NISSAN PRIMERA 1999 Electronic Repair Manual

4. Measure outside diameter ªDpº of crankshaft pin journal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance = CþDp
Standard:
0.031 - 0.055 mm (0.0012 - 0.0022 in)
IIf it exceeds the limit, replace the bearing.
IIf crankshaft pin journal is worn or shows any abnormality,
regrind crank pin and use undersized bearings to maintain the
specified oil clearance.
IRefer to SDS for regrinding diameter of crankshaft pin and
available service parts (EM-200).
IWhen regrinding crankshaft pin, do not grind fillet-roll.
Selective connecting rod bearing
IIf either bearings or crankshaft are being replaced with new
ones, select connecting rod bearings according to the follow-
ing table. Grade numbers are punched in either Arabic or
Roman numerals.
Crankshaft pin journal grade number
012
Connecting rod bearing grade
number012
Identification color
Grade 0: Black
Grade 1: Yellow
Grade 2: Blue
CONNECTING ROD AND PISTON PIN CLEARANCE
(Small end)
Clearance (D þ d):
0.025 - 0.044 mm (0.0010 - 0.0017 in)
IIf clearance exceeds the specifications, replace the bearing.
SEM361D Counter weight
Pin journal
.Maintain more than 0.13 mm (0.051 in)
SEM705D
SEM575B Clearance=Dþd
CYLINDER BLOCKCD20T
Inspection (Cont'd)
EM-171

Bearing replacement
IRemove bearing with a suitable tool.
Do not scratch inner surface of connecting rod.
1. Install new bearing with oil holes aligned correctly.
2. Ream bore using a suitable tool.
Ream bore:
28.025 - 28.038 mm (1.1033 - 1.1039 in)
CONNECTING ROD BEND AND TORSION
Bend and torsion [per 100 mm (3.94 in) length]:
Bend Less than 0.025 mm (0.0010 in)
Torsion Less than 0.025 mm (0.0010 in)
CRANKSHAFT
1. Check crankshaft journals and pins for score, bias, wear or
cracks. If faults are minor, correct with fine emery paper.
2. Check journals and pins with a micrometer for taper and out-
of-round.
Out-of-round (XþY):
Less than 0.005 mm (0.0002 in)
Taper (AþB):
Less than 0.005 mm (0.0002 in)
3. Check crankshaft runout.
Runout (Total indicator reading):
Less than 0.05 mm (0.0020 in)
SEM906
SEM907
EM133
SEM316A Taper:
Out-of-round:
.SEM601A
CYLINDER BLOCKCD20T
Inspection (Cont'd)
EM-172

CYLINDER BLOCK DISTORTION
Clean upper face of cylinder block and measure the distortion.
Limit:
0.10 mm (0.0039 in)
If out of specification, resurface it.
The resurfacing limit of cylinder block is determined by cylin-
der head resurfacing in an engine.
Amount of cylinder head resurfacing is ªAº.
Amount of cylinder block resurfacing is ªBº.
The maximum limit is as follows:
A + B = 0.1 mm (0.004 in)
Nominal cylinder block height from crankshaft center:
227.75 - 227.85 mm (8.9665 - 8.9705 in)
If necessary, replace cylinder block.
CYLINDER BORE
1. Check for scratches or seizure. If seizure is found, hone bore.
2. Using a bore gauge, measure cylinder bore for wear, out-of-
round or taper.
Standard bore diameter:
84.500 - 84.550 mm (3.3268 - 3.3287 in)
Unit: mm (in)
Bore wear limit0.2 (0.008)
Out-of-round (X þ Y) standard0.015 (0.0006)
Taper (A þ B) standard0.010 (0.0004)
If it exceeds the limit, rebore all four cylinders. Replace cylinder
block if necessary.
If cylinder block or piston is replaced, match piston grade with
grade number on cylinder block upper surface.
SEM655A Measuring points
Warpage of surface:
Less than 0.1 mm (0.004 in)
NEM210
H = 227.75-227.85 mm
(8.9665-8.9705 in)
SEM704DA
CYLINDER BLOCKCD20T
Inspection (Cont'd)
EM-173

Reboring
1. The size to which cylinders must be honed, is determined by
adding piston-to-cylinder clearance to the piston skirt diameter
ªAº.
Dimension ªaº:
Approximately 62 mm (2.44 in)
Rebored size calculation
D=A+BþC=A+[0.03 to 0.05 mm
(0.0012 to 0.0020 in)]
where,
D: Honed diameter
A: Skirt diameter as measured
B: Piston-to-wall clearance
C: Machining allowance
0.02 mm (0.0008 in)
2. Install main bearing caps and tighten bolts to the specified
torque. This will prevent distortion of cylinder bores.
3. Cut cylinder bores in the order of 2-4-1-3.
Do not cut too much out of the cylinder bore at a time. Cut only
0.05 mm (0.0020 in) or so in diameter at a time.
4. Hone the cylinders to the required size referring to SDS (EM-
199).
5. Measure the finished cylinder bore for out-of-round and taper.
Measurement of a just machined cylinder bore requires
utmost care since it is expanded by cutting heat.
PISTON-TO-BORE CLEARANCE
Using micrometer
1. Measure piston and cylinder bore diameter.
Piston diameter ªAº:
Refer to SDS (EM-199).
Measuring point ªaº (Distance from the bottom):
Approximately 62 mm (2.44 in)
Bore diameter ªDº:
Refer to SDS (EM-199).
Measuring point (Distance from the top):
Approximately 70 mm (2.76 in)
2. Check that piston clearance is within the specification.
Piston clearance (D þ A):
0.030 - 0.050 mm (0.0012 - 0.0020 in)
SEM176B Piston grade number
Front
SEM904-A
CYLINDER BLOCKCD20T
Inspection (Cont'd)
EM-174

Using feeler gauge
1. Set piston and feeler gauge with spring scale.
2. Measure extracting force while pulling up scale slowly.
Feeler gauge used:
0.05 - 0.07 mm (0.0020 - 0.0028 in)
Extracting force:
7.8 - 14.7 N (0.8 - 1.5 kg, 1.8 - 3.3 lb)
Assembly
PISTON
INumbers stamped on connecting rod and cap correspond
to each cylinder. Care should be taken to avoid a wrong
combination including bearing and connecting rod direc-
tion.
IInstall new snap ring on one side of piston pin hole.
IWhen assembling piston and connecting rod with piston
pin, heat piston to between 60 and 80ÉC (140 and 176ÉF)
and install piston pin with a suitable tool.
IInstall new snap ring.
IAfter assembling, ascertain that piston swings smoothly.
IInstall piston rings with a suitable tool.
Selective top ring; When installing new top ring or replacing
cylinder block, select top ring to adjust ring gap.
Cylinder bore grade
1, 2, 3 4, 5
Top ring grade No. No mark S
CRANKSHAFT
1. Set main bearings in the proper position on cylinder block and
main bearing caps.
IIf either crankshaft, cylinder block or main bearing is
reused again, it is necessary to measure main bearing
clearance.
IUpper bearings (cylinder block side) have oil groove.
IApply new engine oil to bearing surfaces.
SEM550
SEM703D
EM156
SEM251D Punch mark side up
Teflon tube
set position
SEM617 Front
CYLINDER BLOCKCD20T
Inspection (Cont'd)
EM-175

2. Apply engine oil to main bearing surfaces on crankshaft jour-
nal side.
3. Install crankshaft and main bearing caps.
4. Tighten main bearing cap bolts.
: 69 - 78 N´m (7.0 - 8.0 kg-m, 51 - 58 ft-lb)
IArrange the parts so that the indicated numbers on bear-
ing caps are in a row from the front of engine.
ITighten bearing cap bolts gradually in two or three stages
and outwardly from center bearing in sequence.
IAfter securing bearing cap bolts, ascertain that crankshaft
turns smoothly.
IApply new engine oil to threads of bearing cap bolts.
5. Measure crankshaft free end play at center bearing.
Crankshaft free end play:
Standard
0.05 - 0.18 mm (0.0020 - 0.0071 in)
Limit
0.30 mm (0.0118 in)
PISTON WITH CONNECTING ROD
1. Install connecting rod bearings in the connecting rods and
connecting rod caps.
IConfirm that correct size of bearings is used.
Refer to ªInspectionº (EM-170).
IInstall the bearings so that the oil hole in the connecting rod
aligns with the oil hole of the bearing.
IApply engine oil to connecting rod bearing surfaces on
the crankshaft journal side.
ISet piston rings as shown.
NEM377 Bearing No.
Engine
front
SEM362F Engine front
Tighten in numerical order.
SEM363F Feeler gauge
SEM159B Align oil hole.
SEM909
CYLINDER BLOCKCD20T
Assembly (Cont'd)
EM-176

2. Install pistons with connecting rods.
IInstall them into corresponding cylinder using Tool.
IBe careful not to scratch cylinder wall with connecting
rod.
IApply engine oil to cylinder wall, piston and bearing.
IArrange so that the front mark on piston head faces to the
front of engine.
3. Install connecting rod bearing caps.
IApply engine oil to the thread of connecting rod bearing
nut.
(1) Tighten connecting rod bearing nut to 15 1 N´m (1.5 0.1 kg-m,
10.8 0.7 ft-lb).
(2) Then tighten an additional 60
+5É
þ0Éturns with an angular tighten-
ing wrench.
: 15 1 N´m (1.5 0.1 kg-m, 11 0.7 ft-lb) plus
60+5É
þ0Éor
: 37 - 45 N´m (3.8 - 4.6 kg-m, 27 - 33 ft-lb)
4. Measure connecting rod side clearance.
Connecting rod side clearance (Big end play):
Limit
0.3 mm (0.012 in)
FLYWHEEL RUNOUT
Runout (Total indicator reading):
Less than 0.15 mm (0.0059 in)
SEM620-A EM03470000 or suitable tool
SEM364F KV10112100
SEM365F Feeler gauge
EM426
CYLINDER BLOCKCD20T
Assembly (Cont'd)
EM-177

General SpecificationsNCEM0028
EngineQG16DE QG18DE
ClassificationGasoline
Cylinder arrangement4, in-line
Displacement
cm
3(cu in)1,596 (97.39) 1,769 (107.94)
Bore´stroke
mm (in)76.0´88.0 (2.992´3.465) 80.0´88.0 (3.150´3.465)
Valve arrangementDOHC
Firing order1-3-4-2
Number of piston ringsCompression 2
Oil 1
Number of main bearings5
Compression ratio9.5
EM120
abcde f
Valve timingQG16DE 222É 228É -4É (16É) 52É (32É) þ2É 44É
QG18DE 222É 236É 0É (20É) 56É (36É) þ2É 44É
( ): Valve timing control ON
Compression PressureNJEM0029Unit: kPa (bar, kg/cm2, psi)/350 rpm
Standard1,324 (13.24, 13.5, 192)
Minimum1,128 (11.28, 11.5, 164)
Difference limit between cylinders 98 (0.98, 1.0, 14)
Cylinder HeadNCEM0030Unit: mm (in)
Standard Limit
Head surface flatness Less than 0.03 (0.0012) 0.1 (0.004)
Height 117.8 - 118.0 (4.638 - 4.646) Ð
SERVICE DATA AND SPECIFICATIONS (SDS)QG
General Specifications
EM-178

ValveNCEM0031VA LV ENCEM0031S01Unit: mm (in)
SEM188A
T (Margin thickness)
Valve head diameter ªDºIntake 29.9 - 30.2 (1.177 - 1.189)
Exhaust 24.9 - 25.2 (0.980 - 0.992)
Valve length ªLºIntake 92.00 - 92.50 (3.6220 - 3.6417)
Exhaust 92.37 - 92.87 (3.6366 - 3.6563)
Valve stem diameter ªdºIntake 5.465 - 5.480 (0.2152 - 0.2157)
Exhaust 5.445 - 5.460 (0.2144 - 0.2150)
Valve face angle ªaº45É15¢- 45É45¢
Valve margin ªTº limitMore than 0.5 (0.020)
Valve stem end surface grinding limit 0.2 (0.008)
VALVE SPRINGNCEM0031S02
Free height
mm (in)40.0 (1.575)
Pressure N (kg, lb) at height mm (in)Standard 370.0 (37.73, 83.19) at 23.64 (0.9307)
Limit 347.8 (35.46, 78.19) at 23.64 (0.9307)
Out-of-square mm (in)Less than 1.75 (0.0689)
VALVE LIFTERNCEM0031S10Unit: mm (in)
Valve lifter outside diameter 29.960 - 29.975 (1.1795 - 1.1801)
Lifter guide inside diameter 30.000 - 30.021 (1.1811 - 1.1819)
Clearance between valve lifter and valve lifter guide 0.025 - 0.061 (0.0010 - 0.0024)
VALVE CLEARANCENCEM0031S11Unit: mm (in)
For adjusting For checking
Hot Cold* (reference data) Hot
Intake 0.32 - 0.40 (0.013 - 0.016) 0.25 - 0.33 (0.010 - 0.013) 0.21 - 0.49 (0.008 - 0.019)
Exhaust 0.37 - 0.45 (0.015 - 0.018) 0.32 - 0.40 (0.013 - 0.016) 0.30 - 0.58 (0.012 - 0.023)
*: At a temperature of approximately 20ÉC (68ÉF)
Whenever valve clearances are adjusted to cold specifications, check that the clearances satisfy hot specifications and adjust
again if necessary.
SERVICE DATA AND SPECIFICATIONS (SDS)QG
Valve
EM-179

VALVE GUIDENCEM0031S04Unit: mm (in)
MEM096A
Intake Exhaust
Standard Service Standard Service
Valve guideOuter diameter9.523 - 9.534 (0.3749
- 0.3754)9.723 - 9.734 (0.3828
- 0.3832)9.523 - 9.534 (0.3749
- 0.3754)9.723 - 9.734 (0.3828
- 0.3832)
Inner diameter
[Finished size]5.500 - 5.515 (0.2165 - 0.2171) 5.500 - 5.515 (0.2165 - 0.2171)
Cylinder head valve guide hole diameter9.475 - 9.496 (0.3730
- 0.3739)9.685 - 9.696 (0.3813
- 0.3817)9.475 - 9.496 (0.3730
- 0.3739)9.685 - 9.696 (0.3813
- 0.3817)
Interference fit of valve guide0.027 - 0.059 (0.0011 -
0.0023)0.027 - 0.049 (0.0011 -
0.0019)0.027 - 0.059 (0.0011 -
0.0023)0.027 - 0.049 (0.0011 -
0.0019)
Stem to guide clearance 0.020 - 0.050 (0.0008 - 0.0020) 0.040 - 0.070 (0.0016 - 0.0028)
Valve deflection limit (Dial gauge reading) 0.2 (0.008)
Projection length ªLº 11.5 - 11.7 (0.453 - 0.461)
AVAILABLE SHIMSNCEM0031S07
Thickness mm (in) Identification mark
2.00 (0.0787) 2.00
2.02 (0.0795) 2.02
2.04 (0.0803) 2.04
2.06 (0.0811) 2.06
2.08 (0.0819) 2.08
2.10 (0.0827) 2.10
2.12 (0.0835) 2.12
2.14 (0.0843) 2.14
2.16 (0.0850) 2.16
2.18 (0.0858) 2.18
2.20 (0.0866) 2.20
2.22 (0.0874) 2.22
2.24 (0.0882) 2.24
2.26 (0.0890) 2.26
2.28 (0.0898) 2.28
2.30 (0.0906) 2.30
2.32 (0.0913) 2.32
SERVICE DATA AND SPECIFICATIONS (SDS)QG
Valve (Cont'd)
EM-180