Guard front under engine draging ground. not properly installed

• TESTING
• REMOVAL & INSTALLATION

Alternator

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TESTING

The easiest way to test the performance of the alternator is to perform a regulated voltage test.

1. Start the engine and allow it to reach operating temperature.
2. Connect a voltmeter between the positive and negative terminals of the battery.
3. Voltage should be 14.1-14.7 volts.
4. If voltage is higher or lower than specification, connect a voltmeter between the battery positive (B+) voltage output terminal of the alternator and a good engine ground.
5. Voltage should be 14.1-14.7 volts.
6. If voltage is still out of specification, a problem exists in the alternator or voltage regulator.
7. If voltage is now within specification, a problem exists in the wiring to the battery or in the battery itself.

Many automotive parts stores have alternator bench testers available for use by customers. An alternator bench test is the most definite way to determine the condition of your alternator.

REMOVAL & INSTALLATION

1993-94 Models
See Figures 1 through 5

1. Disconnect the negative battery cable, for safety purposes.
2. Remove the right side splash guard from under the vehicle.
3. Disconnect the alternator lead wires and connections. Label them if you are unsure of their locations.

Fig. Fig. 1: The large positive lead connection is protected by a rubber boot

Fig. Fig. 2: Make sure the alternator ground wire is also removed

1. Loosen the drive belt adjusting bolt and slip the belt off the pulley.
2. Remove the lower adjustment bolt, followed by the upper pivot bolt.

Fig. Fig. 3: Remove the lower adjustment bolt ...

Fig. Fig. 4: ... followed by the upper pivot bolt. Make sure you support the alternator

1. Lower the alternator from the vehicle.

To install:

1. Using a C-clamp and a socket, push the upper pivot bushing back in it's bore until it bottoms out.

Fig. Fig. 5: Using a C-clamp to push in the pivot bushing will make installation easier

1. Raise the alternator into the engine bracket, and push the upper pivot bolt all the way through the bracket to support it.
2. Install the lower adjustment bolt, followed by the upper pivot nut.
3. Place the belt on the alternator pulley, and tighten the belt.
4. Tighten the upper and lower mounting bolts.
5. Engage the alternator lead wires and connections.
6. Connect the negative battery cable.
7. Start the vehicle, and check for proper operation.
8. Readjust the belt tension, if necessary. Install the lower splash guard.

1995-98 Models

1. Disconnect the negative battery terminal.
2. Remove the splash guard on the right side of the vehicle.
3. Loosen the alternator belt idler pulley.
4. Slip the drive belt off the alternator pulley.
5. Remove the four air conditioning compressor mounting bolts.
6. Remove the radiator fan and fan shroud.
7. Move the air conditioning compressor forward.
8. Disconnect the alternator harness connector.
9. Remove the alternator mounting bolts, and lower the alternator from the vehicle.

To install:

1. Hold the alternator in place and install the mounting bolts.
2. Plug in the alternator harness connector.
3. Move the air conditioning compressor back into location.
4. Install the radiator cooling fan and shroud.
5. Install the air conditioning compressor mounting bolts.
6. Place the drive belt on the alternator pulley.
7. Tighten the drive belt to the proper tension with the idler pulley.
8. Install the splash guard.
9. Connect the negative battery terminal.

Proper belt tension is important. A belt that is too tight may cause alternator bearing failure; one that is too loose will cause a gradual battery discharge and/or belt slippage, resulting in belt breakage from overheating.

Interior or exterior of sump?
Exterior requires a steel guard bolted under vehicle to stop crunching on rocks etc.
Iinternal corrosion usually sign of water laying in bottom of sump for a long long time..cure is to change oil regularly.
Actual physical erosion caused by something in engine hitting sump???? Take sump off and fix problem...

3.8L Engine

1. Disconnect the negative battery cable.
   
2. Remove the air cleaner outlet tube.
   
3. Unfasten the two bolts retaining the radiator upper sight shield, then position the shield aside.
   
4. Remove the hood weather seal.
   
5. Remove the wiper pivot arms.
   
6. Remove the LH cowl vent screen and wiper module.
   
7. On SC engines, remove intercooler/charge air cooler tubes.
   
8. Install a Three Bar Engine Lifting Support D88L-6000-A or equivalent.
   
9. Raise and safely support the vehicle.
   
10. Remove the front engine support insulator through bolt. On SC, also remove the LH front engine support/mount retaining strap bolt.
    
11. Partially lower the vehicle. Raise the engine with the lifting support tool.
    
12. Raise and safely support the vehicle. Remove the starter motor assembly.
    
13. Position a drain pan, drain the engine oil, and remove the oil filter.
    
14. Remove the starter motor wire, ground strap and oil cooler inlet tube (automatic transmission only).
    
15. Unfasten the oil pan-to-bell housing bolts and Crankshaft Position (CKP) sensor lower shield retaining bolts (if equipped).
    
16. Remove the remaining oil pan retaining bolts.
    
17. Remove the steering shaft pinch bolts and separate the steering shaft.
    
18. Position a transmission jack under the front of the front subframe. Remove the six rearward bolts on the front of subframe, then loosen the two forward subframe bolts.
    
19. Remove the lower shock absorber-to-control arm bolts and nuts (both sides).
    
20. Lower the front subframe.
    
21. Remove the oil pan and empty any residual oil from the pan.
    

To install:

1. Clean mating surfaces of the oil pan and cylinder block. Take great care to avoid damaging the machined surfaces!
   
2. Apply a bead of RTV silicone gasket sealer to the oil pan.
   
3. Fit the oil pan to block to ensure enough clearance has been provided to allow the oil pan to be installed without the sealant being scraped off, under the cylinder block assembly.
   
4. Install the oil pan retaining bolts at the cylinder block, bell housing and install the lower crankshaft sensor shield (if equipped). Tighten to 80-106 inch lbs. (9-12 Nm).
   
5. Raise subframe into position.
   
6. Install the lower shock absorber-to-front suspension lower arm bolts. Tighten to 103-144 ft. lbs. (140-195 Nm).
   
7. Install the two forward front sub-frame bolts and six bolts at the rear of the subframe.
   
8. Connect the steering column input shaft coupling, install the pinch bolt and tighten to 30-42 ft. lbs. (41-57 Nm).
   
9. If equipped with an automatic transaxle, install the oil cooler inlet tube and the oil cooler tube, the starter wire harness and the ground strap.
   
10. Install oil filter.
    
11. Partially lower the vehicle.
    
12. Carefully lower the engine with the engine support, seating the LH side locating pin before the RH side. Install the engine mount through bolts, (on SC engines, install LH mount retaining strap bolt), and tighten to 34-44 ft. lbs. (45-61 Nm).
    
13. Remove the engine support and lifting eyes, or equivalent. Carefully lower the vehicle.
    
14. On SC engines, install the intercooler/charge air cooler tubes.
    
15. Install the wiper module, the LH cowl vent screen and the left and right side wipers.
    
16. Install the hood weather seal.
    
17. Install the radiator upper sight shield and secure with the two retaining bolts.
    
18. Install the air cleaner outlet tube assembly.
    
19. Refill the engine crankcase with appropriate type and quantity of engine oil.
    
20. Connect the negative battery cable. Start the engine and check for leaks.
    
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Engine - Timing Chain/Front Cover Revised Procedure
Classification:
EM98-009
Reference:
NTB98-107
Date:
January 15, 1999
GA16DE TIMING CHAIN/FRONT COVER
REVISED SERVICE PROCEDURE
APPLIED ENGINE:
GA16DE
APPLIED MODELS:
1991-94 Sentra (B13) w/GA16DE
1991-93 NX1600 (B13)
1995-99 Sentra (B14) w/GA16DE
1995-98 200SX (B14) w/GA16DE
SERVICE INFORMATION
A revised service procedure for the engine front cover/timing chain has been adopted for the GA16DE. It is no longer recommended to remove the
cylinder head when removing the timing chain/front cover(s). Utilize the following steps when servicing the front cover, timing chain, guides or
tensioner(s)
PARTS INFORMATION
CLAIMS INFORMATION
Please reference the "Revision C" pages of the Nissan "1992-1999 Warranty Flat Rate Information Manual", Section "AG", Op Codes AG12AA,
AG14AA, AG142A, AG143A, AG144A and AG24AA. Also reference Section "CA", Op Codes CA20AA and CA22AA. You will note that the
descriptions and flat rate times applicable to the B13 and B14 vehicles (with GA16DE engines) for these Op Codes have been revised to reflect this
new procedure.
Caution
^ After removing the timing chain, do not turn the crankshaft and camshaft separately or the valves will strike the piston heads.
^ When installing chain tensioners or other sliding parts, lubricate contacting surfaces with new engine oil.
^ Apply new engine oil to bolt threads and seat surfaces when installing the camshaft sprockets and the crankshaft pulley.
^ Do not spill engine coolant on the drive belts.
^ Please refer to the Service Manual for the correct tightening torque.
Removal
1. Set # 1 piston at TDC on its compression stroke.
2. Remove the spark plug wires.
1995 Nissan-Datsun 200SX L4-1597cc 1.6L DOHC MFI (GA16DE) Page 2
3. Remove the rocker cover (see Figure 1).
4. Remove the coolant reservoir tank with bracket and reposition it for clearance.
5. Support the engine with a suitable jack.
6. Remove cylinder head front mounting bracket.
7. Remove engine front mounting, then the engine front mounting bracket.
8. Remove cylinder head front cover.
9. Remove the upper chain tensioner (see Figure 2).
1995 Nissan-Datsun 200SX L4-1597cc 1.6L DOHC MFI (GA16DE) Page 3
10. Wipe off the links of the upper timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with
the timing marks on the cam sprockets and idler sprocket (see Figure 3)
11. Remove the four (4) front cover to cylinder head bolts.
12. Remove side and lower engine compartment splash covers.
13. Remove the accessory drive belts.
14. Remove the crankshaft pulley.
15. Drain coolant by removing the cylinder block drain plug and opening the radiator drain **** (Refer to MA section of the Service Manual).
16. Drain engine oil.
17. Remove intake manifold support of engine front side.
18. Remove power steering pump, pump bracket and tension rod. Position pump aside for clearance.
19. Remove the thermostat housing (See Figure 4).
1995 Nissan-Datsun 200SX L4-1597cc 1.6L DOHC MFI (GA16DE) Page 4
20. Remove the lower chain tensioner (see Figure 5).
21. Remove the front exhaust tube. Refer to the "FE" section (Exhaust System) of the Service Manual.
22. Remove the front and rear engine gussets (if equipped) on either side of the oil pan.
NOTE:
On A/T models, remove the rear plate cover.
23. Remove the oil pan (see Figure 6).
a. Insert the Tool between the cylinder block and oil pan.
CAUTION:
Be careful not to damage the aluminum mating face. Do not insert a screwdriver, or the oil pan flange will become damaged.
b. Slide the Tool by tapping it on the side of the Tool with a hammer.
24. Remove the A/C compressor and position it aside for clearance.
25. Remove the A/C and alternator bracket with the alternator.
26. Remove the oil pump drive spacer.
CAUTION:
Be careful not to scratch the drive spacer when removing it.
27. Remove the front cover bolts and front cover.
1995 Nissan-Datsun 200SX L4-1597cc 1.6L DOHC MFI (GA16DE) Page 5
CAUTION:
One bolt is located on the water pump (see Figure 7).
*1: Located on engine front mounting bracket.
*2: Located on the water pump.
*3: Located on the power steering oil pump adjusting bar.
CAUTION:
Be careful not to tear or damage the cylinder head gasket.
28. Remove the cylinder block to front cover alignment dowels.
CAUTION:
Do not hit the dowels or the cylinder block will crack.
29. Wipe off the links of the lower timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with
the timing marks on the idler sprocket and crankshaft sprocket (see Figure 8).
Installation
1. Install the crankshaft sprocket, making sure the mating marks face the front of the engine.
2. Install the idler sprocket and lower timing chain using the mating marks and the paint marks made during the removal process.
CAUTION:
1995 Nissan-Datsun 200SX L4-1597cc 1.6L DOHC MFI (GA16DE) Page 6
Be careful not to tear or damage the cylinder head gasket.
3. Install the lower chain guides.
4. Front cover installation:
a. Using a scraper or other suitable tool remove all traces of liquid gasket from the cylinder block and front cover mating surfaces.
b. Install new crankshaft seal in front cover.
c. Install new oil passage O-rings and apply a continuous bead of RTV sealant to the front cover (see Figure 1).
NOTE:
Use Genuine Nissan RTV silicone sealant P/N 999MP-A7007, Three Bond P/N TB1207D or equivalent.
d. Install the front cover to the engine.
CAUTION:
Be careful not to tear or damage the cylinder head gasket or oil seal.
5. Align oil pump drive spacer with the oil pump, and install.
6. Install the oil strainer.
7. Install oil pan, referring to "Installation" in the "OIL PAN" section of the Service Manual.
8. Install upper timing chain and sprockets, using the painted reference marks made during removal.
9. Install upper chain tensioner.
1995 Nissan-Datsun 200SX L4-1597cc 1.6L DOHC MFI (GA16DE) Page 7
a. Before installing the chain tensioner, insert a suitable pin into the pin hole of the chain tensioner (see Figure 2) to hold the tensioner in.
b. Once the tensioner is installed, remove the pin.
10. Install the lower chain tensioner (See Figure 3).
NOTE:
Make sure the gasket is facing the proper direction before installing the tensioner.
CAUTION:
Now rotate the crankshaft by hand. Check that no binding or interference problems occur when the engine is rotated.
11. Install the thermostat housing.
a. Use a scraper to remove all traces of liquid gasket from the mating surfaces of the engine front cover and the thermostat housing.
1995 Nissan-Datsun 200SX L4-1597cc 1.6L DOHC MFI (GA16DE) Page 8
b. Apply a continuous bead of RTV sealant to the housing as shown in Figure 4.
NOTE:
Use Genuine Nissan RTV silicone sealant P/N 999MP-A7007, Three Bond P/N TB1207D or equivalent.
12. Install camshaft sprocket cover:
a. Use a scraper to remove all traces of liquid gasket from the mating surfaces of the cylinder head and camshaft sprocket cover.
b. Apply a continuous bead of RTV sealant to the cover as shown in Figure 5.
NOTE:
Use Genuine Nissan RTV silicone sealant P/N 999MP-A7007, Three Bond P/N TB1207D or equivalent.
d. Install camshaft sprocket cover.
1995 Nissan-Datsun 200SX L4-1597cc 1.6L DOHC MFI (GA16DE) Page 9
13. Apply RTV sealant to rocker cover gasket (see Figure 6a) and install rocker cover, tightening the bolts as shown in Figure 6b.
14. Install the following parts:
a. Crankshaft pulley.
b. A/C compressor and alternator bracket with alternator.
c. A/C compressor.
d. Power steering oil pump and tension rod.
15. Install front and rear engine gussets (if equipped), and rear cover plate (A/T models).
16. Install front exhaust tube.
17. Install upper right engine bracket and mount.
18. Install coolant reservoir tank.
19. Install alternator, power steering and A/C compressor drive belts.
20. Install engine compartment splash guards.
21. Install vacuum hoses, electrical harnesses and connectors.
22. Install spark plug wires.
23. Refill with coolant. Refer to the "MA" section ("Changing engine coolant, Engine Maintenance") of the Service Manual.
24. Refill with engine oil. Refer to the "MA" section ("Changing engine oil, Engine Maintenance") of the Service Manual.

Removal and Installation L4-2.5L (QR25DE) Engines To Remove:

1. Before servicing the vehicle refer to the precautions at the beginning of this section.
2. Remove or disconnect the following:
   • Negative battery cable
   • Engine cover
   • Front/right-side engine undercover
   • Drive belt
   • Alternator harness connector
   • Engine ground wire from top mount
   • Alternator upper and lower mounting bolts
3. Set the alternator aside and remove the top mount.
4. Remove the alternator.

To Install:

1. Slide alternator in place.
2. Install or connect the following:
   • Alternator top mount
   • Alternator upper and lower mounting bolts
   • Engine ground wire from top mount
   • Alternator harness connector
   • Drive belt
   • Front/right-side engine undercover
   • Engine cover
   • Negative battery cable

V6-3.5L (VQ35) To Remove:

1. Before servicing the vehicle refer to the precautions at the beginning of this section.
2. Disconnect the negative battery cable.
3. Drain coolant from the radiator into a suitable container.
4. Remove or disconnect the following:
   • Radiator
   • Front/right-side engine under cover
   • Drive belt
   • Idler pulley
   • Alternator adjustable top mount
   • Alternator lower mount bolt and nuts
   • Alternator lower front bracket bolt
   • Alternator harness connectors
   • Alternator

To Install:

1. Install or connect the following:
   • Alternator in place
   • Alternator harness connectors
   • Alternator lower front bracket bolt
   • Alternator lower mount bolt and nuts
   • Alternator adjustable top mount
   • Idler pulley
   • Drive belt
   • Front/right-side engine under cover
   • Radiator
2. Replace the engine coolant.
3. Connect the negative battery cable.
4. Start the engine and check for leaks.
5. Recheck coolant level and top off as needed.

Remove oil filler cap and dipstick. Pull up to remove large balck plastic engine cover. Tabs are at rear left and lower front right (facing engine). Large (1-1/16") Black plastic hex cap is cover for oil filter, fron of engine between motor and transfer case. Best to use special tool that fits 3/8" socket extension(about $12 - Search fro Lisle 14700 Wrench) since adjustable wrench doesn't fit well. Replace cartrideg and O-ring, then reinstall in reverse order.

here's v6 3.8L

Section 03-01A: Engine, 3.8L 1996 Thunderbird, Cougar Workshop Manual
IN-VEHICLE SERVICE Oil Pan/Oil Pump Screen Cover and Tube Removal

1. Disconnect battery ground cable (14301).
   

1. Remove air cleaner outlet tube (9B659). Refer to Section 03-12 .
   

1. Remove two bolts retaining radiator upper sight shield (8C291) and position radiator upper sight shield aside.
   

1. Remove hood weather seal.
   

1. Remove windshield wipers.
   

1. Remove LH cowl vent screen and wiper module.
   

1. Install Three Bar Engine Support D88L-6000-A or equivalent.
   

1. Raise vehicle on a hoist. Refer to Section 00-02 .
   

1. Remove front engine support insulator through-bolts.
   

1. Partially lower vehicle.
   

1. Raise engine and support with Three Bar Engine Support D88L-6000-A or equivalent.
   

1. Raise vehicle.
   

1. Remove starter motor (11002).
   

1. Position drain pan.
   

1. Drain engine oil.
   

1. Remove oil bypass filter (6714).
   

1. Remove starter motor wire, ground strap and automatic transmission oil cooler lines.
   

1. Remove oil pan-to-bell housing bolts and bolts at crankshaft position sensor lower shield.
   

1. Remove remaining oil pan retaining bolts.
   

1. Remove steering shaft pinch bolt and separate steering shaft.
   

1. Position transmission jack under front sub-frame (5C145).
   

1. Remove six rearward bolts on front sub-frame. Loosen two forward front sub-frame bolts.
   

1. Remove lower shock absorber-to-front suspension lower arm bolts and nuts (both sides).
   

1. Lower front sub-frame.
   

1. Remove oil pan (6675).
   

1. Empty any residual oil from oil pan.
   

1. Remove oil pump screen cover and tube retainer bolts and support bracket nut. Remove oil pump screen cover and tube (6622) and discard oil pump inlet tube gasket (6626).
   

it is called a rock guard it keeps rocks from bouncing into radiator and other engine compartments you can get one from salvage yard are dealer

you should be able to access the connector and bulb without removing headlight assembly. lift the hood and you should see the connector behind the headlight.

Remove protective bottom plastic cover under engine to gain acces to oil pan plug at the back of oil pan. Remove oil pan plug, drain old oil; replace oil filter. Replace plug and fill with oil. Replace plastice guard ubder engine.