compression ................................................................................................................. 22 Cylinder Leakage ........................................................................................................................ 23 LOCATING THE SOURCE OF ENGINE NOISES.................................................................. 23 VG33E Piston Choice ............................................................................................................... 24 VQ30 Timing Chain Noise ....................................................................................................... 24 SR20DE Shower Rail ................................................................................................................ 24 NISSAN CONTINUOUSLY VARIABLE TIMING CONTROL SYSTEM (NCVCS) .......................... 26 System Description.................................................................................................................... 26 Component Description............................................................................................................ 27 New Diagnostic Trouble Codes .............................................................................................. 28 Specification Data ...................................................................................................................... 28 On Board Diagnostic Logic ..................................................................................................... 28
ENGINE MECHANICAL SERVICE

INTRODUCTION Welcome to Nissan North Americas Engine Mechanical Service Training Course. In this course, youll learn engine theory, the type of precision tools and specific procedures youll need 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, connecting rod, 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 the valves; valve springs close the valves. Four-Stroke Engine Cycle The intake, compression, power, and exhaust strokes define one complete four-stroke cycle. At the top of the intake stroke (1A), the cam and lifter arrangement opens the intake valve. As the piston moves down, a fresh air and fuel charge is drawn into the cylinder. At the bottom of the intake 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 of the compression stroke, a spark jumps the spark plug gap, igniting the compressed charge (2B).
1A
1B
2A
2B
The fuel burns rapidly, driving the piston down the cylinder (3A). At the bottom of the power stroke, the exhaust valve opens (3B). The upward stroke of the piston pushes spent exhaust gases from the cylinder (4). When the exhaust valve closes, the cylinder is ready for another cycle. 3A 3B 4
Lower End The cylinder block is the engines foundation, allowing the crankshaft to rotate while the piston reciprocates. 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 and to the crank pin. Connecting rods must be light, yet very strong. The crankshaft rotates in the lowermost portion of the block, changing reciprocating piston movement into a rotational turning force that is used by the drive train and wheels. Some engines have a camshaft mounted in the cylinder block. The camshaft has machined intake and exhaust lobes to move valve lifters and push rods. Push rods rotate a rocker arm to open the valve. Springs are used to close the valve. During the power stroke, heat from combustion quickly increases gas pressure within the cylinder. Heated, expanding gas pressure is the force that actually moves the piston down the cylinder. Sealing the Combustion Chamber Although expanding gas forces the piston down the cylinder, some gas does escape between the piston and the cylinder wall. If enough gas escapes, a good portion of the usable pressure is no longer available to push the piston down the cylinder. The solution to this problem is to seal the chamber with compression rings. Plated rings fit in piston grooves. The edges of the rings ride along on the cylinder wall.
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 is similarly 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 train components. The cylinder head bolts to the cylinder block, and is sealed to the block with a head 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 two camshafts, depending on the design. A cylinder head with one camshaft is known as an Over Head 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 only on 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 injected engines, 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 the crankshaft so that valves open and close at the correct time. Belt-drive timing systems are used in OHC engines. The belt is usually a reinforced rubber compound that is both strong and quiet. 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 by chain guides and a hydraulic chain tensioner. The hydraulic tensioner adjusts tension according to engine speed.
Lubrication System Engine oil is drawn from the sump by the oil pickup. The oil is filtered before being pumped into the engine under pressure to lubricate moving parts. Lubrication galleries are cast into the cylinder block to feed oil quickly throughout the engine. Cross-drilled crankshaft passages run the length of the crankshaft. Oil enters at the main bearings and exits to lubricate connecting rod bearing surfaces. The piston is lubricated by pressurized oil that sprays from a connecting rod squirt-hole. Oil is used to lubricates the cylinder 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 on the crankshaft nose. The valve train in the cylinder head also requires lubrication. Engines with block-mounted camshafts pump oil up through valve lifters and hollow push rods so that oil flows onto the rocker 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 coolant throughout the block. Engine temperature is regulated by the thermostat. When the engine is cold, coolant flow is directed through a bypass circuit back into the engine until operating temperature 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, up through 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 passenger compartment. The heater core resembles a small radiator. Coolant circulates through the heater core and back to the engine block. A blower motor fan pushes air across the heater core. The moving air is warmed by the heater core.
PRECISION TOOLS Precision measuring tools are used extensively for engine work. It is important that you be thoroughly familiar with these tools to assure accurate measurements. In the exercises you will complete during this class, you will practice the use of micrometers, dial indicators, vernier calipers, torque angle gauges, and feeler gauges. Mechanical and Electronic Micrometers The outside micrometer is used to measure the diameter of many engine parts. It is available in many different sizes and forms and may use either the English or Metric measuring system. You can also use a digital micrometer, which is much easier to read. A micrometer generally provides greater precision than a vernier caliper, but has a smaller range. To use a micrometer, place the part in the opening. Next, turn the thimble until the spindle contacts the work. To apply a consistent pressure to the part, use the ratchet stop. Use the clamp ring to hold the thimble in place while you read the micrometer. To read 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 (one thousandth of an inch). Dial Indicators Dial indicators are commonly used to measure valve lift, shaft runout, and cylinder taper, among many other things. Dial indicator faces are calibrated in thousandths of an inch or in millimeters. There is a wide variety of adapters and mounting arms available so that you can use the same indicator in many applications. The most important point when using a dial indicator is to be certain that the tool is firmly mounted and that the actuating rod is parallel to the plane of movement measured.
Vernier Calipers Measuring instruments using a vernier scale have two engraved scales that lie alongside each other. The longer scale on the beam of the instrument is graduated in actual measurements, either millimeters or fractions of an inch. The shorter scale slides along the beam and is called the vernier scale. Its divisions are slightly smaller than the divisions on the beam. The beam is a straightforward measuring rule and the sliding vernier scale is a device for taking an accurate 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 fixed in position on the beam using the clamping screw. The fine adjustment wheel can then make small adjustments to the position of the moveable jaw. Most calipers have separate internal jaws. Dial Calipers Dial calipers are similar to vernier calipers except for the method of reading the dimension. Dial calipers have a circular scale similar to a dial indicator for the fine reading in addition to a vernier scale with larger divisions. Dial calipers are easier to read than vernier calipers, but are more expensive.
Torque Angle Gauge In certain cases the procedure for tightening cylinder head bolts requires you to tighten the bolts a certain number of degrees after torquing them to specification. A torque angle gauge helps you to do this accurately. The gauge connects to a ratchet between the socket and the extension, and shows you the angle to which you are torquing the bolt.
Bore Gauge (Cylinder Gauge/Telescoping Gauge) A bore gauge is used for precision measurement of cylinder bores. It is a T-shaped device with springloaded 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 read the bore diameter on the attached dial indicator. It is best to do this at several points in the bore to check for roundness and taper. Older style bore gauges required to you lock the anvils into place, remove the gauge and determine the bore diameter by measuring the anvil length with a micrometer. Current bore gauge designs incorporate a dial indicator display that eliminates this step.
CHECK FOR WARPAGE OF SURFACE Straight Edge/Feeler Gauges Use a heavy straightedge and a feeler gauge to measure cylinder block and head distortion. Clean the face thoroughly prior to measuring the surface distortion. Check the flatness at both edges and from corner to corner in an X pattern by laying the straightedge across the surface and slipping a feeler gauge between them. You can find specifications in the service manual.
PlastigageTM PlastigageTM is a flexible, thread-like putty used to measure crankshaft bearing clearances. Place a strip of PlastigageTM lengthwise in the center of a journal, install the bearing cap and tighten the bolts to the correct specifications. When you remove the cap, you will find that the PlastigageTM has been flattened. Compare the width of the flattened PlastigageTM 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 belts tension is with a belt tension gauge. With the belt installed on the engine, place the gauge on the belt between two pulleys. Read the gauge to measure the amount of belt deflection, and compare the reading to the chart provided. The tighter the belt is, the less deflection there will be.
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Valve Shim Gauge Plate Kit To correctly check and adjust the valve clearance on the SR20DE engine, you need to use special tool J38957-N and a dial indicator. This tool consists of a plate that is bolted on the cylinder head, after removing the camshafts. Detailed instructions for using the valve shim gauge plate are in the appropriate exercise, later in this course in Module 9.
Special Tool: J38957-N Valve Shim Gauge Plate Kit
CONSULT-II CONSULT-II with converter is the diagnostic scan tool used exclusively with Nissan and Infiniti vehicles. It is fully OBD II compatible and has a wide range of functions.
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BLOCK INSPECTION PROCEDURES Block Distortion Engine block distortion is measured across the face of the block, where the head(s) mount, using a heavy straightedge and a feeler gauge. Clean the face thoroughly before you measure surface distortion. Check the face flatness at both edges and from corner to corner in an X pattern, as shown.
Piston-to-Bore Clearance During engine operation, the piston rings can gradually change the dimensions of the cylinder walls. This in turn affects the way the pistons fit in the cylinder bores, and harms compression and engine power. When overhauling an engine you must measure all the cylinders for taper and out-of-round with a bore gauge. You can find the specifications in the EM section of the Service Manual, under Cylinder Block Inspection. If any of the cylinders are out of specification, you must re-bore all the cylinders. Youll also need to replace the pistons with larger ones. In some circumstances where the cylinders cant be re-bored, you will need to replace the block. Check the piston-to-bore clearance by measuring the piston skirt diameter at the point specified in the EM section of the Service Manual and comparing it to the cylinder bore diameter. Subtract the skirt diameter from the bore diameter. The clearance specification is in the EM section of the service manual under Cylinder Block Inspection, Piston-to-bore Clearance.
Cylinder Taper As a result of cylinder pressure, temperature, and lubrication, the cylinder wears more at the top of the piston travel than at the bottom. This reduction in the wear pattern down the cylinder wall is called taper. Measure the bottom and top of each of the cylinders at right angles to the centerline of the crankshaft. Subtract the bottom diameter measurement from the top diameter measurement to determine the amount of cylinder taper.
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Cylinder Out-of-Round As a result of the side thrust forces generated by combustion on the piston, the cylinder walls can wear until they are no longer round. This can prevent the piston rings from properly sealing. To determine whether the cylinders are out-ofround, use a bore gauge at the area of greatest wear at right angles to the crankshaft and in line with the crankshaft. Subtract the smallest measurement 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 piston ring side clearance with a feeler gauge. You will find the specifications in the EM section of the service manual, under Cylinder Block Inspection. Install the rings in the pistons, then measure between the ring and the groove with the feeler gauge.
NG
Feeler gauge OK
Feeler Gauge Ring
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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 are available for service. Before re-boring the cylinders look in the Service Data and Specifications at the rear of the EM section of the service manual to determine which oversized pistons are available. Be sure to check with your parts department to ensure that you can obtain the correct pistons before you begin boring the cylinders. CRANKSHAFT INSPECTION PROCEDURES Visual When you inspect the crankshaft, pay particular attention to the journal surfaces. Excessive wear 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 for evidence. Uneven wear patterns can indicate bent rods or a bent crankshaft. Runout The crankshaft can warp in operation. You can determine how straight the crankshaft is by measuring its runout. Place the crankshaft in a set of V-blocks and mount a dial indicator with the rod perpendicular to each of the main journals. Rotate the crankshaft in the V-blocks and read the amount of runout on the dial indicator, measuring at the center of each main journal. You can find crankshaft runout specifications in the EM section of the service manual under 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 the cylinder block. To measure crankshaft end play: Install the main bearings in their proper positions on the cylinder block Install the crankshaft Install the main bearing caps or bearing beam and torque them to specifications Turn the crankshaft by hand to ensure that it is properly positioned Mount the dial indicator on the end of the crankshaft, with the indicator rod parallel to the crankshaft Use a large screwdriver or other tool to shift the crankshaft back and forth, and measure the amount of end play shown on the dial indicator
Journal Out-of-Round and Taper The crankshaft bearings maintain a film of oil between the bearing surface and the crankshaft journal. This oil prevents actual contact between the two parts. The clearance is extremely important 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 the rotating journals distribute it to all parts of the bearings. The connecting rod bearings are lubricated through oil holes in the crankshaft. Oil moves across the face of the bearings to prevent wear and cool the bearing. Journals wear in two ways. They may wear out-of-round or they may wear unevenly across the journal face (taper). If the connecting rod bearing journal were out-of-round or if the journal taper were out of specification the result could be crankshaft wear between the crank and the bearing 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 crankshaft journal. This oil prevents actual contact between the two parts. The clearance is extremely important 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 the rotating journals distribute it to all parts of the bearings. The connecting rod bearings are lubricated through oil holes in the crankshaft. Oil moves across the face of the bearings to prevent wear and cool the bearing. Journals wear in two ways: They may wear out-of-round, or they may wear unevenly across the journal face (taper). Crankshaft wear between the crank and the bearing or damage to the connecting rod may occur if the connecting rod bearing journal is out-of-round or if the journal taper is out of specification. Check the engine blocks line bore if you see evidence of out-of-round or taper on a main bearing journal. Send the crankshaft and/or block to a machine shop to have it checked if you find that either out-of-round or taper are not within specifications. Use a micrometer to check the main and connecting rod journals for out-of-round and taper. Measure out-of-round at right angles to the centerline of the crankshaft (X and Y on the illustration). Measure taper in line with the crankshaft centerline at the two outer edges of the journal (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 the camshaft. Runout (contour) measurements provide information about the condition of the camshaft with regard to how much bend (warpage) has occurred in the camshaft. Camshaft end play measurements provide information on how much axial movement exists in the cylinder head. Runout Measurement Camshafts can warp through normal engine wear. Measuring camshaft runout provides an indication of camshaft straightness. To measure the camshaft, placed it on a set of V-blocks with a dial indicator. Mount the indicator rod at a 90o angle to the center camshaft journal. A camshaft that is out of specification must be replaced. Excessive camshaft runout can cause damage to the cylinder head and valve train. End Play Measurement End play measurements provide information about the condition of the camshaft with regard to how much camshaft movement (play) is present in the cylinder head. A dial indicator is used to measure end play. End play is measured with the camshaft installed in the cylinder head. To measure camshaft end play, a dial indicator is mounted with the indicator rod parallel to the direction of movement to be measured. In most cases, excessive end play requires that the camshaft be replaced. However, some camshafts with excessive end play measurements may be shimmed using spacers called locate plates. The locate plates are available in different sizes to compensate for the excessive end play to bring play within specification.
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Sprocket Runout Check camshaft sprocket runout prior to reinstalling the cylinder head. When measuring sprocket runout, take care not to mistake cam endplay for sprocket runout. Measure the runout using a dial indicator.
Cam Height & Cam Journal Clearance Proper valve operation affects engine combustion and driveability. Worn cam lobes may result in reduced valve opening which can cause improper engine combustion and increased emissions. Cam height and cam journal clearance are important aspects of camshaft inspection and cylinder head service and can be performed while the cylinder head is disassembled. Use an outside micrometer to measure cam height. The wear limit specification is stated in the Service Manual. If the cam exceeds the limit specification, the camshaft should be replaced.
Cam Journal Clearance Cam journal clearance measurements may help determine if the cylinder head requires align boring with new cam bearings or if the cylinder head must be replaced. Installing new camshaft bearings in the cylinder head may be all that is required to repair the journal clearances. Visual inspection of the camshaft journals may show obvious signs of scratches or excessive wear.
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Two separate measurements are necessary to calculate camshaft journal clearance. The first is to measure the diameter of the camshaft bearings in the cylinder head. The second measurement is the actual camshaft journal diameter. The difference between the two measurements is the camshaft journal clearance. To measure the cylinder head, a camshaft bracket must be installed and tightened to the proper torque specification. A telescopic bore gauge measures the inner diameter of each of the camshaft bearings. Record the measurements of each cam bearing journal.
End Play
Bolt
Camshaft Plate mm (in) 0.02 (0.0008) 0.03
Unit:
(0.0024)
Engine Rear side
Identification Mark C No Identification Mark
To measure the camshaft journal, use an outside micrometer. Record the cam journal measurements. Subtract the outside cam journal measurement from the inner diameter measurement for each of the camshaft bearings to obtain the cam journal clearance. If any of the cam bearing measurements are excessive, the camshaft is worn and should be replaced.
Locate
(0.0012) 0.06
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CONNECTING ROD BEARING CLEARANCE MEASUREMENT Connecting rods provide the link between the piston and crankshaft. Connecting rods have a bearing at each end; one fits to the piston pin, the other to the crankshaft connecting rod journal. These bearings are lubricated with engine oil under pressure that prevents metal-tometal contact, engine wear, and noise. Repairing engines requires that the connecting rods be checked. To check the rods, use an inside micrometer, an outside micrometer, and PlastigageTM. This is mandatory in order to select the correct size, or grade, of connecting rod bearing. Rod bearing selecting 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 outside micrometer. The measurements are used to calculate the amount of clearance that is filled with pressurized engine oil. The larger, or big end of the connecting rod accommodates rod bearings for attachment to the crankshaft. The small and of the connecting rod contains a bushing for the piston wrist pin. Use an outside micrometer to measure the crankpin journal. Use an inside micrometer to measure the diameter of the big ends bearing surface. Subtract the crankpin journal diameter measurement from the big end bearing journal diameter measurement to get the big end bearing clearance. A similar procedure is conducted at the small end. Measure the diameter of the piston wrist pin with an outside caliper. Measure the small end bore with an inside micrometer. Subtract the 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 and a 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 correct clearances. If the clearance is excessive at the small end, the piston and wrist pin assembly should be replaced 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 the crankshaft 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: If the crankshaft is replaced with a new one, the connecting rod bearing is selected in one of three different manners dependent upon the engine serviced. Use the appropriate Service Manual and pay particular attention to the engine application and the direction that the crankshaft is read. Rod bearing selection can be read left-to-right or right-to-left, depending on application.
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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 undersized bearing should be selected to assure that the clearance specification is obtained. If PlastigageTM indicates excessive bearing clearance when compared to the scale, a thicker or undersized 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 clearance at the big end. An inside and outside micrometer are used to make the measurements and then clearance is calculated. CYLINDER HEAD TORQUING Wnemever removing or installing the cylinder head, or when cylinder head bolts are torqued, it is essential to determine whether the existing cylinder head bolts can be reused or if they must be replaced. Correct bolt torquing in the correct sequence is essential to attain proper cylinder head pressure 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 in order to determine if they can be reused. Apply a light coat of oil to the threads and seating surfaces of the cylinder head bolt before installing. Follow the Service Manual procedure to tighten the cylinder head bolts and torque the bolts in sequence, as indicated. Loosen the bolts, then torque to specification. Use the torque angle gauge and turn the bolts clockwise 90 to 95 degrees. This tightens the bolt to the proper torque while also stretching the bolts to provide a stronger clamping force. Stretching the bolts beyond specification ruins the elasticity of the bolt and least to a failed fastener. Note: Cylinder head bolts must be tightened using a six step process. A torque wrench AND torque angle meter must be used. A torque wrench alone will NOT tighten the bolts to the required specification.
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OPERATION AND DIAGNOSIS OF ELECTRONIC LIQUID ENGINE MOUNTS The new VQ engine mounting system reduces noise and vibration generated by the engine. The front and rear engine mounts are located on a full-floating center member and sub frame to minimize engine vibration in the high speed range. The front and rear engine mounts are liquid-filled to reduce noise, shake and vibration during idling and in the low-medium speed range. With electronically-controlled liquid-filled engine mounts, the engine mount orifices are switched by electric control, controlled by the Electronic Control Module (ECM). Electronically-controlled liquid-filled engine mounts are diagnosed with CONSULT-II Data Monitor Mode and Active Test Mode. ENGINE COOLING SYSTEM The cooling system keeps the engine running at its most efficient operating temperature under all operating conditions. Inefficient cooling system operation results in poor engine performance and driveability and may cause accelerated wear. Begin any cooling system diagnosis with a visual inspection. This includes the condition of the hoses, radiator, drive belts and coolant. Use a pressure test to check for small leaks in the cooling system and radiator cap. Check the condition of radiator, engine inlet and outlet hoses and heater hoses to confirm their integrity. 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, you should replace it. Check to be sure there is no evidence of damage, such as cracked rubber or obvious breakdown of the material. The overall purpose of the cooling system is to remove heat from the engine. Water is the best liquid for heat removal. However, water freezes at 32oF and vaporizes at 212oF. It also promotes 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, but ethylene glycol transfers heat more poorly than water. To maintain the good heat removing qualities of the water in the solution while still giving adequate protection against freezing, the coolant-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 engines cylinders and measures the cylinders ability to hold pressure. You can check the condition of the piston rings, valves and head gasket by testing compression and cylinder leakage.
AR ENGINE MOUNTING LEFT ENGINE MOUNT
HT ENGINE MOUNTING
ONT ENGINE MOUNTING CENTER MEMBER
22
The cylinder compression tester is an instrument used to measure the compression retained in each cylinder. The needle on the face of the gauge indicates the maximum compression pressure 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 a spark plug port. Crank the engine. Record the gauge reading. Next, compare the compression measurements for each cylinder against the specifications in the Service Manual. Additional results 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 the compression tester when cranking the engine, it is a good idea to watch for obvious disparities between 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 reach specification, may indicate worn piston rings. A gauge reading higher than specification may indicate carbon deposit build up in the combustion chamber.
Cylinder Leakage The cylinder leakage test tells you about each cylinders ability to hold pressure. It can help you identify the location and extent of a cylinder leak. To use a cylinder leakage tester, position the piston in the cylinder to be tested at top dead center, install the testers adapter in the spark plug hole and apply compressed air. The gauge on the tester indicates the total compression leakage expressed as a percentage. A zero percent gauge reading indicates no leakage from the cylinder, however all cylinders normally leak a small amount past the piston rings. 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 and compare 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 by broken or worn rings, a cracked piston or worn cylinder walls. Air bubbles in the radiator indicates cylinder leakage into the cooling system. This may indicate cracks in the water jackets, block, or head gasket. High percentage of leakage in two adjacent cylinders indicates a head gasket problem or an engine block crack between the cylinders.
23
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 the noise, the source is associated with the crankshaft. Pinch off the PCV hose to increase crankcase pressure. If the noise stops or is reduced, 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 a cylinder balance test. If the noise stops when you disable a particular cylinder, it is associated 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 R40 series used a non-coated piston in cylinders #1, #2, #5, and #6. If it is necessary to replace pistons in these cylinders, install noncoated pistons. Install moly-coated pistons of the correct grade into cylinders #3, #4, and #5. The coated pistons are designed with a tighter piston-to-bore clearance than non-coated pistons to reduce noise and scuffing. Always check for bulletins with ASIST before selecting and installing replacement pistons. VQ30DE Timing Chain Noise The timing chain tensioner, tensioner gasket and guide are available for 1995-1996 Maxima and 1996 I30 VQ30DE engines if a rattle of either several seconds or continuously is heard coming 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 repairs are 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 cam bearing retaining caps.
24
VQ35DE NISSAN VARIABLE INTAKE SYSTEM (NVIS) The Nissan Variable Intake System provides optimum intake runner length, relative to high and low engine speed, for torque and horsepower. When the NVIS is OFF at low and middle engine speeds, inlet air is routed through the long passages in the intake manifold. This increases the inertial energy of the inlet air and greatly increases low speed torque. When the engine operates at higher speed, the NVIS system in turned ON, which opens the shorter intake manifold runners. VQ30DE Dual-Stage Cooling System The VQ30DE uses a dual thermostat cooling system with a new water control valve for improved fuel economy and emissions performance. Coolant is routed from the water pump to the cylinder head when the water control valve is closed. An additional path is opened so that coolant can also flow through passages in the cylinder block when the valve is open.
25
Nissan Continuously Variable Valve Timing Control System (NCVCS) System Description This system increases engine torque in low and mid rpm range. At high rpm, horsepower and fuel 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 intake cam.
:Piston Movement :Oil Flow Front Timing Chain Case Primary Sprocket CVTC (IVTC) Cover Rear Timing Chain Case IVTC Valve
Secondary Sprocket
Oil Pressure Intake Camshaft
Drain Drain Piston
Oil Pressure
TDC
TDC
Exhaust Valve
Intake Valve Retension (no oil flow) Retard Angle
Exhaust Valve
Intake Valve
Advance Angle
26
IVTC Valve is activated by signals from the ECM. Longer pulse width (high duty cycle) increases pressure in the system, advancing intake cam timing Shorter pulse width (low duty cycle) reduces pressure in the system, retarding intake cam timing. Equal pulse width stops oil flow, fixing the timing at 0 advance
Component 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)
IVTC Valves
Camshaft Bracket
Intake Valve Timing Control Unit (Intake Cam Sprocket)
Cylinder Head
Intake Timing Sensor Bank #1 Rear Timing Chain Case
CVTC Cover
Intake Timing Sensor Bank #2
Front Timing Chain Case
27
Note Note: In the ESM, IVTC is also referred to as CVTC. New Diagnostic T rouble Codes Trouble
N e w D i a g n o s t i c Tr o u b l e C o d e s
DTC P1111 P1136 P1140 P1145 Description Solenoid - Bank 1 Solenoid - Bank 2 Sensor - Bank 1 Sensor - Bank 2 C O N S U LT- I I Te r m i n o l o g y INT/V SOL (B1) INT/V SOL (B2) INT/V TIM (B1) INT/V TIM (B2)
With the NCVCS, there are diagnostic trouble codes. The following chart indicates the new codes:
CONSULT-II Reference Value in Data Monitor Mode

Monitor Item INT/V TIM (B1) INT/V TIM (B2) Condition After warming up engine Shift Lever to NEUTRAL Quickly depressed accelerator pedal No load After warming up engine Shift Lever to NEUTRAL Quickly depressed accelerator pedal No load Idle 2,000 rpm Idle 2,000 rpm 0 CA Approximately 12-18 CA 0% *Approximately 40% Specification
INT/V SOL (B1) INT/V SOL (B2)
*This represents a duty cycle in relation to the solenoid ON time.
Specification Data The following specification data are used with CONSULT-II: On 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. In fail-safe mode, the IVTC valve does not function.
28
S E C T I O N 2
E X E R C I S E S
ENGINE MECHANICAL SERVICE SIGN-OFF SHEET
Worksheet
Title
Instructor Initials
Module 1 Module 2 Module 3 Module 4 Module 5 Module 6 Module 7 Module 8 Module 9 Module 10 Module 11 Module 12 Module 13 Module 14 Module 15 Module 16 Module 17 Module 18
"Engine Fundamentals" Video Understanding the Operation of Variable Valve Timing and Inspecting the NCVCS Using CONSULT-II Electronically-Controlled Engine Mounts Power Balance Test Using CONSULT-II Cooling System Check Oil Pressure Test Engine Compression and Leakage Test Engine Identification and Service Manual Usage SR20DE Valve Adjustment Hydraulic Valve Lash Adjusters QR25DE Valve Clearance Inspection and Adjustment Engine Noise Diagnosis VQ35DE Timing Chain Installation VK45DE Timing Chain Replacement (Infiniti Only) VQ35DE Water Pump Removal and Installation Cylinder Head Bolt Torquing QG18DE Valve Adjustment QR25DE Timing Chain and Balancer Unit (Nissan Only)
NOTES
ii
ENGINE FUNDAMENTALS VIDEO

Objective Objective: Given a videotape and VCR, the technician will be able to understand the fundamentals of engine operation. All technicians should have a firm understanding of the four-stroke engine cycle. This video describes many common engine types used by Nissan. Engine diagnosis begins when the technician fully understands engine operation.
Module 1
Relevance Relevance:
Resources Resources: The following items are provided: VCR player Engine Fundamentals videotape Text Section Skill Check Check: Your understanding of the operation of a four-cycle engine is verified by successfully answering the questions in this module.
Engine Fundamentals Video
1.
Module 1
One complete four-stroke engine cycle consists of: ________________________________________ ________________________________________ ________________________________________ ________________________________________
2.
Describe the main purpose of the crankshaft. ________________________________________ ________________________________________ ________________________________________
3.
List valve train components in order of operation: ________________________________________ ________________________________________ ________________________________________ ________________________________________
4.
List what moves the piston on the power stroke? ________________________________________ ________________________________________
5.
List three piston rings facts. ________________________________________ ________________________________________ ________________________________________
6.
What is the purpose of the oil control ring? ________________________________________ ________________________________________ ________________________________________
Module 1
7.
What is the function of the NCVCS system? ________________________________________ ________________________________________ ________________________________________ ________________________________________
8.
The timing chain expands due to centrifugal force. How is the chain kept in place? ________________________________________ ________________________________________ ________________________________________
9.
List the order of events when referring to coolant flow. ________________________________________ ________________________________________ ________________________________________ ________________________________________
10. Where does coolant flow while the engine is cold? ________________________________________ ________________________________________
NOTES
UNDERSTANDING THE OPERATION OF VARIABLE VALVE TIMING AND INSPECTING THE NISSAN CONTINUOUSLY VARIABLE VALVE TIMING CONTROL SYSTEM (NCVCS) USING CONSULT-II
Objective Objective: Given a vehicle equipped with the VQ35DE engine and a CONSULT-II, perform basic function test of NCVCS. The VQ35DE is an all-new engine. Although similar to the VQ30DE engine used in Maxima, there are several significant differences which may impact diagnosis.
Module 2
Relevance Relevance:
Resources Resources: The following items are provided: Vehicle with VQ35DE engine CONSULT-II Electronic Service Manual (ESM) Text Section (pages 26-28)
Skill Check Check: Your understanding of the operation of this system is verified by recording data with CONSULT-II and attaching printouts into this module.
NCVCS
Monitoring Signals
1.
Module 2
Use the text section (pages 26-28) of your Student Guide to answer questions one through eight. Thoroughly review this material and use it to answer the following questions. What fluid regulates intake camshaft position? ________________________________ ________________________________
2. 3.
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 timing function? ________________________________ ________________________________
6.
Under which driving conditions is valve timing activated? ________________________________ ________________________________
NCVCS
7.
When the engine is idling, what happens to the following: Intake valve open/close time: ADV ANCES / NORMAL (Circle one) ADVANCES Valve overlap: INCREASES / NORMAL (Circle one) Control Solenoid Valve: 0% / ~40% (Circle one)
Module 2
8.
At low to medium speed, what happens to the following: Intake valve open/close time: ADV ANCES / NORMAL (Circle one) ADVANCES Valve overlap: INCREASES / NORMAL (Circle one) Control Solenoid Valve: 0% / ~40% (Circle one)
NCVCS
NISSAN
9.
Connect CONSULT-II to the the DLC.
CONSULT-II
10. Start the engine and warm it up to normal operating temperature. ART on the CONSULT-II Main Menu. 11. Touch ST START
Module 2
AED99C
START
SUB MODE LIGHT COPY
SELECT SYSTEM ENGINE A/T AIR BAG ABS SMART ENTRANCE
12. Touch ENGINE ENGINE. The NCVCS system is one of the systems controlled by the ECM for engine operation.
BACK
LIGHT
COPY
SELECT DIAG MODE WORK SUPPORT SELF-DIAG RESULTS DATA MONITOR DATA MONITOR (SPEC) ACTIVE TEST DTC & SRT CONFIRMATION
TA MONIT 13. Touch DA DAT MONITOR OR to select the diagnostic mode.
Scroll Down BACK LIGHT COPY
NCVCS
DATA MONITOR SELECT MONITOR ITEM ECM INPUT SIGNALS MAIN SIGNALS SELECTION FROM MENU
14. Touch SELECTION FROM MENU to choose inputs to include on the display.
Module 2
SETTING MODE
Numerical Display
BACK
LIGHT
COPY
DATA MONITOR SELECT MONITOR ITEM IGN TIMING CAL/LD VALUE ABSOL TH-P/S MASS AIRFLOW IACV-AAC/V
15. Touch each of the following inputs to highlight them: ENG SPEED THRTL POS SEN CAL/LD V ALUE VALUE INT/V TIM (B1) INT/V TIM (B2) INT/V SOL (B1) INT/V SOL (B2)
Page Up SETTING MODE
Page Down
Barchart Display
START COPY
BACK
LIGHT
16. Touch SETTING to set up the snapshot parameters that follow.
SET RECORDING CONDITION
AUTO TRIG MANU TRIG
TRIGGER POINT
17. Touch MANU TRIG to set the snapshot recording condition. Leave the default conditions in place for both TRIGGER POINT and Recording Speed.
>>
>>
0% 20% 40% 60% 80% 100%
Recording Speed
MIN MAX
>>
/64 /32 /16 /8 /4 /2 FULL
>>
MODE B A C K LIGHT COPY
NCVCS
DATA MONITOR MONITOR ENG SPEED THRTL POS SEN CAL/LD VALUE INT/V TIM (B1) INT/V TIM (B2) INT/V SOL (B1) INT/V SOL (B2) 763 rpm 0.44 V 29% 0 CA 1 CA 0% 0%
Module 2
ART 18. Touch BACK BACK, then touch ST START ART. The screen should look similar to the image at left. Notice that each of the inputs selected in step 8 are now actively displayed on the CONSULT-II screen.
RECORD MODE BACK LIGHT S T A R T
Attach Printout Here
19. Touch COPY and attach printout at left.
20. Accelerate to 1,500 rpm and while holding the rpm steady, touch COPY COPY. Attach printout at left. 21. Allow the engine to return to idle. 22. Based on the printout at left, what was the calculated load percentage? __________________________________ 23. Shut off the engine.
NCVCS
Bank #2 Bank #1
24. Disconnect the intake timing sensor connector for Bank 1. See illustration at left for proper location. 25. Start the engine. 26. Accelerate the engine to 1,500 rpm. 27. Touch COPY and attach the printout at left. 28. Allow the engine to return to idle. 29. From your printout, are both camshaft sensors indicating the same amount of advance? YES/ NO (Circle one)
Module 2
Intake Timing Sensors
30. Did the value of B1 sensor change? YES/ NO Note Note: (Circle one)
A fixed reading indicates that the system is not functioning properly.
SELF-DIAG RESULTS DTC RESULTS

INTK TIM S/CIRC-B1 [P-1140]
TIME 1t
31. Touch BACK and return to the SELECT DIAG TS TS. MODE, then touch SELF-DIAG RESUL RESULTS Any stored DTCs should now be displayed on the screen.
F.F. DATA ERASE MODE BACK PRINT LIGHT COPY
NCVCS
32. Touch PRINT to print all DTCs. Attach the printouts at left. Attach Printout Here 33. Touch the box of the first DTC displayed. 34. What information is now displayed? ____________________________________ ____________________________________ Note: This system uses a 2-stage fault detection logic. The Malfunction Indicator Light (MIL) on the instrument panel will illuminate after the second time the engine is started with a fault in the system.
Module 2
35. Touch SCROLL DOWN to read all information. 36. From the information given, determine the possible causes for this DTC and attach the printout at left.
SELECT DIAG MODE WORK SUPPORT SELF-DIAG RESULTS DATA MONITOR DATA MONITOR (SPEC) ACTIVE TEST DTC & SRT CONFIRMATION
37. Shut off the engine and reconnect the sensor connections. 38. Turn ignition back ON and touch ERASE to clear all DTCs, then print the screen and attach at left. 39. If you had difficulty performing the Skill Check stated at the beginning of this module, ask your instructor for assistance. 40. When you have completed the Skill Check to your satisfaction, see your instructor for verification of your work.
Scroll Down BACK LIGHT COPY
NCVCS
You have now completed this module. If you have any doubt about your skills in completing this module, please return to step #1 and review your work. Once you are confident of your skills, have your instructor verify your work and initial your module. Instructors Initials _____________________ Return the workstation to the condition in which it was found.
Module 2
NCVCS
NOTES
10
NCVCS
ELECTRONICALLY-CONTROLLED ENGINE MOUNTS

Objective: Given a vehicle with one or more electronically-controlled engine mounts and a CONSULT-II scan tool, verify proper operation of electronically-controlled, liquid-filled engine mounts using CONSULT-II. Understanding how to properly verify proper operation of electronicallycontrolled liquid-filled engine mounts is important to complete diagnosis and repair of noise, vibration and harshness (NVH) concerns.
Module 3
Relevance:
Resources: The following items are provided: Vehicle w/Electronically-Controlled Engine Mounts CONSULT-II Scan Tool Skill Check: The instructor will check your understanding of electronic engine mount operation by verifying that all steps in this module were properly followed and that questions were answered properly.
Electronically-Controlled Engine Mounts
Active Test
1.
REAR ENGINE MOUNTING LEFT ENGINE MOUNTING
Verify that the most recent diagnostic card and resident software are installed in the CONSULT-II. Withe the ignition switch OFF, connect the CONSULT-II unit to the vehicles data link connector. Turn the ignition ON and start the engine. ART on the CONSULT-II screen. Touch ST START Touch ENGINE. TA MONIT OR. Touch DA DAT MONITOR. ART . Touch MAIN SIGNALS, then ST START ART.
Module 3
RIGHT ENGINE MOUNTING
2.
3.
FRONT ENGINE MOUNTING CENTER MEMBER
4. 5.
FRONT
6. 7.
Note: The engine must be at normal operating temperature before proceeding. 8. Observing the CONSULT-II screen, what is the reading from the engine coolant temperature sensor? ________________________________________ 9. Is the reading within specifications? YES/NO (Circle one) 10. Touch BACK twice to return to the SELECT DIAG MODE screen. 11. Touch ACTIVE TEST TEST. 12. Page Down and touch ENGINE MOUNTING MOUNTING. ART . 13. Touch ST START ART.
14. What items are monitored under MAIN SIGNALS SIGNALS? ________________________________________ ________________________________________ 14a) Place vehicle in D with foot on brake pedal. 15. Touch TRV/IDL TRV/IDL. This is the command for the engine mounts to switch from IDLE to TRAVEL mode and back.
Module 3
Note: You can verify operation by feeling a change in vibration on the hood or drivers door. 16. What might the customer complaint be if the engine mount were not operating? ________________________________________ ________________________________________ 17. Repeat the same scenario as explained above, however this time instead of touching SELECTION FROM MENU, touch MAIN SIGNALS SIGNALS. Print your data and attach in to the space at the left. 18. Is the engine mount operating properly? YES / NO (Circle one) 18a) Place vehicle in Park.
Data Monitor This exercise uses the graph feature of CONSULT or CONSULT-II. 19. With the ignition switch OFF, connect the CONSULT unit.
Module 3
20. Turn the ignition ON and start the engine. ART on the CONSULT screen. 21. Touch ST START 22. Touch ENGINE ENGINE. TA MONIT OR 23. Touch DA DAT MONITOR OR. Note: ENGINE MOUNT may be accessed using MAIN SIGNALS or SELECTION FROM MENU in DATA MONITOR. 24. Touch SELECTION FROM MENU MENU. 25. Page forward through the menu and touch CKPS/RPM, THRO TTLE POSITION THROTTLE SENSOR . SENSOR, and ENGINE MOUNT MOUNT. Note: When performing the following step the engine must be revved for the test to operate. O TRIG 26. Touch SETTING and choose AUT AUTO and MAX RECORDING SPEED. 27. Touch BACK BACK. ART 28. Touch ST START ART. 29. With engine idling, touch RECORD RECORD, then rev engine to travel. OP ORE. 30. Touch ST STOP OP, then touch ST STORE. ORE again and then touch BACK. 31. Touch ST STORE Y. 32. Touch DISPLA DISPLAY
33. Touch GRAPH GRAPH. 34. Touch COPY COPY.

35. Touch SCROLL DOWN. 36. Touch COPY COPY. 37. Graph each selected item, print-out each graph, and attach them to the spaces at the left. 38. Compare each graph to the other. 39. What does this comparison indicate? ________________________________________ ________________________________________ ________________________________________
Module 3
You have now finished this module. If you have any doubt about your skills in completing this module, please return to step #1 and review your work. Once you are confident of your skills, have your instructor verify your work and initial your module.
Instructors Initials ____________________ Return the workstation to the condition in which it was found.
NOTES
POWER BALANCE TEST USING CONSULT-II

Objective: Given a training vehicle and CONSULT-II scan tool, perform a power balance test and use the results to determine if one or more cylinders is misfiring. The power balance test is the quickest and most efficient way to isolate a misfiring cylinder and determine if the cause of an engine noise is electrical or mechanical in nature. CONSULT-II provides a fast and simple way to perform the test.
Module 4
Relevance:
Resources: The following items are provided: Vehicle CONSULT-II Skill Check: The instructor will verify your understanding of this procedure by checking that all steps have been properly completed and that all questions are correctly answered.
Power Balance Test Using CONSULT-II
1.
Connect CONSULT to the Diagnostic Data Link and turn it ON. ART Touch ST START ART. Touch ENGINE ENGINE. Touch ACTIVE TEST TEST. Select POWER BALANCE test. Following the directions in the CONSULT manual, perform the power balance test. If you have any trouble, ask your instructor for help.
ACTIVE TEST POWER BALANCE MONITOR CMPS-RPM(REF) 900rpm 1.66V 25%
2. 3. 4. 5.
Module 4
MAS AIR/FL SE IACV-ACC/V
TEST START
MODE
BAC K
LIGHT
COPY
6.
Be sure to note the engine RPM before and during the test for each cylinder. Note the RPM drop for each cylinder in the table below.
Cylinder # RPM Before Test RPM During Test
1 2 3 4 5 6
Module 4
7.
Did any cylinder fail the test (no drop in rpm when tested)? YES / NO (Circle one)
8.
What is indicated when all cylinders show a similar drop in engine speed? ________________________________________ ________________________________________
9.
What is indicated if an engine is making a noise that changes with RPM, and the noise disappears while a cylinder is being tested during the cylinder balance test? ________________________________________ ________________________________________
You have now finished this module. If you have any doubt about your skills in completing this module, please return to step #1 and review your work. Once you are confident of your skills, have your instructor verify your work. Instructors Initials ____________________
Module 4
Return the workstation to the condition in which it was found.
COOLING SYSTEM CHECK

Objective: Given a vehicle, hydrometer, cooling system pressure tester and applicable Service Manual, perform a cooling system check for evidence of leaks, damage, or deterioration to assure proper cooling system performance. The cooling system keeps the engine running at its most efficient operating temperature under all conditions. Inefficient cooling system operation results in poor engine performance and driveability. This module will familiarize you with the essential techniques of cooling system diagnosis.
Relevance:
Module 5
Resources: The following items are provided: Vehicle Coolant Hydrometer Coolant System Pressure Tester Service Manual
Skill Check: Your understanding of the tools and information necessary to properly perform this procedure is verified by using the hydrometer and pressure tester according to the Service Manual procedure and by correctly answering all the questions in this module .
Cooling System Check
Note: Visual inspection of the system should precede any cooling system inspection. This includes the condition of the hoses, radiator, drive belts and coolant. Pressure testing the cooling system and radiator cap will identify very small leaks and internal leaks not detected in the visual inspection.
Module 5
1. Visually inspect the condition of drive belts for the vehicle at your workstation. Check the condition of radiator, engine inlet and outlet hoses and heater hoses to confirm their integrity. Heated water causes the rubber material to deteriorate from the inside out. Squeeze the hose. It should be firm. If the hose feels mushy or soft in any way, it should be replaced. Check to be sure there is no evidence of damage such as cracked rubber or obvious breakdown of the material. 2. Do any of the hoses on the vehicle at this workstation need replacing? YES / NO (Circle one) 3. Note problems identified during the visual inspection here: ________________________________________ ________________________________________
4.
The liquid best suited for its heat removing qualities in the cooling system is: (Check one) Ethylene glycol Water
5.
Adding too much (over 50%) ethylene glycol antifreeze results in? (Check one) Reduces the heat removing efficiency of the coolant solution Raises the freezing point of the coolant solution Reducing inhibitors to prevent corrosion of the cooling system
Module 5
6.
It is very important to maintain a ratio of ethylene glycol to water that maximizes the cooling efficiency of the coolant while maintaining adequate freeze protection. What is the target ratio? (Check one) 50% ethylene glycol to 50% water 40% ethylene glycol to 60% water 60% ethylene glycol to 40% 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 ethylene glycol (anti-freeze) Unacceptable - need more water
8.
Using a hydrometer, test the coolant solution on the vehicle at your workstation to assure that it has the proper coolant mixture. Does the vehicle at your workstation have the proper coolant mixture? YES / NO (Circle one)
9.
Module 5
PRESSURE TO TEMPERATURE RATIO 1lb. increase = 3 boiling temperature increase 6lb. increase = 18 boiling temperature increase
Increasing the Pressure of the Solution: Increasing the pressure of the antifreeze solution will raise the cooling systems boiling point. For every 1lb. increase in pressure, the boiling point is raised 3F. The radiator cap functions to maintain pressure in the cooling system. Low pressure may be caused by a defective radiator cap. A pressure tester is a hand held pump with an attached gauge which indicates applied pressure. It may be used to determine the condition of the radiator cap as well as to test the cooling system for leaks which are not detected during visual inspection.
Refer to the LC or CO Section of the service manual and locate Cooling System Check. 10. Perform a radiator cap pressure test on the vehicle at your workstation using the pressure tester and following service manual procedures. WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure fluid escaping from the radiator. Wrap a thick cloth around the cap. Slowly push down and turn it a quarter-turn to allow built-up pressure to escape. Carefully remove the cap by pushing down and turning it all the way . way. 11. What is the radiator cap relief pressure specifications for the vehicle at your workstation? ________________________________________ 12. Is the radiator cap of the vehicle within specifications? YES / NO (Circle one)
EG17650001
Module 5
13. What should be done if the cap is not within specifications? (Check one) Replace the gasket retainer of the cap Replace the cap gasket Replace the cap
14. Locate Checking the Cooling System for Leaks section of the Service Manual. . 15. Check for leaks in the cooling system using the pressure tester and following service manual procedures for the vehicle at your workstation. 16. What test pressure should be applied to the system?
Module 5
________________________________ 17. Were any cooling system leaks found? YES / NO (Circle one) 18. Exceeding the specifications could cause the following problem: (Check one) Damage to the radiator Damage to the pressure tester gauge Damage to the filler neck
Other Methods to Detect Internal Leaks Internal leaks may be detected in several ways. Air leaks from the water pump or exhaust leaks from the cylinder head gasket may be detected using chemical combustion leak detectors. Exhaust leaks may also be detected using an aftermarket leak tester or an exhaust gas analyzer.
WARNING: Use caution when removing the radiator cap. 19. You may check for exhaust leaks using the aftermarket tester as described below: Install a sealing ring in the filler neck Attach the pressure tester to the radiator and open the relief valve Run the engine to normal operating temperature Close the relief valve and observe the gauge CAUTION: Do not pressurize the system above maximum specifications. A steady reading on the pressure gauge at or near specifications means the system is OK. An excessive increase in pressure may indicate exhaust pressure leaking into the cooling system from a head gasket leak, a crack in the cylinder block, or a crack in the cylinder head. A pressure decrease or a fluctuating gauge may indicate an exhaust leak into the cooling system from a crack in the cylinder head exhaust port. A decreased fluctuation will result when the leaking cylinder is deactivated (disable spark or injector)
Module 5
20. You may check for exhaust leaks using exhaust gas analyzer as described below: Run the engine to normal operating conditions Carefully remove the radiator cap Hold the analyzer probe at the top of the filler neck (do not immerse the probe in the coolant) Accelerate to 2,000 rpm, then return to idle Observe the analyzer for an increase in HC and CO CAUTION: Do not immerse the exhaust gas analyzer probe in the coolant. You have now finished this module. If you have any doubt about your skills in completing this module, please return to step #1 and review your work. Once you are confident of your skills, have your instructor verify your work and initial your module. Instructors Initials ____________________ Please return your workstation to the condition in which it was found.
Module 5
OIL PRESSURE TEST

Objective: Given a training vehicle, oil pressure gauge and the appropriate Service Manual, you will be able to perform an oil pressure test using a pressure gauge and interpret the results. The pressure of the engine oil affects vehicle operation and engine wear. Oil pressure that is too low can cause oil starvation to moving parts and increase friction, which promotes wear. Excessive oil pressure can damage bearings, increase the risk of crankshaft or camshaft failure, and promote leakage around seals.
Relevance:
Module 6
Resources: The following items are provided: Vehicle Oil Pressure Gauge Service Manual Skill Check: Your instructor will verify your understanding of this procedure by checking that the Service Manual procedure was followed properly and that all questions are properly answered.
Oil Pressure Test
Oil pressure is developed by the oil pump and regulated by a pressure regulating valve. After passing through the oil filter the oil passes to the main oil gallery which distributes the oil throughout the engine. Prior to performing any test on the engine oil system, always check the oil level to assure the engine is full to the correct level. See the service manual for the vehicle at your workstation. Locate the LC or LU Section and find Lubrication Circuit then answer the following questions. Notice that the schematic illustrates the lubrication circuit and the direction of flow. 1. What components are fed directly from the main oil gallery? ________________________________________ ________________________________________ 2. What vehicle conditions would lead you to use the Lubrication Circuit Chart Chart? ________________________________________ ________________________________________ 3. Locate the Oil Pressure Check procedure in the Engine Lubrication System section of the service manual.
Module 6
Notice that there is an illustration which indicates the location of the oil pressure switch. It is usually located on the engine block (screwed into the main oil gallery) near the oil filter or on the oil filter adapter, depending on the vehicle.
Oil Pressure Test
4.
Where is the oil pressure switch located on the vehicle at your workstation? ________________________________________ ________________________________________
When the switch is removed, an oil pressure gauge can be installed into the tap on the main oil gallery for measuring oil pressure. 5. Note the specifications for pressures with the engine at idle speed and at specific engine speeds. What is the pressure specification at idle speed for the vehicle at your workstation? ________________________________________ ________________________________________ 6. At what engine speed should the pressure be tested on the vehicle at your workstation? (Check one) 3000 rpm 3200 rpm 4000 rpm 2000 rpm 7. What is the pressure specifications for the vehicle at your workstation at the engine speed indicated above? ________________________________________ ________________________________________
Module 6
Oil Pressure Test
8.
Connect the pressure gauge and perform an oil pressure test on the vehicle at your workstation following the service manual procedure. Then answer the questions that follow. In which gear position should the vehicle be in to perform the oil pressure check? (Check one) First gear Third gear
9.
Module 6
Neutral/Park 10. Should the vehicle be at normal operating temperature to conduct this test? YES / NO (Circle one) 11. What does the service manual suggest you do if the difference between the specifications is extreme? ________________________________________ ________________________________________ 12. What were the results of the pressure test for the vehicle at your workstation?
RPM At idle Test RPM _________
Pressure ____________ ____________
Oil Pressure Test
13. Were the pressure readings within specifications? YES / NO (Circle one) You have now completed this module and should be able to perform and interpret an oil pressure test using a pressure gauge and following the service manual procedures. If you have any doubt about your skills in completing this module, please return to step #1 and review your work. Once you are confident of your skills, have your instructor verify your work and initial your module. Instructors Initials _____________________ Return the workstation to the condition in which it was found.
Module 6
Oil Pressure Test
NOTES
Oil Pressure Test
ENGINE COMPRESSION AND LEAKAGE TEST

Objective: Given a vehicle, a cylinder compression gauge, a cylinder leakage tester, a CONSULT-II scan tool and the applicable Service Manual, perform an engine compression test and a cylinder leakage test to determine the condition of the piston rings, valves, and head gasket based on specifications indicated in the Service Manual.
Module 7
Relevance: Compression and leakage tests are vital for determining a cylinders ability to hold pressure. Resources: The following items are provided: Vehicle Electronic Service Manual (ESM) Compression Gauge Cylinder Leakage Tester CONSULT-II Skill Check: The instructor will check your understanding of the procedures by verifying that all steps were followed and that all questions were correctly answered. The instructor may also ask questions regarding when these procedures are performed, and why.
Engine Compression and Leakage Test
Compression T est Test

Refer to the EM section of the service manual for the vehicle at your workstation, locate the section entitled Measurement of Compression Pressure and answer the following questions. 1. Should the engine be at normal operating temperature to conduct this test? YES / NO (Circle one) 2. Should the ignition switch be OFF when you begin the test? YES / NO (Circle one) 3. Prior to performing the compression pressure measurement, you should: (Check one) Disconnect distributor center cable Remove all spark plugs Release fuel pressure All of the above selections The EC section in the service manual refers you a Fuel Pressure Release procedure that you will need to perform in order to answer the following questions.
Module 7
4.
Refer to the procedure indicated in the EC section of the service manual and answer the following questions. Which diagnostic mode should be used when performing the procedure above using CONSULT-II? ________________________________ ________________________________
5.
6.
Should you remove the fuel pump fuse If performing the fuel pressure release procedure without using CONSULT-II? YES / NO (Circle one)
Module 7
7.
Perform the fuel pressure release procedure according to the service manual on the vehicle at your workstation.
Locate Compression Pressure Measurement in the EM section of the service manual for the vehicle at your workstation and answer the following questions. 8. How many spark plugs have to be removed to ensure accurate results on the vehicle at your workstation? ________________________________
9.
Why must the fuel injection system and ignition system be disabled when performing a compression test? (Check one) Prevents fuel from being injected into the cylinders Prevents damage to the ignition system during the test Prevents an engine fire in the shop All of the above
Module 7
10. Why does the procedure require you to keep the throttle valve wide open by depressing the accelerator pedal? _______________________________ 11. Why should the vehicles battery be fullycharged when performing this test? (Check one) To generate high secondary voltage To assure specified engine speed To avoid damage to the ignition coil None listed above Note: Spark plugs should be removed during the compression test to prevent drag on the engine during cranking.
12. Crank the engine a few times while observing the compression gauge and record the reading. Reading: ___________________ 13. Which gauge indication do you record? (Check one) The gauge indication after five compression strokes The gauge indication on the first compression stroke The highest gauge indication None listed above 14. What are the specifications in the service manual for the vehicle at your workstation?
Module 7
ITEM Standard engine compression pressure Minimum engine compression pressure Difference limit between cylinders
SPECIFICATION
If the Dry Test did not provide enough compression, perform a Wet Cylinder Compression Test. This involves adding a few drops of engine oil into the cylinders through the spark plug holes. Repeat the compression test for each cylinder. 15. Perform a compression test on the vehicle at your workstation according to the service manual procedures.
Cylinder
D r y Te s t
We t Te s t
Module 7
16. When would a wet test be necessary? _______________________________ _______________________________ 17. Were the results of the engine compression test within specifications for the vehicle at your workstation? YES / NO (Circle one) 18. What did the wet test results reveal? _______________________________ _______________________________
19. What might you conclude if your compression test indicated low compression in two adjacent cylinders during both the dry and wet compression tests? (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 dry compression test indicated low compression but adding oil to that cylinder during 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 your compression test indicated low compression during the dry test and remained 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
Note Note:
Compression readings which vary between cylinders will have a negative effect on engine performance.
Leakage T est Test

22. Perform a cylinder leakage test on the vehicle at your workstation. Indicate your test results on the table on the next page. Follow the manufacturs instructions for using the cylinder test equipment. Be sure to observe the following procedures.
Module 7
Do not use the hose adapter for a compression gauge. Run the engine to bring it to normal operating temperature. Disable the ignition system. Disable the fuel system. Remove all spark plugs. Remove the air cleaner, crankcase filler cap, dipstick, and radiator cap (be sure the coolant is at the appropriate level). Disconnect the PCV valve inlet hose from crankcase. Install the testers adapter attachment in the spark plug hole of the cylinder at TDC on its compression stroke and the other tester attachment to its compressed air source. Pressurize the cylinder according to the manufacturers directions. Note the gauge readings (this shows the percentage of air leakage from the cylinder).
Repeat the test for each cylinder. If the leakage exceeds 20%, listen and look to locate the source of the leakage.
Cylinder No.
% of Leakage
Module 7
23. Did any cylinders fail the leakage test? YES / NO (Circle one) 24. If so, what was the cause? _______________________________ _______________________________ _______________________________ If you have repaired or altered the vehicle at your workstation to complete this module, please assure that it is returned to the original condition. You have now finished this module. If you have any doubt about your skills in completing this module, please return to step #1 and review your work. Once you are confident of your skills, have your instructor verify your work. Instructors Initials ____________________ Return the workstation to the condition in which it was found.
NO TES NOTES
10
ENGINE IDENTIFICATION AND SERVICE MANUAL USAGE

Objective: Given an ASIST terminal with Electronic Service Manual (ESM), correctly identify an engine assembly based on the Engine Identification Code and locate the proper diagnosis/ repair sections, specifications and procedures applicable to the vehicle being serviced. Before you can perform engine maintenance or diagnosis, you need to know where to find important information. The Electronic Service Manual (ESM) helps you find the information you need quickly and easily.
Relevance:
Resources: The following items are provided: ASIST Workstation ASIST/ESM Disks Skill Check: Verify that you can identify engines and use the Electronic Service Manual by correctly answering the questions in this module.
Module 8
Engine Identification & Service Manual Usage
Engine Identification
1. On the ASIST Main Screen, click the Service Manual button. Select a vehicle. Select Service Manual. On the Quick Reference Index, click General Information (GI). Using the Contents page under Identification Information, locate the illustration that shows the location of the Vehicle Identification Plate. Locate the illustration of the vehicle identification number plate. Notice that information about the vehicles engine, date of manufacture, and place of manufacture is included in the number. Where is the vehicle identification plate located according to the service manual? ________________________________________ The EM section of the service manual identifies repair information and specifications based upon the engine model number. Because more than one engine may be installed in a particular vehicle model, you must apply the correct specifications and procedures to the vehicle that you are servicing. The engine model number is an alphanumeric (consisting of both letters and numbers) code. The code identifies specific properties of the engine installed in the vehicle. The code contains four pieces of information about the engine.
2. 3.
4.
5.
Module 8
6.
Example: VQ35DE VQ = Engine family: A description for a particular engine group. 35 = Displacement codes X 100: 3.5 liter (3500cc) engine. D = Equipment codes: Double overhead cam E = Fuel delivery type: Multipoint injection Listed are the various equipment codes:
E = Multipoint electronic fuel injection S = Carbureted D = Double overhead cam T = Turbocharged i = Throttle Body Injection TT = Twin Turbocharged
Module 8
Answer the following questions if the Engine Model I.D. Number were VQ35DE. 7. What is the family name designation indicated for this engine? ________________________________________
8.
What is the engine displacement indicated? ________________________________________
9.
Is this engine equipped with double overhead cams? YES / NO (Circle one)
10. What is the fuel delivery type? ________________________________________ Answer the following questions if the Engine Model I.D. Number were VQ30DE. 11. What is the family name designation indicated for this engine? ________________________________________ 12. What is the engine displacement indicated? ________________________________________ 13. Is this engine equipped with double overhead cams?
Module 8
YES / NO (Circle one) 14. What is the fuel delivery type? ________________________________________ 15. Returning to the Quick Reference Index, click TION (GI) link. on the GENERAL INFORMA INFORMATION 16. Use the CONTENTS in the GI section and TION INFORMA TION click on IDENTIFICA IDENTIFICATION INFORMATION TION. 17. Can you determine what engine is installed in the vehicle from the Vehicle Identification Number (VIN)? YES / NO (Circle one) 18. Where is the engine serial number located on the engine(s) for the vehicle selected? ________________________________________ ________________________________________
19. Return to the GENERAL INFORMA INFORMATION TION (GI) CONTENTS section. Refer to the in the GI section. 20. Can you find tightening torque specifications for standard bolts in this section of the service manual? ________________________________________ 21. What mark is embossed on the bolt head of a grade 7T bolt? ________________________________________ 22. On a M6 bolt, what does the M stand for? ________________________________________ 23. Return to the Quick Reference Index. Click on the MAINTENANCE SECTION (MA) link. 24. Refer to the CONTENTS in the MA section and locate the table indicating recommended fluids and lubricants. 25. What is the recommended capacity of engine oil (in quarts) with changing the oil and oil filter? ________________________________________ 26. In your experience, what may result if the engine oil level is too high? ________________________________________ ________________________________________ ________________________________________
Module 8
CAUTION: Do not overfill beyond the recommended level. Doing so can result in a buildup of deposits in the combustion chamber and intake manifold. A buildup of deposits around the throttle plates and AAC Valves may result in poor idle quality.
27. Find the SAE Viscosity Number chart. 28. What weight of engine oil is preferred for all ambient temperatures? ________________________________________ 29. Go back to the Quick Reference Index. Click on the ENGINE MECHANICAL (EM) link. 30. On the CONTENTS page of the EM section, locate the PRECAUTIONS sub section indicating parts that require angular tightening. 31. Do cylinder head bolts require angular tightening? YES / NO (Circle one) 32. Do connecting rod cap nuts require angular tightening? YES / NO (Circle one) 33. In what sub section of the EM section of the service manual can you find a blow-up illustration of the engine with indicated torque specifications for component parts? ________________________________________
Module 8
34. Where in the EM section of the service manual can you find the engine firing order? ________________________________________ ________________________________________ The Service Data and Specifications (SDS) subsection of the service manual contains valuable information regarding inspection and adjustment of engine components. Every section of the service manual has an SDS subsection. Refer to the SDS sub section in the EM section of the service manual and answer the questions that follow. 35. How many grades of pistons are available? ________________________________________
Module 8
Note: If more than one engine is available for the vehicle, specify the engine application.
36. How many grades of main bearings are available? ________________________________________
Note: If more than one engine is available for the vehicle, specify the engine application.
37. What is the main bearing clearance limit specification? ________________________________________ 38. What is the connecting rod bearing clearance standard specification? ________________________________________ 39. Return to the Quick Reference Index. Click on ENGINE LUBRICA TION & COOLING LUBRICATION SYSTEMS (L C) link. (LC) 40. On the CONTENTS page of the L LC C section, find the Engine Lubrication Circuit subsection and click on Lubrication Circuit.
Module 8
Notice that the lubrication circuit diagram indicates the direction of oil passage through the engine.
41. Is there a similar circuit diagram which indicates the direction of water though the engine? YES / NO (Circle one) 42. Where in the service manual can you find information regarding cooling fan operation? ________________________________________ Why? ________________________________________ ________________________________________ ________________________________________
You have now completed this module and should be able to identify the engine assembly based on the Engine Identification Code and locate the proper diagnosis/repair sections in the service manual to assure that the correct specifications and procedures are applied to the serviced vehicle. If you have any doubt about your skills in completing this module, please return to step #2 and review your work. Once you are confident of your skills, have your instructor verify your work and initial your module. Instructors Initials _____________________ Return the workstation to the condition in which it was found.
Module 8
NOTES
10
SR20DE VALVE ADJUSTMENT

Objective: Given a SR20DE engine and a Service Manual, correctly adjust the valves of the SR20DE Engine using special service tool No. J38957-N. Correctly checking and adjusting valve clearance on the SR20DE engine requires special tool No. J38957-N. This procedure synchronizes the two valves to the single rocker arm while maintaining proper contact between the rocker arm and cam lobe.
Relevance:
Resources: The following items are provided: SR20DE engine Special Tool J38957-N Service Manual Skill Check: Verify that you can perform the technique by correctly answering the questions, which demonstrate understanding of each step listed in the Service Manual. Your instructor will verify that the valves are properly adjusted and that all questions are correctly answered.
Module 9
SR20DE Valve Adjustment
1.
Valve adjustment is necessary following the replacement of what parts or service procedures? (Indicate in the space provided below): ________________________________________ ________________________________________ Note: Keep parts in order so that they can be installed in their original positions during assembly.
2.
Remove rocker arms, shims, guides, and both camshafts using the procedure described in the service manual EM section. Make sure the rocker arm guides are installed in their proper place (centered in the valve spring retainers). Install the special tool plate into the cylinder head over the No. 1 and No. 2 cylinders. Align the tool plate holes with the mating cam journal holes in the cylinder head and secure the plate with two furnished bolts. Center the tool plate and tighten the bolts securely.
3.
Module 9
Special Tool: J38957-N Valve Shim Gauge Plate Kit
4.
5.
6.
Working on the No. 1 cylinder intake valves, insert the dial indicator through the hole directly above the valve equipped with the rocker arm guide (see the illustration at the left).
7.
Move the dial indicator back and forth in the plate hole until it is centered directly over the rocker arm guide. Slowly move it around until there is no fluctuation in the dial indicator needle. The rocker arm guide will tip back and forth on the valve stem therefore the dial indicator must be correctly centered or the indicated reading will be incorrect. Record the dial reading and note the cylinder number and valve. Cylinder #: _______ Valve: _________
8.
Rocker Arm Guide Valve Spring Retainer
Measurement: ___________ 9. What is the most important operation when measuring the distance on the rocker arm guide? ________________________________________ ________________________________________ ________________________________________ 10. Withdraw the dial indicator and insert it into the adjacent hole for the intake valve of that cylinder. After removing the shim, align the pointer with the center of the valve stem. 11. Move the dial indicator back and forth in the plate hole until it is centered directly over the valve stem. Slowly move it around until there is no fluctuation in the dial indicator needle (see the illustration at left).
Module 9
Valve
12. Record the dial reading and note the cylinder number and valve. Cylinder #: ____ Valve: ____________ Measurement: ___________ 13. Select a shim that is equal to the difference between the two measurements. Subtract the measurement taken in step 8 (rocker arm guide) from the measurement taken in step 12 (valve stem). (see the illustration at left). This dimension (T1) will indicate the thickness required to synchronize the two valves to their single rocker arm. Step 12 Measurement ______ Step 8 Measurement - ______
T
Thickness required
Module 9
Shim
= ______
Indicates T= 2.800 (0.1102 in)
Notice in the illustration at the left that one side of the rocker arm is machined to accommocate the groove in one shim.
Rocker Arm
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.).
Shim Rocker Arm Guide
Available Shims Thickness mm (in.) Ident Mark 2.800 (0.1102) 2.825 (0.1112) 2.850 (0.1122) 2.875 (0.1132) 2.900 (0.1142) 2.925 (0.1152) 2.950 (0.1161) 2.975 (0.1171) 3.000 (0.1181) 28 00 28 25 28 50 29 75 29 00 29 25 29 50 29 75 30 00
Available Shims Thickness mm (in.) Ident. Mark 3.025 (0.1191) 3.050 (0.1201) 3.075 (0.1211) 3.100 (0.1220) 3.125 (0.1230) 3.150 (0.1240) 3.175 (0.1250) 3.200 (0.1260) 30 25 30 50 30 75 31 00 31 25 31 50 31 75 32 00
14. What would be the symptom if the shim height is 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 be able to correctly adjust the valves of the SR20DE engine using special service tool No. J38957-N. If you have any doubt about your skills in completing this worksheet, please return to step #1 and review your work. Once you are confident of your skills, have your instructor verify your work. Instructors I nitials Initials nitials_____________________ Return the workstation to the condition in which it was found.
Module 9
NOTES
HYDRAULIC VALVE LASH ADJUSTERS

Objective: Given an SR20DE engine and a service manual, properly bleed air from hydraulic valve lash adjusters. Understanding how to bleed valve lash adjusters is essential to proper engine overhaul.
Relevance:
Resources: The following items are provided: SR20DE Engine Service Manual Skill Check: Verify that you can properly bleed the adjusters following the instructions in the Service Manual and by correctly answering all questions in the module.
Module 10
Hydraulic Valve Lash Adjusters
1.
Welding Rod Engine Oil
Begin this module with the hydraulic valve adjuster removed from the cylinder head, a container of clean engine oil, and a piece of aluminum welding rod or other suitable tool of the appropriate diameter, with the end finished off so it will not damage the check valve ball. On which page in the service manual is the hydraulic valve lash adjuster bleeding procedure listed? ________________________________________
2.
3.
Follow the valve hydraulic lash adjuster bleeding procedure listed in the service manual as Illustrated. Be careful not to scratch or damage the check valve with the rod. Can you disassemble the hydraulic lash adjuster for service? YES / NO (Circle one)
4.
Module 10
5.
Can you bleed the air in the valve hydraulic lash adjuster high pressure chambers by running the engine? YES / NO (Circle one)
6.
Can the hydraulic valve lash adjuster plunger be compressed with your fingers once it has been properly bled? YES / NO (Circle one): If YES YES, what is the problem? ________________________________________ ________________________________________
7.
What is the proper procedure if the hydraulic lash adjuster cannot be bled properly? ________________________________________ ________________________________________
8.
What would the symptom be if the valve hydraulic lash adjuster has not been bled properly? ________________________________________ ________________________________________
9.
Review the objective of this module. If you are unclear about any aspect of the objective, request assistance from your instructor.
You have now completed this module. If you have any doubt about your skills in completing this module, please return to step #1 and review your work. Once you are confident of your skills, have your instructor verify your work. Instructors Initials____________________ nstructors Initials Return the workstation to the condition in which it was found.
Module 10
NOTES
QR25DE VALVE CLEARANCE INSPECTION AND ADJUSTMENT

Objective: Given a QR25DE engine, correctly perform the valve clearance inspection and adjustment. The procedure is new because shims are no longer used. Knowing this procedure will help you better service this engine in your dealership.
Relevance:
Resources: ESM Section EM Skill Check: Perform valve clearance inspection, identify proper valve lifter selection and identify proper camshaft removal and installation procedure.
Module 11
QR25DE Valve Clearance and Adjustment
1. Locate the valve clearance and adjustment procedure in the ESM. Print these pages to use for reference at the workstation. 2. When should the valve clearance be inspected? ________________________________________ ________________________________________ ________________________________________ ________________________________________ 3. What are the valve clearance specifications for the QR25DE engine? HO T HOT Intake
. ___________________. ___________________ ___________________ ___________________. .
Exhaust
COLD
Module 11
Intake
___________________ ___________________ ___________________. ___________________. .
Exhaust
4. Follow the service manual procedure and prepare the engine to check intake and exhaust clearance on cylinder #4. 5. Cylinder #4 must be at TDC of the _______________ stroke before checking valve clearance.
6. Measure and record intake valve clearance for cylinder #4 in the following chart. Circle the outcome of measurement below. MEASUREMENT (front) . OK (rear) . OK / NG / NG
7. Measure and record exhaust valve clearance for cylinder #4 in the following chart. Circle the outcome of measurement below. MEASUREMENT (front) . OK (rear) . OK / NG / NG
8. If a valve clearance is out of specification, what component must be replaced to correct the clearance? ________________________________________ 9. What component(s) must be removed in order to access this part? ________________________________________ 10. According to the service manual, what other valve clearances can be inspected at the same time with cylinder #4? ________________________________________ ________________________________________ ________________________________________
Module 11
11. According to the service manual, should the specs for a cold engine or hot engine be used for adjustment? COLD / HO T HOT (Circle One)
12. What is the equation for calculating the correct thickness for the replacement valve lifter? ________________________________________ ________________________________________ ________________________________________ NO TE: NOTE: Measurement accuracy of the valve clearance and removed lifter is critical since you cant confirm your results until the camshafts are installed!
IMPORT MPORTANT ANT: You will NOT be removing the camMPORT ANT shafts during this exercise. See your instructor for dimension t1 (thickness of the removed lifter). Record the dimensions t1 below.
Module 11
INTAKE Front Rear EXHAUST Front Rear . . . .
13. Using the equation from step #12 list the replacement valve lifter(s) needed to correct the valve clearance for the intake valves you identified as NG in step #6. REPLACEMENT LIFTER Thickness Front Rear ID Mark
. .
14. Using the equation from step #12 list the replacement valve lifter(s) needed to correct valve clearance for the exhaust valves identified as NG in #7. REPLACEMENT LIFTER Thickness Front Rear ID Mark
. .
15. What page in the service manual does the camshaft removal and installation instructions begin? ________________________________________ 16. According to the service manual cylinder #1 must be at ___ on its ____________________stroke prior to removing the camshafts. 17. When following the service manual procedure for camshaft removal, will the timing chain disengage from the crankshaft sprocket while the front cover is attached to the block? YES / NO (Circle one)
Module 11
18. Visually, how can you differentiate the intake camshaft from the exhaust camshaft when they are removed from the engine? ________________________________________ ________________________________________ ________________________________________ 19. When installing the camshafts, the intake camshaft dowel pin must be at _____ oclock and the exhaust camshaft dowel pin must be at ______ oclock. 20. The marks that identify the intake camshaft brackets are: NUMBERS / LETTERS (Circle One) 21. The marks that identify the exhaust camshaft brackets are: NUMBERS / LETTERS (Circle One)
Module 11
22. Locate the procedure for tightening the camshaft brackets. Read this procedure and explain why it is a 4-step torque/tightening sequence. ________________________________________ ________________________________________ ________________________________________ 23. According to the service manual, if the camshaft endplay is out of specification, what must be replaced first? ________________________________________
You have successfully completed this worksheet. You should now be able to inspect and adjust valve clearance on the QR25DE engine. If you have any doubts about the skills you have acquired, please return to Step 1 and review your work. When you are confident of your skills, contact your instructor and have him verify your work. Instructors Initials: ________________ Please return this workstation to the condition in which you found it.
Module 11
NOTES
ENGINE NOISE DIAGNOSIS

Objective: Given an engine noise audio tape/CD and this module, identify common engine noises and describe the most likely causes of each noise. Understanding and interpreting engine noises is an important part of engine diagnosis. This module will help you to understand the meaning of different engine noises.
Relevance:
Resources: The following items are provided: Engine Noise Diagnosis Audio Tape/CD
Skill Check: Your understanding of engine noises and how to identify them will be determined by successfully answering the questions in this module.
Module 12
Engine Noise Diagnosis
ENGINE NOISE DIAGNOSIS AUDIO TAPE/CD

This module includes an audio tape/CD. Following the instructions in the module, you will listen to the audio then work through the module. After you have completed all the activities in the module, have the instructor sign off the module and sign-off sheet. The tape, Engine Noise Diagnosis, is recorded on two sides. One side contains a collection of examples of common engine noises with a descriptive narration. The other side of the tape gives the same noises, without narration. You will be asked to identify the sounds on that side of the tape at the end of this module. The audio tape/CD is also a job aid. Keep it as a resource and listen to it when you are faced with an engine-noise repair. 1. Listen to the audio tape/CD now. Put a check mark by each noise as you listen to it: (Check one) Timing belt tension too tight Timing belt tension too loose
Module 12
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 the following noises by their description. Please mark the 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) Timing belt too tight Timing belt tension too loose Drive belt too tight Drive belt too loose 4. An intermittent shrieking noise at the front of the engine when the air conditioner compressor cycles on: (Check one) Timing belt too tight Timing belt slipping Drive belt too tight Drive belt slipping
Module 12
5.
A shrieking sound when the wheels are turned hard: (Check one) Timing belt too tight Timing belt tension too loose Drive belt too tight Drive belt tension too loose
6.
A knock at the crankshaft pulley, noticeable as the engine warms up: (Check one) Rod bearing Main bearing Piston pin Piston slap
7.
A knock at the side of the engine which is louder when the engine is cold: (Check one) Rod bearing Main bearing Piston pin
Module 12
Piston slap 8. A thumping noise at the side of the block which is louder when the engine is hot and diminishes when 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 which is louder when the engine is hot and doesnt go away when any cylinder is shorted out: (Check one) Rod bearing Main bearing Piston pin Piston slap
10. A clicking noise which originates near the cylinder head or rocker cover: (Check one) Hydraulic lifter Valve stem Piston pin Rod bearing 11. A squeaky-hissing sound which gets louder as the engine warms up: (Check one) Hydraulic lifter Valve stem Piston pin Rod bearing You have now finished this module. If you have any doubt about your skills in completing this module, please return to step #1 and review your work. Once you are confident of your skills, have your instructor verify your work. Instructors Initials ____________________ Return your workstation to the condition in which it was found.
Module 12
NOTES
VQ35DE TIMING CHAIN INSTALLATION

Objective: You will be able to perform timing chain installation on the VQ35DE engine. The timing chain installation procedure needs to be performed properly to avoid engine damage.
Relevance:
Resources: ESM Section EM ESM Job Aid Skill Check: Perform timing chain installation and ensure timing chain and sprockets are aligned correctly.
Module 13
VQ35DE Timing Chain Installation
1.
Locate and print the timing chain installation procedure in the ESM. Position the crankshaft where the ESM specifies. The crankshaft key should be at: Circle one: 9:00 10:00 11:00 12:00
2.
3.
Can you locate a mark to help with the alignment? ____________________________________
4.
Install the crankshaft sprocket. How can you tell if the sprocket is installed correctly? ____________________________________ ____________________________________ ____________________________________
5.
Make sure the dowel pin on the bank 1 exhaust cam is positioned as illustrated on the left. Position the Bank 2 camshafts in the position indicated in the diagram on the left. On the intake cam, what size hole must be facing up? LARGE / SMALL (Circle one) Follow the service manual procedure to install Bank 2 secondary chain and sprockets.
Module 13
6.
7.
8.
9.
Which marks on the exhaust cam sprocket must be lined up with the double gold links and which mark on the intake sprocket must line up with the single gold link? ROUND / OV AL OVAL (Circle one)
10. Tighten the camshaft sprocket mounting bolt by hand. 11. Remove the stopper pin from the secondary chain tensioner. 12. Install the primary chain by aligning the yellow links with the mating marks on the intake sprockets and the orange link with the mating mark on the crank. 13. Install the internal (upper) chain guide. 14. Install the primary chain tensioner. Service Tip: Check timing chain alignment and verify that the chain properly engages all sprockets and that the chain guides have been installed in the proper direction. This completes the timing chain installation for this workstation. Please notify your instructor for verification of your work. Instructor Signoff: .
Module 13
Please return the workstation to its original condition.
NOTES
VK45DE TIMING CHAIN REPLACEMENT
GITN 0028A GITN 0029A GITN 0030A GITN 0031A GITN 0032A GITN 0038A GITN 0039A GITN 0040A GITN 0041A GITN 0042A GITN 4003A GITN 0044A GITN 0005A Module
14
Objective Objective:
Given a VK45DE engine and Service Manual, you will demonstrate the skills necessary to properly remove and replace the timing chain on the VK45DE engine.
Relevance Relevance: Knowing how to properly remove and replace the timing chain on a VK45DE engine is essenial to properly and accurately service this engine. Resources Resources: The following are provided: VK45DE engine Service Manual Hand tools Puller (steering wheel)
Skill Check Check: Your instructor will check your understanding of this procedure by inspecting your work and verifying that all questions are answered correctly. In particular, proper cam timing will be checked.
GITN 0002A GITN 0003A GITN 0007A GITN 0008A VK45DE Timing Chain Replacement 1
14
1. 2.
Open the Service Manual to the timing chain section or refer to the copy provided. Set number 1 piston on TDC on its compression stroke. Do this by removing the cam position sensor. Rotate the crankshaft while looking through the sensor opening in the timing cover. When the group of 3 sensor marks just begin to pass the opening, stop. Then align the balancer (crank pulley) to the TDC timing mark. Remove the oil pan. Remove the crankshaft damper.
TDC
3. 4.
Balance Weight
Note: Do not remove the balance weights (left and right hexagon bolts) at the front of the crankshaft pulley. These are installed at the engine plant to dynamically balance the engine. 5. 6. Remove the left and right CVTC actuator covers from the timing cover. Remove the timing cover.
Note: There is an o-ring and filter screen assembly in the timing cover for bank 1 and bank 2 CVTC oil passages. The o-ring and screen can easily fall out of the passage during timing cover removal. Verify that they are in the proper locations after removing the timing cover and when reinstalling the timing cover. 7. Remove the oil pump assembly. You will need to use a puller or slide hammer to remove the oil pump drive as it is an interference fit on the crankshaft.
GITN 0002A GITN 0003A GITN 0007A GITN 0008A 2
VK45DE Timing Chain Replacement
8.
Remove left and right rocker covers. With the engine at TDC for cylinder number 1, the left bank camshafts should be in the position shown (see illustration at left).
GITN 0028A GITN 0029A GITN 0030A GITN 0031A
9.
Using a 24mm open-end wrench to hold each camshaft, break loose the sprocket retaining bolts.
GITN 0032A GITN 0038A GITN 0039A GITN 0040A GITN 0041A GITN 0042A GITN 4003A GITN 0044A GITN 0005A Module
14
10. Remove the left and right chain tensioners. 11. Remove the exhaust camshaft sprocket retaining bolts, then remove the exhaust sprockets. 12. Remove the intake camshaft sprockets, timing chains and crankshaft sprockets. 13. Are the timing chains the same for the left and right bank? YES / NO (circle one) 14. Are the exhaust camshaft sprockets interchangeable left to right? YES / NO (circle one) 15. Are the intake camshaft sprockets/CVTC actuators interchangeable left to right? YES / NO (circle one)
14
16. Why? _____________________________________ _____________________________________ _____________________________________ Instructor Sign Off ________________________
Note: The guides are marked to indicate left or right bank to insure correct installation. Timing Chain Installation Note: Completely install the right timing chain first, followed by the left. Right crankshaft timing gear marks cannot be seen when the left sprocket 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 be at the 12:00 position relative to the top of the cylinder head (see illustration at left).
19. Using a wrench to hold the intake camshaft in place, torque the intake sprocket bolt. Note: The intake camshaft sprocket/CVTC actuator can be installed in two different positions. Use the index slot that places the R at approximately the 12 oclock position in relation to the top of the cylinder head. 20. Install the timing chain around the crankshaft and intake camshaft sprockets.
GITN 0002A GITN 0003A GITN 0007A GITN 0008A 4
Note: The orange or blue link must line up with the crankshaft index mark and the yellow or gold links must line up with each camshaft index mark. Make sure the chain is properly routed around the timing chain oil jet.
Orange or Blue Links
14
21. Install the right bank exhaust camshaft sprocket. You may have to position the camshaft correctly to line up the index marks. Use the 24 mm. Open-end wrench to rotate the camshaft if required. Note: Hold the exhaust cam shaft firmly with the wrench when torquing the sprocket to isolate the timing chain from the torque applied to the bolt. 22. Compress the right bank tensioner and use a suitable pin to hold the piston in the retracted position. Note: The right bank tensioner has an oil hole at the top of the piston. Do not cover the hole while compressing the piston as oil needs to escape through the hole as you compress the piston. 23. Install the tensioner and release the pin. This will keep the right bank chain in the correct position during installation of the left bank. 24. Properly torque the right intake and exhaust sprocket bolts then recheck timing mark alignment. 25. Install the left bank crankshaft sprocket and intake camshaft sprocket/CVTC actuator. Use a wrench to hold the camshaft while torquing the bolt.
GITN 0002A GITN 0003A GITN 0007A GITN 0008A
14
Note: The left bank intake sprocket/CVTC actuator must be installed with the letter L in the 12 oclock position with respect to the top of the cylinder head. Make sure the chain guide is in its proper position when installing the intake sprocket. If it is out of position, the sprocket or guide must be removed to install in the correct position.
26. Install the left bank timing chain. The orange or blue link must line up with the index mark on the crankshaft, and the yellow or gold link with the index mark on the intake camshaft sprocket. Note: Make sure the chain is properly routed around the timing chain oil jet. 27. Install the left bank exhaust camshaft sprocket using the left bank index mark. If necessary, use the 24mm. open-ended wrench to rotate the camshaft(s) for proper alignment. 28. Compress the left bank chain tensioner and use a suitable pin to hold the piston in the retracted position.
Orange and Blue Links
29. Install the tensioner on the engine and remove the pin. GITN 0007A GITN 0008A 6 30. Properly torque the left intake and exhaust sprocket bolts then recheck timing mark alignment.
31. Are all the index marks and timing chain colored links in proper position? YES / NO (circle one) If No, repeat the installation procedure to correct the problem.
14
Instructor Sign Off: _______________________
32. Rotate the engine two to three times. 33. Reinstall the other components as directed by your instructor. 34. If you had difficulty performing the Skill Check stated at the beginning of this module, ask your instructor for assistance. 35. When you have completed the Skill Check to your satisfaction, see your instructor for verification of your work.
Instructors Initials ________________________ Return the workstation to the condition in which it was found.
NO TES NOTES
VQ35DE WATER PUMP REMOVAL AND INSTALLATION

Objective: At the end of this work session you will be able to remove and install the water pump for the VQ35DE engine to assure the proper circulation of coolant to the engine. Understanding how to properly remove and replace the water pump in a VQ35DE engine is essential to properly and accurately service this engine. The following items are provided: VQ35DE engine on stand Applicable Service Manual Basic tools
Relevance:
Resources:
Skill Check: The instructor will check your understanding of this procedure by inspecting your work and verifying that all questions are answered correctly.
Module 15
VQ35DE Water Pump Removal and Installation
1.
The water pump for the new VQ engine is chain driven (from the outer side of the timing chain) rather than belt driven to simplify the auxiliary equipment drive system and to shorten the overall length of the engine. The water pump is small and built into the (rear) timing case subassembly of the engine.
2.
Module 15
3.
Water pump removal is complicated due to the restricted space between the engine and the body side member of the vehicle. To facilitate the servicing of the water pump: The side member is slightly modified to make water pump removal easier. Two special covers have been installed in the timing chain case for easier access to the pump and chain tensioner.
Module 15
4.
Locate water drains on engine block.
5.
When you perform this service on a vehicle, be sure to drain the coolant to below the level of the water pump, or coolant will enter the engine crankcase. Drain the water from the radiator by opening the radiator drain cock. Do not forget to drain the coolant through the drain opening at the location where the alternator would attach to the timing chain case.
6.
Confirm that the # 1 cylinder is positioned at T.D.C. on its compression stroke.
TIMING CHAIN TENSIONER REMOVAL 7. See Service Manual first. Remove the cover installed in the timing chain case to allow access to the timing chain tensioner. (Do not remove water pump at this time).
Module 15
8.
Use caution when removing the cover from the timing case. The case is made of aluminum and can easily be damaged. Remove any sealing material from the tensioner cover and the outside of the timing chain case.
9.
10. The timing chain must be relaxed to disengage the water pump. The timing chain tensioner must be removed to allow slack in the timing chain. 11. The space between the engine front cover and the side member is restricted making it difficult to see the two bolts which secure the chain tensioner to the (rear) chain case subassembly. Therefore, the tensioner removal procedure must be performed by feel. Take care not to drop the bolts into the case. Note: Failure to follow this procedure may result in the internal parts of the tensioner (sleeve, spring bar, etc.) to be forced out by the reaction of the built-in spring and drop into the case.
PUSH
12. Retract the tensioner plunger by pulling the lever down to release the plunger stop tab. Note:
Hole
Insert a stopper pin (2.5 mm or 0.98 in. Allen wrench) into the tensioner body hole to hold the lever while retracting the plunger.
13. While holding the slack guide by hand, as illustrated, remove the tensioner. Instructors Initials ____________________
Module 15
WATER PUMP REMOVAL Note: See Service Manual prior to water pump removal. 14. To disengage the water pump from the chain, rotate the crankshaft approximately 20 degrees (2nd timing mark on crank pulley) counterclockwise. This will relax the timing chain tension. 15. Remove the water pump access cover, installed in the timing chain case. Be careful when removing the cover to the timing chain case. The case is made of aluminum and can be easily damaged.
Module 15
16. Remove any sealing material from the water pump cover and the outside of the timing chain case.
17. Water pump input pressure is high. This high pressure prevents easy removal of the water pump. To overcome this problem, perform the following procedure to remove the water pump. 18. Remove the three M8 bolts from the water pump flange. 19. Two of the holes on the water pump flange are tapped holes. Install two M8 bolts in the two M8 tapped holes on the water pump flange and tighten them until they contact the counter bores on the timing case. 20. Alternately turn the two M8 bolts one-half rotation each time to drive the water pump out.
Module 15
Note:
Failure to follow this procedure may result in damage to the pump or timing chain.
21. As a result of the restricted space between the engine and the body side member, there is a definite water pump removal and installation direction.
22. Failure to follow the directional procedure for removal and installation may result in damage to the water pump. 23. When the O-ring surface and the water pump are free to move by hand, pull the O-ring section straight out. Remove the water pump from the timing chain case. Be careful not to bump the O-ring sealing surface or the micro finished section of the timing chain case during removal. 24. Move the water pump in the direction indicated by the letter A (in the illustration at the left) until it touches the side member. 25. Lift the water pump in the direction indicated by the letter B in the illustration. Instructors Initials ____________________ 26. Before reinstalling the water pump into the timing case, ensure that the mating surfaces for the O-rings are clean, free of scratches and lubricated. A 27. Reinstall the water pump in the reverse order of removal. Be sure to follow the procedure outlined above regarding the direction of removal and installation of the pump. Torque all bolts to Service Manual specifications.
Module 15
O-rings Vane
28. After the water pump is installed and the timing chain has been positioned on the pump, rotate the crankshaft back 20 degrees in a clockwise direction to move the chain slack back to the timing chain tensioner.
Mechanical Seal Mechanical Seal
29. Pull the slack guide back to permit reinstallation of the chain tensioner. Reinstall the tensioner. Torque all bolts to Service Manual specifications. 30. Remove the stopper pin from the tensioner body so that the tensioner may contact the slack guide.
Module 15
31. When performing this operation on a vehicle: Be certain that the sealant is properly applied to the tensioner and water pump covers of the timing chain case, it must completely cover the mating surfaces. Be sure to apply the coat of sealant to the shaded areas illustrated below and tighten the bolts to Service Manual specifications.
Module 15
10
32. If performing this procedure on a vehicle, after installing the tensioner, run the engine at about 3000 rpm under no load to purge air from the high pressure chamber. 33. Lubricating oil will not reach the tensioner immediately following installation. A rattling noise will be heard for approximately 10 seconds of tensioner operation. This indicates that air still remains in the chamber. This is normal and will not affect the other areas of operation. You have now completed this module. If you have any doubt about your skills in completing this module, please return to step #1 and review your work. Once you are confident of your skills, have your instructor verify your work. Instructors Initials ____________________ Return the workstation to the condition in which it was found.
Module 15
11
NOTES
12
CYLINDER HEAD TORQUING

Objective: Given a training engine, a torque wrench , torque angle meter and a Service Manual you will demonstrate the skills necessary to properly measure head bolts to determine whether they can be reused, and properly torque the cylinder head bolts to specifications. Any time you remove and reinstall a cylinder head or retorque cylinder head bolts it is essential to determine whether the existing head bolts can be reused or must be replaced. Also, correct bolt torquing is essential to maintain cylinder head pressure and prevent damage to the head gasket.
Relevance:
Resources: The following items are provided: Engine Torque Wrench Torque Angle Meter Service Manual
Skill Check: The instructor will check your understanding of these skills by verifying the accuracy of your work and checking that all questions are answered correctly. Also, your understanding of plastic zone bolts and using the torque angle meter will be checked.
Module 16
Cylinder Head Torquing
Note: Depending upon the engine, plastic zone bolts are measured either for length or diameter to determine if they can be reused. Verify the procedure using the applicable Service Manual. 1. On what page in the Service Manual can you find the instructions for cylinder head bolt measuring? ________________________________ 2. 3. Remove one half of the cylinder head bolts. According to the Service Manual, can these bolts be reused? ________________________________ Note: The cylinder head does not need to be removed during this workshop exercise. The objective is for you to perform the correct torquing procedure. 5. On what page in the Service Manual is the sequence for tightening cylinder head bolts located? ________________________________ 6. Apply a light coat of oil to the threads and seating surfaces of the cylinder head bolt before installing.
Module 16
7.
Follow the Service Manual procedure to tighten the cylinder head bolts. Torque the bolts as indicated. Loosen the bolts, then torque to specification.
8. 9.
10. Use the torque angle gauge and turn the bolts to the specified amount. This tightens the bolt to the proper torque and keeps the bolt from stretching beyond specification. Note: Cylinder head bolts must be tightened using a multi-step process. A torque wrench AND torque angle meter must be used. A torque wrench alone will NOT tighten the bolts to the required specification!
You have now finished this module. If you have any doubt about your skills in completing this module, please return to step #1 and review your work. Once you are confident of your skills, have your instructor verify your work. Instructors Initials _____________________ Return the workstation to the condition in which it was found.
Module 16
NOTES
QG18DE VALVE ADJUSTMENT
Objective:
Use Special tools, feeler gauges and a Service Manual to properly measure valve clearance, determine correct specifications and adjust valve clearance on a QG18DE engine. The QG18DE engine has a unique valve train configuration. Knowing how to properly inspect, adjust and service the valve train is critical to timely and accurate repair.
Relevance:
Resources: The following items are provided: QG18DE Engine Service Manual Feeler Gauge Special Tool J-38972-1 Special Tool J-38972-2
Skill Check: The instructor will check your understanding of these skills by verifying the accuracy of your work and checking that all questions are answered correctly.
Module 17
QG18DE Valve Adjustment
1.
What is the clearance specification for INTAKE valves on the QG18DE engine? ________________________________________
2.
What is the clearance specification for EXHAUST valves on the QG18DE engine? ________________________________________
3.
Should the measurement be taken with the cylinder head Hot or Cold? ________________________________________
4.
Record INTAKE valve clearance measurements in the following chart for the cylinder you are assigned to work on.
MEASUREMENT
O.K.
N.G.
5.
Record EXHAUST valve clearance measurements in the following chart for the cylinder you are assigned to work on.
MEASUREMENT
O.K.
N.G.
Module 17
6.
If any clearances are out of specification, adjust them according to the procedure found in the Service Manual. Recheck the valve clearances. What is the maintenance service interval for checking and adjusting valve clearance? _________________________________________
TOOL (A)
TOOL (B)
7. 8.
9.
What other service conditions may require a valve adjustment? _________________________________________ _________________________________________
You have now completed this module. If you have any doubt about your skills in completing this module, please return to step #1 and review your work. Once you are confident of your skills, have your instructor verify your work.
Lifter Plate (Shim) Thickness Available at intervals of 0.02 mm (0.0008 im) thickness
Instructors Initials _________________________ Return the workstation to the condition in which it was found.
Module 17
NOTES
QR25DE TIMING CHAIN AND BALANCER UNIT

Objective: You will be able to remove and install the timing chain on the QR25DE engine. The QR25DE engine is new and uses a narrow-pitch, silent-type timing chain, hydraulic tensioners and a compact balancer. This worksheet will help you become familiar with this procedure so you can better service this engine in your dealership. Resources: ESM Section EM ESM Job Aid QR25DE engine on stand Skill Check: Correctly perform the timingchain removal and installation procedure (includes balancer unit), per ESM procedures.
Relevance:
Module 18
QR25DE Timing Chain and Balancer Unit
1.
Locate the timing chain removal and installation procedures in the ESM, Section EM. Print these pages for reference at the workstation. Following the ESM, prepare the engine for timing chain removal by setting the #1 cylinder at TDC on the compression stroke. The crankshaft pulley and camshaft sprockets should look like the illustrations on the left. Continue with the ESM procedure to remove the front cover, timing chain, tensioner and camshaft sprockets. Note the CAUTION in the ESM. Is this a freewheeling engine? YES / NO (Circle one) Continue with the ESM procedure to remove the timing chain for the balancer unit. What key service point should be observed here? ________________________________________ ________________________________________ ________________________________________
2.
3.
4.
5.
6.
At this point, both timing chains, the tensioners, the camshaft sprockets and the crankshaft sprocket should be removed.
Note T remove the balancer unit. Note: DO NO NOT 7. According to the ESM, can the balancer unit be disassembled for service? YES / NO (Circle one)
Module 18
The balancer unit has been disassembled in the photo at the left for reference only. Note that the unit has two counter-rotating shafts that must be in time with each other and with the camshaft. 8. Rotate the balancer unit drive sprockets by hand. What do you notice as you rotate the balancer unit? ________________________________________ ________________________________________ ________________________________________ 9. When removing/installing the balancer unit, can the mounting bolts be reused? YES / NO / IT DEPENDS (Circle one) Explain: ________________________________________ ________________________________________ ________________________________________ 10. What customer concerns could be caused by the balancer unit? ________________________________________ ________________________________________ ________________________________________
Module 18
11. Follow the ESM procedure to install the balancer unit, timing chain, crankshaft sprocket and tensioner assembly. Which direction should the crankshaft key point? (Circle one) 12:00 / 3:00 / 6:00 / 9:00 Note: There may be two link colors on the timing chain. There are 26 links between the gold/ yellow mating marks on the timing chain. There are 64 links between the camshaft sprocket gold/yellow link and the crankshaft sprocket orange/blue link on the timing chain side without the tensioner. 12. When referencing this engine, what color timing chain link must be lined up with the mating mark on the crankshaft sprocket? ________________________________________
13. In relation to crankshaft speed, at what speed do the balancer unit shafts rotate? (Check one) 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 rotate at this speed? ________________________________________ ________________________________________ ________________________________________
Module 18
14. Continue with the ESM procedure to install the camshaft sprockets, timing chain and tensioner. 15. According to the ESM, is it safe to turn the crankshaft after installing the timing chain but before installing the front cover? YES / NO (Circle one) Why or why not? ________________________________________
Crankshaft sprocket chain guides Oil jet
________________________________________ 16. Before installing the front cover, locate the timing chain oil jet, CVTC solenoid oil screen and crank sprocket chain guides in the front cover assembly. (Refer to the photos at the left.) The oil jet or CVTC oil screen may become clogged. Additionally, the CVTC oil screen may fall out during service.
PTN182
CVTC oil screen

PTN183
Module 18
Service Tip Tip: Refer to the illustration at the left for specified areas to install RTV silicone sealant on the front cover sealing surface. Notice the sealant applied to position A, which is a bolt hole through the center of the cover. 17. Locate the CVTC oil passage on the illustration to the left, and circle the location. 18. How many O-rings are used with the front cover? ________________________________________ Where are the O-rings located? ________________________________________ ________________________________________ ________________________________________ STOP . See instructor prior to installing the OP. front cover and upper oil pan.
You have successfully completed this worksheet. You should now be able to remove and install the timing chain on the QR25DE engine and properly time the engine. If you have any doubts about the skills you have acquired, please return to Step 1 and review your work. When you are confident of your skills, have your instructor verify your work. Instructors Initials: ________________ Please return this workstation to the condition in which you found it.
Module 18
S E C T I O N 3
N O T E S
NOTES
NOTES
ii
NOTES
iii
NOTES
iv
NOTES
NOTES
vi

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ENGINE MECHANICAL SERVICE

This manual uses post consumer recycled fibers

ENGINE MECHANICAL SERVICE COURSE OBJECTIVES

TABLE OF CONTENTS INTRODUCTION ....................................................................................................................3 ENGINE THEORY ..................................................................................................................3

ENGINE MECHANICAL SERVICE

Feeler Gauge Ring

Camshaft Plate mm (in) 0.02 (0.0008) 0.03

Engine Rear side

Identification Mark C No Identification Mark

ONT ENGINE MOUNTING CENTER MEMBER

Oil Pressure Intake Camshaft

Drain Drain Piston

Intake Valve Retension (no oil flow) Retard Angle

Intake Valve Timing Control Unit (Intake Cam Sprocket)

Intake Timing Sensor Bank #1 Rear Timing Chain Case

Intake Timing Sensor Bank #2

Front Timing Chain Case

CONSULT-II Reference Value in Data Monitor Mode

INT/V SOL (B1) INT/V SOL (B2)

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

ENGINE MECHANICAL SERVICE SIGN-OFF SHEET

ENGINE FUNDAMENTALS VIDEO

Engine Fundamentals Video

Describe the main purpose of the crankshaft. ________________________________________ ________________________________________ ________________________________________

List three piston rings facts. ________________________________________ ________________________________________ ________________________________________

Engine Fundamentals Video

Engine Fundamentals Video

Engine Fundamentals Video

Under which driving conditions is valve timing activated? ________________________________ ________________________________

Connect CONSULT-II to the the DLC.

SUB MODE LIGHT COPY

SELECT SYSTEM ENGINE A/T AIR BAG ABS SMART ENTRANCE

TA MONIT 13. Touch DA DAT MONITOR OR to select the diagnostic mode.

Scroll Down BACK LIGHT COPY

Page Up SETTING MODE

16. Touch SETTING to set up the snapshot parameters that follow.

SET RECORDING CONDITION

AUTO TRIG MANU TRIG

MODE B A C K LIGHT COPY

RECORD MODE BACK LIGHT S T A R T

Attach Printout Here

19. Touch COPY and attach printout at left.

Attach Printout Here

Intake Timing Sensors

A fixed reading indicates that the system is not functioning properly.

SELF-DIAG RESULTS DTC RESULTS

F.F. DATA ERASE MODE BACK PRINT LIGHT COPY

Scroll Down BACK LIGHT COPY

ELECTRONICALLY-CONTROLLED ENGINE MOUNTS

Electronically-Controlled Engine Mounts

RIGHT ENGINE MOUNTING

Electronically-Controlled Engine Mounts

Electronically-Controlled Engine Mounts

Electronically-Controlled Engine Mounts

33. Touch GRAPH GRAPH. 34. Touch COPY COPY.

Attach Printout Here

Electronically-Controlled Engine Mounts

Electronically-Controlled Engine Mounts

POWER BALANCE TEST USING CONSULT-II

Power Balance Test Using CONSULT-II

ACTIVE TEST POWER BALANCE MONITOR CMPS-RPM(REF) 900rpm 1.66V 25%

MAS AIR/FL SE IACV-ACC/V

Describe the main purpose of the crankshaft.

List three piston rings facts.

Under which driving conditions is valve timing activated?

Pressure

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_________ _ _. _________. .