NISSAN ALMERA N15 1995 Service Manual

AB

Taper:A-B
Out-at-round: X-
y

Oil groove
y

SEM316A
SEM366E CYLINDER
BLOCK ~
Inspection (Cont'd)
CRANKSHAFT
1. Check crankshaft mainandpinjournals forscore, wearor
cracks.
2. With amicrometer, measurejournalsfortaper andout-of-
round.
Out-of-round (X-V):
Less than0.005 mm(O.0002 in)
Taper (A-B):
Less than0.002 mm(O.0001 in)

3. Measure crankshaft runout.

Runout (Totalindicator reading):
Less than0.05mm(O.0020 in)
BEARING CLEARANCE

• Use Method Aor Method B.Method Ais preferred because
it is more accurate.

Method A(Using boregauge &micrometer)
Main bearing

1. Set main bearings intheir proper positions oncylinder
block andmain bearing cap.
2. Install mainbearing captocylinder block.

Tighten allbolts incorrect orderintwo orthree stages.

3. Measure innerdiameter "A"ofeach main bearing.
4. Measure outerdiameter "Om"ofeach mainjournal in
crankshaft.
5. Calculate mainbearing clearance.

Main bearing clearance
=
A-
Om
Standard:
0.018 .0.042 mm(O.0007 .0.0017 in)
Limit: 0.1mm (O.004 in)

6. Ifitexceeds thelimit, replace bearing.
7. Ifclearance cannotbeadjusted withinthestandard ofany
bearing, grindcrankshaft journalanduseundersized bear-
ing.

EM-52

Mainjournal andpinjournal

R

SEM588ACYLINDER
BLOCK
[ill

Inspection (Conl'd)
When grinding crankpinand crank journal:
a. Grind untilclearance iswithin specified standardbearing
clearance.
b. Fillets should befinished asshown inthe figure.
R: 2.3 -2.5 mm (0.091 -0.098 in)

•

~ Front

No.5

Main journal
grade number
Cylinder
block
SEM427C
8.
Ifcrankshaft, cylinderblockormain bearing isreused
again, measure mainbearing clearance. Ifthe above parts
are allreplaced, selectthickness ofmain bearings asfol-
lows:

a. Grade number ofeach cylinder blockmainjournal is
punched onthe respective cylinderblock.These numbers
are punched ineither Arabic orRoman numerals.
b. Grade number ofeach crankshaft mainjournal ispunched
on the respective crankshaft. Thesenumbers arepunched
in either Arabic orRoman numerals.
c. Select mainbearing withsuitable thickness according tothe
following table.
Main bearing gradecolor:

Main journal
grade number

0
1

2

Crankshaft
journal gradenumber

0
Black
Brown Green

1
BrownGreenYellow

2
GreenYellow Blue

Crank
journal
grade number
SEM436C

\i1hOle
o,.",,!f0

Front ~~

Q
I\}:J

Identification color~
SEM194C
For
example:
Main journal gradenumber: 1
Crankshaft journalgradenumber: 2
Main bearing gradenumber
=
1
+
2 Yellow

)=====
.-:::::::======_ ..

;::..----

AEM027Connecting
rodbearing (Bigend)

1. Install connecting rodbearing toconnecting rodand cap.
2. Install connecting rodcap toconnecting rod.

Tighten boltstothe specified torque.

3. Measure innerdiameter "C"ofeach bearing.

EM-53

CYLINDERBLOCK .@K]
Inspection (Cont'd)
4. Measure outerdiameter "Op"ofeach crankshaft pinjour-
nal.
5. Calculate connecting rodbearing clearance.
Connecting rodbearing clearance
=
C-Dp
Standard:
0.014 -0.039 mm(0.0006 •0.0015 in)
Limit: 0.1mm (0.004 in)
6. Ifitexceeds thelimit, replace bearing.
7. Ifclearance cannotbeadjusted withinthestandard ofany
bearing, grindcrankshaft journalanduseundersized bear-
ing. Refer tostep 7of "BEARING CLEARANCE -Main
bearing" (EM-52).
CONNECTING RODBUSHING CLEARANCE (Smallend)
1. Measure innerdiameter "C"ofbushing.
8.
Ifbearing, crankshaft orconnecting rodisreplaced witha
new one, select connecting rodbearing according tothe
following table.
Connecting rodbearing gradenumber:
Grade numbers arepunched ineither Arabic orRoman numer-
als.
Method B(Using plastigage)
CAUTION:
• Donot turn crankshaft orconnecting rodwhile plastigage is
being inserted.
• When bearing clearance exceedsthespecified limit,ensure
that theproper bearing hasbeen installed. Thenifexces-
sive bearing clearance exists,useathicker mainbearing or
undersized bearingsothat thespecified bearingclearance
is obtained.
Brown
Green
Connecting
rodbearing
grade color

a
1
2

Crank
pingrade color

SEM437C
EM-54

AEM030
SEM062A
SEM291C
SEM367E CYLINDER
BLOCK ~
Inspection (ConI'd)

2. Measure outerdiameter lOOp"ofpiston pin.
3. Calculate connecting rodbushing clearance.

Connecting rodbushing clearance
=
C-Dp
Standard: 0.005 •0.017 mm(0.0002 •0.0007 in)
Limit:
0.023 mm(0.0009 in) •
If itexceeds thelimit, replace connecting rodassembly orcon-
necting rodbushing andlorpistonpin.
REPLACEMENT OFCONNECTING RODBUSHING (Small
end)

1. Drive insmall endbushing untilitis flush withendsurface
of rod.

Be sure toalign theoilholes.

2. Ream thebushing sothat clearance withpiston piniswithin
specification.
Clearance betweenconnecting rodbushing andpiston
pin: 0.005 -0.017 mm(0.0002 -0.0007 in)
FLYWHEEL RUNOUT
Runout (Totalindicator reading):
Flywheel (MITmodel)
Less than0.15mm(0.0059 in)
Drive plate(AITmodel)*
Less than0.2mm (0.008 in)

*:
Measuring points
Approximately 115mm (4.53 in)from crankshaft
center
Assembly PISTON
1. Install newsnap ringonone side ofpiston pinhole.
2. Heat piston to60 to70°C (140to158°F) andassemble piston,
piston pin,connecting rodand new snap ring.

• Align thedirection ofpiston andconnecting rod.
• Numbers stampedonconnecting rodand capcorrespond to
each cylinder.
• After assembly, makesureconnecting rodswings
smoothly.
EM-55

Punchmarksideup
(if mark ispresent.)
SEM965E CYLINDER
BLOCK @KJ
Assembly (Coni'd)

3. Set piston ringsasshown.

CAUTION:
• When piston ringsarenotreplaced, makesurethatpiston
rings aremounted intheir original position.
• When piston ringsarebeing replaced andnopunch mark
is present, pistonringscanbemounted witheither sideup.
For Europe andIsrael models
Engine
front

Q

Oil
ring
expander
tf
V

;l

Top and second ring
Punch marksideup
(if mark ispresen!.)

.::::::::J
c::
Oil ring
expander
*c:

Engine
il

front
~ •
Top ring
• Oil ring
~ upperrail

IJ

/') Oilring
~ ~lower rail
SEM160B
SEM208F
Top ring
Oil ring

~ It
upper rail

!J

~.Oil ring
lower rail
SEM200F Except
forEurope andIsrael models
#5

#4 ~

Oil hole #3 ~-'U
~"\)~ ~
~~
Oilgroove
SEM366E
CRANKSHAFT

1. Set main bearings intheir proper positions oncylinder
block andmain bearing cap.

• Confirm thatcorrect mainbearings areused. Referto
"Inspection" (EM-52).
• Apply engine oiltobearing surfaces.
EM-56

IdentificationNo.

\ca
p
\

NO.1
t.:?

Enginefront

SEM420C CYLINDER
BLOCK
Assembly (Cont'd)

•

Front
Pistonringcompressor

SEM293C
2.
Install crankshaft andmain bearing capsandtighten bolts
to the specified torque.

• Apply newengine oiltobolt threads andseat surface.
• Prior totightening bearingcapbolts, placebearing capin
its proper position byshifting crankshaft inthe axial direc-
tion.
• Tighten bearing capbolts gradually intwo orthree stages.
Start withcenter bearing andmove outward sequentially.
• After securing bearingcapbolts, makesurecrankshaft
turns smoothly byhand.

3. Measure crankshaft endplay.

Crankshaft endplay:
Standard:
0.060 -0.180 mm(0.0024 -0.0071 in)
Limit: 0.3 mm (0.012 in)
If beyond thelimit, replace thrustbearing witha

new one.

4. Install connecting rodbearings inconnecting rodsandcon-
necting rodcaps.

• Confirm thatcorrect bearings areused. Referto
"Inspection" (EM-52).
• Install bearings sothat oilhole inconnecting rodaligns with
oil hole ofbearing.
• Apply engine oiltobolt threads andbearing surfaces.

5. Install pistons withconnecting rods.
a. Install themintocorresponding cylinderswithTool.

• Becareful nottoscratch cylinder wallbyconnecting rod.
• Arrange sothat front mark onpiston headfaces toward
front ofengine.
• Apply engine oiltopiston ringsandsliding surface ofpis-
ton.
EM-57

Rearoilseal retainer

SEM736DCYLINDER
BLOCK
[ill

Assembly (Cont'd)

b. Install connecting rodcaps.
Tighten connecting rodcap nuts tothe specified torque.

tD.J:
Connecting rodcap nuts
(1) Tighten to13.72 to15.68 N'm(1.399 to1.599
kg-m, 10.120 to11.566 ft-Ib).
(2) Turn nutsto35° to40° degrees clockwise withan
angle wrench. Ifan angle wrench isnot avail-
able tighten nutsto23 to28 N'm (2.3to2.9 kg-m,
17 to21 ft-Ib).

6. Measure connecting rodside clearance.

Connecting rodside clearance:
Standard:
0.200 -0.470 mm(0.0079 -0.0185 in)
limit:
0.52 mm(0.0205 in)
If beyond thelimit, replace connecting rod
and/or crankshaft.

7. Install rearoilseal retainer.
a. Before installing rearoilseal retainer, removealltraces of
liquid gasket fromcylinder blockandretainer witha
scraper.
b. Apply acontinuous beadofliquid gasket torear oilseal
retainer.
• Apply around innersideofbolt holes.

EM-58

OUTERCOMPONENT PARTS

•

SEM231F

SEC.
130-140-150-210-211-221

~ __to:J
13•16 (1.3 -1.6, 9.12)

to:J
16•21 (1.6. 2.1,12. 15)
to:J

20•29

(2.0 •3.0,

14 .22)

to:J
41-52 (4.2 -5.3, 30-38)

~---- D_?

. 'J ~

~~~ 0
-t::;-.....~ /,
0

to:J
21-26 ./"

(2.1. 2.7, ,./"~/'
12 -1~)
fs\
19-~~7

~ to:J
16•21
Q

to:J
18. 21 ,
to:J
45_60 (1.6-2.1, 0
Ii]
6.3 _8.3
(1.8 •2.1, (4.6•6.1, 12•15)
1
(0.64•0.85,

to:J
16•19 13-15)
to:J
16•21 33•44)
(1.6 -1.9, (1.6-2.1,
to:J
16•21

12 -14)

12•15)

t"J
16•,.
f"-~
t"J
15•21
r::!
*
H
...----4lJ

~~'. '1~
J
r \~ ~~'..,:;
1,
~Q.
/¥i-;:
--'Il

1il3.7 -5.0
J~
--A)
to:J
16-21
~11V>/

(0.38 _0.51, A~ - (1.6.2.1,12•15)\...,//
~to:J
20.29(2.0-3.0, 14-22)
33.0 •44.3)
Y
&'/-
:f~l
to:J
20•26 (2.0 •2.7, 14-20)

to:J :
N'm (kg-m, fl-Ib)
to:J
16-21 (1.6 -2.1, 12-15)~/

Ii] :
N'm (kg-m, in-Ib) •

~ :Apply
liquidgasket.
*:
Refer toLC section
("Thermostat", "ENGINECOOLING SYSTEM").

G)
Oilfiller cap
@

Oilcatcher
@

Thermostat

@
Rocker cover
@

Oilfilter
@

Water inlet

@
PCVvalve
@

Water pipeassembly
@

Starter motor

@
Camshaft
positionsensor,igni-
@

Thermal transmitter
@

Power steering oilpump
tion coiland power transistor

@
Engine coolant temperature adjusting
bar
built intodistributor
sensor
@

Power
steering oilpump

@
Intake manifold supports

@
Thermostat housing bracket

@
Knock sensor

@
Airrelief plug

rJ)
Oilfilter bracket

EM-59

OUTERCOMPONENT PARTS
SEC.

to
18
to
22
N'm

(1.8
to
2.2 kg-m,

Tighten innumerical order.13to16ft-Ib).
~
2.9.3.8

(0.30 -0.39,
26.0 -33.9.)

1

I
{O.,'OgO

J{"ogO

?

~ ;N'm (kg-m, ft-Ib)

~ :N.m (kg-m, in-Ib)

SEM232F
G) Injector

@
Pressure regulator

@
Intake manifold
@ EGR tube
@ EGR valve
@

EGRC-BPT valve
(J) Intake manifold collector
@ Rod
@ Accel-drum unit

@)
Throttle position sensor
EM-60 @
Throttle body

@
IACV-air regulator

@
IACV-AAC valve

@
IACV-FICD solenoidvalve

SEC.118-140-230-275

~ :N.m (kg-m, in-Ib)

tc.J :
N'm (kg-m, ft-Ib)

D :Apply
liquidgasket.
(}) Oillevel gauge

@
Alternator adjustingbar

@
Compressor bracket

@
Alternator bracket
OUTER
COMPONENT PARTS
@
Water outlet

@
Drain plug

(J)
Crankcase ventilationoilsepa-
rator

EM-61
tc.J

37•48

(3.8 •4.9, 27.35)

tc.J
40.50 (4.1-5.1, 30-37)

SEM233F
@
Exhaust manifold

@
Heated oxygen sensor

@
Exhaust manifold cover
•