Nissan 240SX/Altima 1993-1998 Repair Guide

Engine

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REMOVAL & INSTALLATION



In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as "disconnect the exhaust system'' or "remove the radiator.'' In most instances, a detailed removal procedure can be found elsewhere in this guide.

It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible approaches to any repair procedure.

Removal and installation of the engine can be made easier if you follow these basic points:



If you have to drain any of the fluids, use a suitable container.
 
Always tag any wires or hoses and, if possible, the components they came from before disconnecting them.
 
Because there are so many bolts and fasteners involved, store and label the retainers from components separately in muffin pans, jars or coffee cans. This will prevent confusion during installation.
 
After unbolting the transmission or transaxle, always make sure it is properly supported.
 
If it is necessary to disconnect the air conditioning system, have this service performed by a qualified technician using a recovery/recycling station. If the system does not have to be disconnected, unbolt the compressor and set it aside.
 
When unbolting the engine mounts, always make sure the engine is properly supported. When removing the engine, make sure that any lifting devices are properly attached to the engine. It is recommended that if your engine is supplied with lifting hooks, your lifting apparatus be attached to them.
 
Lift the engine from its compartment slowly, checking that no hoses, wires or other components are still connected.
 
After the engine is clear of the compartment, place it on an engine stand or workbench.
 
After the engine has been removed, you can perform a partial or full teardown of the engine using the procedures outlined in this guide.
 

Altima

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the engine mounts-Altima


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. The fuel system will remain under pressure after the ignition has been turned OFF.

The engine and transaxle must be removed as a single unit. The engine and transaxle are removed from under the vehicle.

  1. Matchmark the location of the hinges on the hood and remove the hood from the vehicle.
  2.  
  3. Properly relieve fuel system pressure.
  4.  
  5. Disconnect the negative, then the positive battery cables. Remove the battery and battery tray.
  6.  
  7. Drain and recycle the engine coolant.
  8.  
  9. If equipped with an automatic transaxle, disconnect the cooler lines from the radiator.
  10.  
  11. Remove the upper and lower hoses from the radiator and then remove the radiator assembly.
  12.  
  13. Disconnect the heater hoses from the engine.
  14.  
  15. Disconnect the throttle cable and cruise control cable (if equipped).
  16.  
  17. Remove the air cleaner, air box, and intake hose.
  18.  
  19. Disconnect the fuel feed and return hoses.
  20.  
  21. Label and disconnect all appropriate vacuum hoses.
  22.  
  23. Label and disconnect all appropriate electrical harnesses.
  24.  
  25. Disconnect the wiring from the starter motor.
  26.  
  27. If equipped, disconnect the slave cylinder from the transaxle. It is not necessary to disconnect the hydraulic hose.
  28.  
  29. Remove the accessory drive belts.
  30.  
  31. Remove the alternator, A/C compressor and power steering pump from the engine.
  32.  

Do not disconnect the A/C lines. Lay the A/C compressor aside in the engine compartment.

  1. Remove the right and left halfshafts from the transaxle.
  2.  
  3. Disconnect the exhaust pipe from the exhaust manifold.
  4.  
  5. Support the engine with a sling and support the transaxle with a jack.
  6.  
  7. Disconnect the left and right engine mounting through-bolts.
  8.  
  9. Remove the bolts that secure the crossmember to the vehicle and remove the crossmember.
  10.  
  11. Remove the front and rear engine mounts.
  12.  

The engine and transaxle assembly should be removed through the bottom of the vehicle. Do not attempt to remove the assembly from above.

  1. Lower the transaxle and engine assembly from the vehicle.
  2.  

To install:
  1. Position the engine and transaxle in the vehicle.
  2.  
  3. Install the front and rear engine mounts. Tighten the through-bolts to 27-55 ft. lbs. (62-75 Nm).
  4.  
  5. Install the right and left engine mounts. Tighten the through-bolts to 12-21 ft. lbs. (21-55 Nm).
  6.  
  7. Install the crossmember and tighten the mounting bolts to 57-72 ft. lbs. (77-98 Nm).
  8.  
  9. Remove the engine and transaxle supports.
  10.  
  11. The balance of installation is the reverse of the removal procedure.
  12.  
  13. Refill and bleed the cooling system.
  14.  
  15. Refill the engine with the correct grade and viscosity of engine oil. Check all the fluid levels.
  16.  
  17. Start the engine, bleed the cooling system, and check for leaks. Make all the necessary adjustments.
  18.  
  19. Install the hood.
  20.  

220SX

See Figure 2



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the engine mounts-220SX


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. The fuel system will remain under pressure after the ignition has been turned OFF.

  1. Matchmark the location of the hinges on the hood. Unbolt and remove the hood.
  2.  
  3. Properly relieve fuel system pressure.
  4.  
  5. Disconnect the negative, then the positive battery cables. Remove the battery.
  6.  
  7. Remove the engine undercover.
  8.  
  9. Remove the transmission from the vehicle.
  10.  
  11. Drain and recycle the engine coolant.
  12.  
  13. Drain and recycle the engine oil.
  14.  
  15. Disconnect the automatic transmission-to-radiator cooling tubes (if applicable). Remove the radiator and radiator shroud.
  16.  
  17. Remove the air cleaner.
  18.  
  19. Remove the accessory drive belts.
  20.  
  21. Remove the fan and pulley.
  22.  
  23. Label and disconnect all appropriate vacuum lines.
  24.  
  25. Label and disconnect all appropriate electrical harnesses.
  26.  
  27. Label and disconnect the ignition wires from the spark plugs.
  28.  
  29. Disconnect the fuel feed and return lines.
  30.  
  31. Disconnect the heater hoses and throttle connections.
  32.  
  33. Remove the front exhaust pipe from the vehicle.
  34.  

Do not disconnect the A/C lines. Remove the A/C compressor and set it aside in the engine compartment.

  1. Remove the alternator, A/C compressor, and power steering pump from the engine.
  2.  
  3. Disconnect the power brake booster hose from the engine.
  4.  
  5. Attach a hoist to the lifting hooks on the engine (at either end of the cylinder head). Support the engine.
  6.  
  7. Remove the engine mounting nuts from both lower sides of the engine mounts.
  8.  

The engine assembly is removed from the top of the vehicle. When removing the engine, guide it carefully to avoid hitting parts such as the master cylinder.

  1. Remove the engine from the vehicle.
  2.  

To install:
  1. Position the engine in the vehicle.
  2.  
  3. Tighten the engine mounting nuts to 51-58 ft. lbs. (69-78 Nm).
  4.  

It may be necessary to lower or raise the engine hoist to correctly position the engine with the mount holes.

  1. Install the transmission and tighten the transmission mount to 16-21 ft. lbs. (22-28 Nm).
  2.  
  3. The balance of installation is the reverse of the removal procedure.
  4.  
  5. Refill the engine, transmission, and cooling system with the proper types and amounts of fluid.
  6.  
  7. Start the engine and run at idle until normal operating temperature is reached. Check for leaks.
  8.  

 
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