RE-Assembly of Timing Chain

1. A. Re-install timing chain utilizing scribe marks at the cam and crankshaft sprockets. Confirm that #1 piston is at TDC. The keyways for camshaft and crankshaft sprockets must be aligned vertically.
B. Torque cam sprocket bolt to 113-157 N-m; 87-116 ft.lbs. To prevent camshaft sprocket from moving, hold with Nissan Special Tool # J34312.
C. Re-install crankshaft oil splash plate.

2. Re-install countermeasure timing chain guide. Torque fastener/pivot bolt to 13-19 N-m; 9.4-13.7 ft.lbs.

FIGURE 13:

3. Re-install countermeasure timing chain tensioner. The tensioner must be installed in a pre-loaded position! To do this, pivot the tensioner CLOCKWISE as far as possible (Figure 13). Torque bolts to 7-8 N-m; 5-5.8 ft.lbs.
4. Clean engine block/timing chain cover mating surfaces. Be very careful not to damage CYLINDER HEAD GASKET.

FIGURE 14:

5. Replace the 2 timing chain cover oil seals (P/N's 15066-40F01 and 15066-40F11). Replace crankshaft oil seal at timing chain cover.

NOTE: Coat timing chain cover oil seals and crankshaft oil seal with lithium grease prior to installation. In addition, the 2 timing chain cover oil seals should be installed on the engine block first, not on timing cover (Figure 14).

FIGURE 15:

6. Apply Nissan Genuine Liquid Gasket, P/N 999MP-A7007, or equivalent, to timing chain cover (Figure 15).
CAUTION: Be careful not to apply too much Liquid Gasket. Otherwise, the small vent holes on the top of the timing chain tensioner may become clogged and the unit will lose pressure.
7. Re-attach timing chain cover. Make sure that locating dowels and timing chain cover oil seals (2) are properly aligned and seated. Torque bolts to 16-21 N-m; 12-15 ft.lbs.
A. Re-attach crankcase oil vent housing. Clean mounting surfaces. Apply Liquid Gasket sparingly and re-tighten bolts.
B. Re-attach coolant by-pass (U-shaped) hose.

FIGURE 16A:

FIGURE 16B:

8. If necessary, install new rubber plug. First, clean area, then coat the plug with Liquid Gasket. Re-install rocker cover. If appropriate, use a new gasket. Be careful to avoid interference between the rocker cover and rocker arms.
A. Temporarily tighten bolts 1 and 2 to 3 N-m; 2.2 ft.lbs. (Figure 16A).
B. Tighten all bolts to 7-10 N-m; 5.1 to 7.2 ft.lbs. in the sequence shown (Figure 16B).
9. Raise vehicle.

10. Re-install oil pump, using a new gasket, P/N 15066-21001.
NOTE: All previously scribed lines must match.
A. Re-install distributor. Lube rubber O-ring with lithium grease before installation. Re-check that #1 piston is at TDC.
11. Re-install the oil pan:
A. Re-install all transmission cover plates and mounting hardware.
B. Before installing oil pan, remove all traces of Liquid Gasket from mating surfaces at the engine block and oil pan.
C. Apply a 3.5 - 4.5 mm bead of Nissan Genuine Liquid Gasket or equivalent, to the mating surface of the oil pan. The sealer must be spread evenly.

FIGURE 17:

D. Re-install oil pan. Tighten bolts 7-8 N-m; 5.1-5.8 ft.lbs. according to the pattern shown above (Figure 17).
CAUTION: Wait at least 30 minutes before refilling engine oil.
12. Tighten the 4 front cross-member fasteners to 88-108 N-m; 65-80 ft.lbs.

13. Carefully lower transmission jack; Re-attach fasteners for right/left engine mounts. Torque to 69-78 N-m; 51-58 ft.lbs.

14. Re-attach sway bar and associated mounting hardware.

15. Re-attach molded plastic lower engine shield, then lower vehicle.

16. Re-attach: Crankshaft pulley. Torque to 18-157 N-m; 87-116 ft.lbs. To prevent crankshaft from moving, using Nissan Special Tool J25377:
^ Compressor idler pulley (torque to 27-35 N-m; 20-26 ft.lbs.)
^ Power steering pump bracket. ^ Power steering pump.
^ Top idler pulley and bracket. ^ Alternator bracket.
^ Cooling fan (torque attachment bolts to 6-10 N-m; 4.3-7.2 ft.lbs).

FIGURE 18:

17. Re-assemble and adjust: alternator; A/C compressor; and power steering drive belts. It is essential to properly align the "poly-groove belt" on the pulley (Figure 18).
18. Re-install radiator: NOTE: Make sure drain petcock is closed.
A. Re-install A/T hoses (if so equipped)
B. Re-connect lower radiator hose, smaller-diameter cooling hose (behind lower radiator cooling hose) and thermo-switch electrical connection.
C. Re-attach radiator mounting supports. Torque bolts to 3.1-4.2 N-m; 2.4-3.1 ft.lbs.
D. Re-attach radiator shroud: The lower portion will snap-fit into the top radiator shroud. This assembly is secured to the radiator by 4 cap screws. Torque these to 3.2-4.2 N-m; 2.4-3.1 ft.lbs.
E. Re-connect top radiator hose and reservoir hose.

19. Re-attach evaporative emission hoses and ECCS wire harness to radiator shroud mounting clips; Re-connect inlet duct.
NOTE: If additional re-assembly details are required, refer to this Bulletin, "Disassembly of Timing Chain," Steps 8-14.

20. Re-connect (-) battery cable.

21. Replace oil filter. Refill engine oil.

22. Re-fill coolant reservoir. (See 1989 240 SX Service Manual, Section MA-9, for complete refill procedure).

23. Check and Adjust ignition timing.

24. Re-program radio pre-set stations and reset clock.


WARRANTY INFORMATION:

PNC CS CT OPERATION NO. FLAT RATE
P9010 9Y 99 P90100 5.0 hrs.