Procedure E - Install Exhaust Heat Shield Kit

Procedure E - Install Exhaust Heat Shield Kit:

(For PNC codes R3007, R3014, and R3016 ONLY)

NOTE:
Vehicles with PNC code R3015 or R3017 DO NOT need a heat shield kit installed. This includes some 2003 vehicles and all 2004 vehicles. Refer to Service Comm for the vehicle-specific PNC code.











There are four (4) Heat Shield Kits available in this campaign. Please select the correct one from the chart shown.

Preliminary Steps:

1. Record all radio station presets.

2. Make sure the ignition key is in the OFF position.

3. Disconnect the negative battery cable.

Remove Alternator:





4. This Step For Altima ONLY: Reposition (lift up about an inch) the Relay Box to allow enough clearance for removing the Lower Alternator Mounting Bolt. See Figure E5.

^ Remove one nut at the lower front of the Relay Box (see Figure E5).

^ Use a flat-blade screwdriver to release the Clip on the side (facing the Alternator) of the Relay Box (see Figure E5).

NOTE:
You can also re-position the relay box by removing the lower front nut and sliding the relay box forward.

5. This Step For Sentra ONLY:

^ Remove both upper radiator mounting brackets.

^ Remove the passenger-side front inner fender well in order to remove the alternator.

6. Remove the top Plastic Engine Cover (as applicable).





7. Remove all wire harness connections from the Alternator (see Figure E6).

8. Remove the Alternator Belt (see Figure E6).

9. Remove the Alternator Mounting Bolts (see Figure E6).





IMPORTANT:
Prevent the belt tensioner from loosing its tension by inserting a screwdriver (or other suitable device) through the tensioner mounting hole (see Figure E7).

10. Remove the Alternator from the vehicle.

Disconnect Oxygen Sensor Wire Harness:





11. Disconnect the Oxygen Sensor Wire Harness Connector (see Figure E8).

12. Remove the Oxygen Sensor Wire Harness from the Upper Front Exhaust Manifold/Catalyst Heat Shield Clips.

Remove Upper Front Exhaust Manifold/Catalyst Heat Shield:

IMPORTANT:
If you break off a heat shield screw(s) in an Exhaust Manifold/Catalyst that is supposed to be re-used on the vehicle, perform Procedure G - Install Keen-Sert(s) As Needed.

13. Remove Upper Front Exhaust Manifold/Catalyst Heat Shield:





^ Carefully remove four screws that secure the Heat Shield (see Figure E9).

^ IMPORTANT:
Use "penetrating" oil. Loosen screws 1A turn with hand-tool (do not use power tool) and apply penetrating oil before removing screws completely.

^ Remove the Heat Shield

Remove Front Exhaust Pipe:

NOTE:
You may have already removed the Front Exhaust Pipe in Procedure D. If so, proceed with step 17.





14. Remove the two nuts that secure the Front Exhaust Pipe to the Exhaust Manifold/Catalyst (see Figure E10).

Discard the old gasket as you'll be installing a new one later.

NOTE:
The stud(s) may come out of the Catalyst when removing the nut - this is okay. Just re-install them later.

NOTE:
Steps 15, 16, and 18 through 26 are for Altima ONLY.





15. This Step For Altima ONLY: Remove the two nuts that secure the Front Exhaust Pipe to the Muffler (see Figure E11). Then, separate the Front Exhaust Pipe from the Muffler. Save the gasket as you'll need to re-use it later.

IMPORTANT:
Use "penetrating" oil. Loosen screws 1/2 turn with hand-tool (do not use power tool) and apply penetrating oil before removing screws completely.





16. This Step For Altima ONLY: Slide the Front Exhaust Pipe Hanger Pin out of the Front Exhaust Pipe Hanger (see Figure E12). Remove the Exhaust Pipe from the vehicle.

Loosen/Remove Exhaust Manifold/Catalyst Support Bracket Bolts (Altima & Sentra):





17. Loosen the bolt that secures the bracket to the engine block, and remove the bolt that secures the bracket to the Exhaust Manifold/Catalyst (see Figure E13).

Remove Front Exhaust Pipe Hanger (Altima ONLY):





18. Remove two bolts and remove the Front Exhaust Pipe Hanger (see Figure E14).

Install New Hanger Support Bracket (Altima ONLY):

19. Install the new Hanger Support Bracket along with the old Front Exhaust Hanger (see Figure E15).

Remove Mass Damper Nut (Altima ONLY):





20. Remove the the Mass Damper Nut as shown in Figure E16.

NOTE:
Some vehicles may NOT be equipped with a Mass Damper.

Install New Rubber Pad Insulator (Altima ONLY):





21. Guide the new Rubber Pad Insulator UP between the Passenger Side Axle Shaft and the Engine Mount (see Figure E17).

22. Then, hook the upper portion of the Rubber Pad Insulator onto the Engine Mount (see Detail View A in Figure E17).





23. Securely press the Rubber Pad Insulator into the holes of the Engine Mount (see Figure E18).

Install New Rear-Side Crossmember Heat Shield (Altima ONLY):





24. Remove the two main Steering Rack and Pinion mounting bolts (see Figure E19).

25. Install the new Rear-Side Crossmember Heat Shield using the Rack and Pinion bolts (see Figure E19).

2002 Altima: Torque bolts to: 136 - 164 N-m (13.8-16.8Kg-m, 100-121 ft-lb).

2003 Altima: Torque bolts to: 110 - 140 N-m (12 - 14 Kg-m, 82 - 103 ft-lb).

Install New Front-Side Crossmember Heat Shield (Altima ONLY):





26. Install the new Front-Side Crossmember Heat Shield to the Mass Damper and to the newly installed Hanger Support Bracket with two nuts (P/N 08918-3401A-KT). See Figure E20.

NOTE:
Some Altima vehicles may NOT be equipped with a Mass Damper. If this is the case, add the new Spacer (supplied in the kit) between the heat shield and the crossmember mount (see Figure E20).

Remove Exhaust Manifold/Catalyst:





27. Remove five nuts that secure the Exhaust Manifold/Catalyst to the cylinder head (see Figure E21).

IMPORTANT:
Use "penetrating" oil. Loosen screws 1/2 turn with hand-tool (do not use power tool) and apply penetrating oil before removing screws completely.

28. Remove the Exhaust Manifold/Catalyst from the vehicle and place it on your work bench.

Install New Heat Shield on Old Exhaust Manifold/Catalyst:

NOTE:
For installing a new Heat Shield on a new Exhaust Manifold/Catalyst.

IMPORTANT:

^ Use suitable hand protection when handling the Exhaust Manifold/Catalyst heat shields.

^ Be careful NOT to damage the Oxygen sensors when performing this procedure.





29. Remove three screws and remove the old Upper Rear Heat Shield from the manifold (see Figure E22).

^ IMPORTANT:
Use "penetrating" oil. Loosen screws 1/2 turn with hand-tool (do not use power tool) and apply penetrating oil before removing screws completely.

^ Confirm there is no damage to the threads inside the mounting bosses.

^ If you break off a heat shield screw(s) in an Exhaust Manifold/Catalyst that is supposed to be re-used on the vehicle, perform Procedure G - Install "Keen-Sert(s)" As Needed.





30. Install the new Rear Heat Shield onto the old Exhaust Manifold/Catalyst with four new screws (see Figure E23a).

31. Turn the manifold over (see Figure E23b).

32. Remove the three screws that secure the old Front Lower Heat Shield onto the manifold. Leave the heat shield in position, as it does not get replaced.

^ IMPORTANT:
Use "penetrating" oil. Loosen screws 1/2 turn with hand-tool (do not use power tool) and apply penetrating oil before removing screws completely.

^ Confirm there is no damage to the threads inside the mounting bosses.

^ If you break off a heat shield screw(s) in an Exhaust Manifold/Catalyst that is supposed to be re-used on the vehicle, perform Procedure G - Install "Keen- Sert(s)" As Needed. See page 33 of this bulletin.

33. Install the new Heat Shield Support Bracket using six new screws (see Figure E23b).

NOTE:
For Sentra: Remove the lower Oxygen Sensor at this time. This will provide additional clearance needed when installing the Manifold/Catalyst in the vehicle (covered later in this procedure).

Install New Heat Shield on New Exhaust Manifold/Catalyst:

IMPORTANT:

^ Use suitable hand protection when handling the Exhaust Manifold/Catalyst heat shields.

^ Be careful NOT to damage the Oxygen sensors when performing this procedure.





34. Remove three screws and remove the old Lower Front Heat Shield from the old manifold (see Figure E24).

^ IMPORTANT:
Use "penetrating" oil. Loosen screws 1/2 turn with hand-tool (do not use power tool) and apply penetrating oil before removing screws completely.

^ Confirm there is no damage to the threads inside the mounting bosses.

^ If you break off a heat shield screw(s) in an Exhaust Manifold/Catalyst that is supposed to be re-used on the vehicle, perform Procedure G - Install "Keen-Sert(s)" As Needed.

35. Remove the old Oxygen Sensors from the old manifold (see Figure E24).





36. Install the new Rear Heat Shield onto the new Exhaust Manifold/Catalyst with four new screws (see Figure E25a).

37. Turn the manifold over (see Figure E25b).

38. Position the old Front Lower Heat Shield onto the manifold, but do not install any screws yet (see Figure E25b).

39. Install the new Heat Shield Support Bracket using six new screws (see Figure E25b).

NOTE:
Sentra ONLY: With regard to step 40, do NOT re-install the lower Oxygen Sensor at this time. This will provide additional clearance needed when installing the Manifold/Catalyst in the vehicle (covered later in this procedure).

40. Re-install both Oxygen Sensors.

Install Exhaust Manifold/Catalyst to Cylinder Head:





41. This Step For Sentra ONLY: Remove two nuts and remove the Cooling Fan Heat Shield (see Figure E26).

NOTE:
Removing this Heat Shield is needed for additional clearance when installing the Exhaust Manifold/Catalyst in the vehicle.

42. Re-install the Exhaust Manifold/Catalyst assembly to the Cylinder Head using a new gasket and new nuts from the kit.

^ Tighten the Manifold mounting nuts to: 29 - 32 ft-lbs.

43. Re-install the Manifold Support Bracket.

44. Re-install the Front Exhaust Pipe:

^ Use a new gasket between the Pipe and the Exhaust Manifold/Catalyst (see PARTS INFORMATION for the gasket part number).

^ Re-use the old gasket between the Pipe and the muffler.

^ Make sure the larger ends of the springs are placed against the Exhaust Manifold/Catalyst.

45. This Step For Sentra ONLY: Re-install the:

^ Cooling Fan Heat Shield

^ Both upper radiator support brackets

^ Lower Oxygen Sensor

^ Passenger-side front inner fender well

46. Install the manifold upper front heat shield.

47. Re-connect the Oxygen Sensor Wire Harness to the vehicle harness.

48. Re-install the alternator.

49. This Step For Altima ONLY: Re-install the Relay Box.

50. Re-install the plastic engine cover (as applicable).

51. Re-connect the negative battery cable.

52. Re-program all radio station presets.

53. Return to the Repair Flow Chart for further instructions.