NISSAN ALMERA 2001 Service Manual

Removal and InstallationNJEM0069
SEM554G
WARNING:
+Situate vehicle on a flat and solid surface.
+Place chocks at front and back of rear wheels.
+Do not remove engine until exhaust system has com-
pletely cooled off. Otherwise, you may burn yourself
and/or fire may break out in fuel line.
+For safety during subsequent steps, the tension of wires
should be slackened against the engine.
+Before removing front axle from transaxle, place safety
stands under designated front supporting points. Refer to
GI-45, ªGarage Jack and Safety Standº.
+Be sure to hoist engine and transaxle in a safe manner.
+For engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG.
CAUTION:
+When lifting engine, be careful not to strike adjacent parts,
especially the following: Accelerator wire casing, brake
lines, and brake master cylinder.
+In hoisting the engine, always use engine slingers in a
safe manner.
+In removing drive shaft, be careful not to damage grease
seal of transaxle.
+Before separating engine and transaxle, remove the
ENGINE ASSEMBLYYD
Removal and Installation
EM-137

crankshaft position sensor (TDC sensor) from the assem-
bly.
+Always pay extra attention not to damage edge of crank-
shaft position sensor (TDC sensor) or ring gear teeth.
REMOVALNJEM0069S011. Remove engine undercover, and hood for hoisting.
2. Drain coolant from both cylinder block and radiator. Refer to
LC-44, ªChanging Engine Coolantº.
3. Remove the following parts:
+Battery
+RH and LH front wheels
+RH and LH splash covers (combined with undercover)
+Auxiliary belts
+Alternator
+Alternator brackets
+Radiator and cooling fan
+Engine cover
+Air ducts and air cleaner case
LH side of engine room:
4. Disconnect all harnesses and grounds that are connected to
components on vehicle.
5. Disconnect vacuum hose on vacuum pump side.
6. Disconnect fuel feed and fuel return hoses on engine side.
+Immediately put blind plugs into the openings to prevent
fuel from flowing out.
7. Disconnect heater hose. Plug opening of hose to prevent cool-
ant from flowing out.
RH side of engine room:
8. Remove air conditioner compressor from brackets and move
it toward vehicle side. Secure compressor on vehicle side with
rope.
Vehicle underside:
9. Remove exhaust front tube.
10. Disconnect two hoses from power steering pump and plug to
stop fluid.
11. Remove M/T control rod and support rod.
12. Remove ABS wheel sensor, and temporarily hang brake cali-
per with rope on vehicle side.
13. Remove RH and LH drive shafts.
SEM666G
14. Install engine slingers to cylinder head.
: 30 - 37 N´m (3.0 - 3.8 kg-m, 22 - 27 ft-lb)
+Use engine slingers and securing bolts of the specified
service parts.
15. Lift up vehicle to appropriate level where work can be per-
formed efficiently. Using two transmission jacks, securely sup-
port engine oil pan and bottom surface of transaxle.
ENGINE ASSEMBLYYD
Removal and Installation (Cont'd)
EM-138

SEM189G
+Make sure that support is stable with the use of safety
blocks.
16. Install hooks of lifting chain into engine slingers and tighten
chain so that engine still remains on transmission jacks with-
out being lifted up.
17. Remove engine mount insulator RH.
18. Remove through-bolt of engine mount insulator LH.
19. Remove bolts securing center member at front and rear.
JEM190G
20. Carefully lower transmission jacks in accordance with the low-
ering pace of the hoist, and remove engine and transaxle
assembly from vehicle.
+While working, check that no parts of engine assembly
interfere with adjacent parts on the vehicle.
+While working, make sure that parts requiring disconnec-
tion are not left connected, and that no parts interfere with
vehicle.
+To prevent vehicle from falling down, perform operation
carefully so that the center of gravity of the vehicle will not
shift.
21. Remove center member.
+Before starting removal operation, first place the assem-
bly on a level surface and securely support the bottom
surface with wood blocks. Using a hoist, lift engine
slingers, and make sure the assembly is stable.
22. Separate engine and transaxle.
INSTALLATIONNJEM0069S02Install in the reverse order of removal, observing the following:
+While installing, be careful to keep mount insulators free of oil
smear and damage.
+When parts require specified installation directions/positions,
install by using the identifying marks indicating up or front.
+While keeping the mount insulators free of twists or distortions,
start tightening from the through-bolt on the engine mount
insulator LH. This mount is used as the reference position.
ENGINE ASSEMBLYYD
Removal and Installation (Cont'd)
EM-139

ComponentsNJEM0070
SEM510GA
CYLINDER BLOCKYD
Components
EM-140

Removal and InstallationNJEM0071CAUTION:
+When installing bearings, pistons, or other sliding parts,
lubricate contacting surfaces with new engine oil.
+Place removed parts such as bearings and bearing caps
in their proper order and direction.
+When installing connecting rod nuts, and main bearing
cap bolts, apply new engine oil to threads and seating
surfaces.
+Do not allow any magnetic materials to contact the signal
plate of flywheel.
+Do not remove the signal plate at back.
+Do not place the signal plate side facing under.
+Handle with care so as not to damage the signal plate
[especially four places on protrusions for signal of crank
position sensor (TDC sensor)].
DisassemblyNJEM0072PISTON AND CRANKSHAFTNJEM0072S011. Remove engine. Refer to ªENGINE ASSEMBLYº, ªRemoval
and Installationº, EM-137.
2. Place engine on a work stand.
a. Remove flywheel.
+Hold ring gear with ring gear stopper (KV10105630,
KV10105610). Then, loosen securing bolts with TORX socket
(size: Q8 E20, Commercial Service Tool) and remove them.
As an alternative method, hold the crankshaft pulley with a
pulley holder (SST) to remove the flywheel.
JEM192G
b. Install engine sub-attachment (SST) to rear surface of cylinder
block.
+To install, align the hole on the sub-attachment with the knock
pin on the cylinder block.
+The engine sub-attachment has five bolts.
c. Install engine attachment (SST).
+The four sets of bolts and nuts are multi-purpose products.
CYLINDER BLOCKYD
Removal and Installation
EM-141

JEM193G
d. Hoist up engine and install it on the engine stand (SST).
+Another method is to set engine sub-attachment and engine
attachment on engine stand beforehand, and then, install
engine.
3. Drain engine oil and coolant from engine.
4. Remove the following and the associated parts:
+Exhaust manifold
+Turbocharger assembly
+Injection tube
+Intake manifold
+Oil pan (upper and lower)
+Secondary timing chain
+Fuel injection pump
+Primary timing chain
+Rocker cover
+High pressure injection nozzle assembly
+Camshaft
+Cylinder head
+Thermostat, water pipes
+Oil cooler
+Auxiliary component brackets
5. Remove fuel injection pump bracket.
SEM500G
6. If the replacement of pilot bushing is necessary, remove it with
pilot bushing puller (SST).
7. Remove rear oil seal retainer.
+Insert a flat-bladed screwdriver between main bearing cap and
rear oil seal retainer to remove retainer.
8. Remove rear oil seal from rear oil seal retainer.
+Punch out with a flat-bladed screwdriver.
+Be careful not to damage rear oil seal retainer.
JEM195G
9. Remove piston and connecting rod assembly.
a. Set crankshaft pin of the removal location at a position close
to BDC.
b. Remove connecting rod cap.
c. Push piston and connecting rod assembly toward cylinder
head using a hammer handle.
+Before removing piston and connecting rod assembly, check
connecting rod side clearance. Refer to EM-144, ªCONNECT-
ING ROD SIDE CLEARANCEº.
10. Remove connecting rod bearings from connecting rod and
connecting rod cap.
CYLINDER BLOCKYD
Disassembly (Cont'd)
EM-142

+Store the removed parts in sets by the cylinder No. to avoid
mixing them up.
JEM196G
11. Remove piston rings from pistons.
+Use piston ring expander (Commercial Service Tool).
+Avoid scratching pistons during removal.
+Be careful not to damage piston rings by expanding
excessively.
CAUTION:
+When piston rings are not replaced, make sure that piston
rings are mounted in their original positions.
JEM197G
12. Remove piston from connecting rod.
a. Remove snap rings using snap ring pliers.
JEM198G
b. With an industrial drier, heat pistons to 60 to 70ÉC (140 to
158ÉF).
JEM199G
c. Push out piston pin with a rod approx. 26 mm (1.02 in) in
diameter.
CYLINDER BLOCKYD
Disassembly (Cont'd)
EM-143

JEM200G
13. Remove main bearing cap bolts.
+With a TORX socket (size: E-14, Commercial Service Tool),
loosen main bearing cap bolts in several stages in the reverse
order of that shown in the figure and remove them.
+Before loosening main bearing cap bolts, measure crankshaft
end play. Refer to EM-144, ªCRANKSHAFT END PLAYº.
JEM201G
14. Remove main bearing caps.
+Using main bearing cap bolts, remove by rocking bearing cap
back and forth.
15. Remove crankshaft.
16. Remove main bearings and thrust bearings from cylinder block
and main bearing caps.
+Check the correct installation locations of removed parts.
Store them so they do not get mixed up.
17. Remove oil jet.
18. Remove oil jet check valve.
JEM202G
InspectionNJEM0073CRANKSHAFT END PLAYNJEM0073S13+Measure the moving distance of the crankshaft with the dial
gauge when the crankshaft is moved fully forward or back-
ward.
Standard: 0.10 - 0.25 mm (0.0039 - 0.0098 in)
Limit: 0.30 mm (0.0118 in)
+If the value exceeds the limit, replace thrust bearings with new
ones and measure again. If the measurement exceeds the limit
again, replace crankshaft with a new one.
JEM203G
CONNECTING ROD SIDE CLEARANCENJEM0073S14+Measure the side clearance between connecting rod and crank
arm with feeler gauge.
Standard: 0.200 - 0.350 mm (0.0079 - 0.0138 in)
Limit: 0.4 mm (0.0157 in)
+If the value exceeds the limit, replace connecting rod and mea-
sure again. If the measurement exceeds the limit again,
replace the crankshaft.
CYLINDER BLOCKYD
Disassembly (Cont'd)
EM-144

AEM023
PISTON AND PISTON PIN CLEARANCENJEM0073S011. Measure inner diameter of piston pin hole ªdpº.
Standard diameter ªdpº:
27.997 - 28.005 mm (1.1022 - 1.1026 in)
AEM024
2. Measure outer diameter of piston pin ªDpº.
Standard diameter ªDpº:
27.994 - 28.000 mm (1.1021 - 1.1024 in)
3. Calculate interference fit of piston pin to piston.
Dp þ dp = 0.002 - 0.006 mm (0.0001 - 0.0002 in)
If it exceeds the above value, replace piston assembly with pin.
PISTON RING SIDE CLEARANCENJEM0073S02Side clearance:
Top ring
0.120 - 0.180 mm (0.0047 - 0.0071 in)
2nd ring
0.050 - 0.090 mm (0.0020 - 0.0035 in)
Oil ring
0.030 - 0.070 mm (0.0012 - 0.0028 in)
Max. limit of side clearance:
Top ring 0.2 mm (0.008 in)
2nd ring 0.1 mm (0.004 in)
JEM205G
+To measure top ring side clearance, align the outer circumfer-
ences of the ring and piston while pressing ring upward against
the upper surface of the ring groove. Under this condition,
measure the clearance between ring and bottom surface of the
ring groove.
+If out of specification, replace piston ring. If clearance exceeds
maximum limit with new ring, replace piston.
SEM599A
PISTON RING END GAPNJEM0073S03End gap:
Top ring 0.20 - 0.35 mm (0.0079 - 0.0138 in)
2nd ring 0.39 - 0.54 mm (0.0154 - 0.0213 in)
Oil ring 0.25 - 0.50 mm (0.0098 - 0.0197 in)
Max. limit of ring gap:
Top ring 1.0 mm (0.039 in)
2nd ring 1.0 mm (0.039 in)
Oil ring 1.0 mm (0.039 in)
CYLINDER BLOCKYD
Inspection (Cont'd)
EM-145

If out of specification, replace piston ring. If gap still exceeds the
limit even with a new ring, do the following. Rebore cylinder and
use oversized piston and piston rings.
Refer to SDS (EM-167).
+When replacing the piston, check the cylinder block surface for
scratches or seizure. If scratches or seizure is found, hone or
replace the cylinder block.
SEM038F
SEM003F
CONNECTING ROD BEND AND TORSIONNJEM0073S04Bend:
Limit 0.12 mm (0.0047 in)
per 100 mm (3.94 in) length
Torsion:
Limit 0.12 mm (0.0047 in)
per 100 mm (3.94 in) length
If it exceeds the limit, replace connecting rod assembly.
SEM501G
CYLINDER BLOCK DISTORTION AND WEARNJEM0073S05+Clean upper surface of cylinder block.
Use a reliable straightedge and feeler gauge to check the flat-
ness of cylinder block surface.
Check along six positions shown in the figure.
Distortion limit: 0.04 mm (0.0016 in)
+If out of specification, resurface it. The limit for cylinder block
resurfacing is determined by cylinder head resurfacing in
engine.
Resurfacing limit:
Amount of cylinder head resurfacing is ªAº.
Amount of cylinder block resurfacing is ªBº.
The maximum limit is as follows:
A + B = 0.07mm (0.0028 in)
Nominal cylinder block height from crankshaft center:
252.95 - 253.05 mm (9.9586 - 9.9626 in)
+If necessary, replace cylinder block.
CYLINDER BLOCKYD
Inspection (Cont'd)
EM-146