service NISSAN ALMERA 2001 Service Manual

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

+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

SEM509G
When re-using a removed cylinder block:
+Measure the inner diameter of the cylinder block bore.
+Determine the bore grade by comparing the measurement with
the values under ªCylinder bore IDº of the table below. Choose
a piston of the same grade.
Selective fitting for piston:
Unit: mm (in)
Grade (punched) 1 2 3
Cylinder bore ID86.000 - 86.010
(3.3858 - 3.3862)86.010 - 86.020
(3.3862 - 3.3866)86.020 - 86.030
(3.3866 - 3.3870)
Piston OD85.920 - 85.930
(3.3827 - 3.3831)85.930 - 85.940
(3.3831 - 3.3835)85.940 - 85.950
(3.3835 - 3.3839)
5. Determine piston oversize according to amount of cylinder
wear.
+For oversize pistons, 0.25 and 0.5OS [0.25 mm (0.0098 in),
0.5 mm (0.0197 in) oversize] are available as service parts.
Refer to SDS, EM-167. When using an oversize piston,
hone cylinder so that the clearance between piston and
cylinder becomes the specified value. Be sure to use
appropriate oversize piston ring for the oversize piston.
6. Cylinder bore size is determined by adding piston-to-bore
clearance to piston diameter ªAº.
Rebored size calculation: D = A+BþC
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
7. Cut cylinder bores.
+When any cylinder needs boring, all other cylinders must
also be bored.
+Do not cut too much out of cylinder bore at a time. Cut
only 0.05 mm (0.0020 in) or so in diameter at a time.
8. Hone cylinders to obtain specified piston-to-bore clearance.
9. Measure finished cylinder bore for out-of-round and taper.
+Measurement should be done after cylinder bore cools
down.
SEM316A
CRANKSHAFTNJEM0073S071. Check crankshaft main and pin journals for score, wear or
cracks.
2. With a micrometer, measure journals for taper and out-of-
round.
Out-of-round (X þ Y):
Standard
0.003 mm (0.0001 in)
Limit
0.005 mm (0.0002 in)
Taper (A þ B):
CYLINDER BLOCKYD
Inspection (Cont'd)
EM-148

AssemblyNJEM0074PISTONNJEM0074S011. With using snap ring pliers, install snap rings to grooves at the
rear side of the piston.
+Install securely to fully fit into the groove.
2. Install piston to the connecting rod.
+Heat the piston with an industrial drier to 60 to 70ÉC (140 to
158ÉF) so that the piston pin can be easily inserted by finger.
Then, insert the piston pin from the front of the piston into the
piston and into the connecting rod.
JEM227G
+Assemble so that the front mark on the piston top surface and
cylinder No. stamped on connecting rod are positioned as
shown in the figure.
3. Install snap ring on piston front.
+Refer to step 1. above for notes for installation.
+After installing, check that the connecting rod moves smoothly.
4. Install piston rings using piston ring expander (Commercial
Service Tool).
+Be extremely careful to avoid any damage to the piston.
JEM228G
+Install top ring and second ring with the punched surface fac-
ing upward.
Identification mark:
Top ring AE
Second ring AE2
+Install rings so that three closed gap position 120É apart one
another.
+Closed gaps do not need to face in a specific directions, as
long as each are positioned 120É apart.
JEM223G
CRANKSHAFTNJEM0074S021. Blow air sufficiently into the coolant passage, oil passage in the
cylinder block, inside of crankshaft case, and inside of cylinder
bores to remove any foreign materials.
2. Install oil jet relief valves.
3. Install oil jets.
JEM224G
4. Install main bearings and thrust bearings.
a. Remove debris, dust, and oil from the locations on the cylin-
der block and main bearing caps where bearings are installed.
b. Install thrust bearing on each side of cylinder block No. 3
housing.
+Install thrust bearings with oil groove facing in the direction of
the crankshaft arm (outside).
CYLINDER BLOCKYD
Assembly
EM-155

JEM229G
11. Install connecting rod bearing to connecting rod and connect-
ing rod cap.
+Before installing, apply engine oil on the front (inner) surface
of bearing. Do not apply oil to the back surface, but thoroughly
clean it.
+Align stopper notches on connecting rod and protrusions on
bearing and install.
JEM230G
12. Install piston and connecting rod assembly to crankshaft.
+Set crankshaft pin of the installation location at BDC.
+Match the cylinder No. of connecting rod to the location of cyl-
inder.
+Using piston ring compressor (Commercial Service Tool),
install so that the front mark on the piston top surface faces in
the direction of engine front.
JEM227G
13. Install connecting rod caps.
+Match the cylinder No. punched on connecting rod and that on
cap.
+Make sure that the front mark on connecting rod cap faces
towards the front of the engine.
JEM231G
JEM232G
14. Tighten connecting rod nuts according to the following proce-
dure:
a. Apply engine oil on bolt threads and seat surface of nuts.
b. Tighten to 29 to 30 N´m (2.9 to 3.1 kg-m, 21 to 22 ft-lb).
c. Loosen completely to 0 N´m (0 kg-m, 0 in-lb).
d. Tighten to 19 to 20 N´m (1.9 to 2.1 kg-m, 14 to 15 ft-lb).
e. Tighten 120É to 125É [target: 120É]. (angular tightening)
+Always use either an angle wrench (SST) or protractor
during angular tightening. Avoid tightening based on
visual checks alone.
+After tightening nuts, check that crankshaft rotates smoothly.
+Check connecting rod side clearance. Refer to EM-144, ªCON-
NECTING ROD SIDE CLEARANCEº.
15. Force fit rear oil seal into rear oil seal retainer.
+Using a drift [105 mm (4.13 in) dia.], force fit so that the dimen-
sion is as specified in the figure.
+Avoid inclined fitting. Force fit perpendicularly.
CYLINDER BLOCKYD
Assembly (Cont'd)
EM-157

JEM233G
16. Install rear oil seal retainer.
+Apply a continuous bead of specified liquid gasket (Refer to
EM-77, ªLiquid Gasket Application Procedureº.) on locations
shown in the figure.
JEM234G
17. Install pilot bushing.
+Force fit with the drift [approx. 19 mm (0.75 in) dia.].
SEM513G
18. Install fuel injection pump bracket.
+Install insulator according to the shape of the block, and secure
by placing the bracket against the insulator. (Not installed on
some models)
+Align the bracket with the dowel pins on the block to install.
+The two bolts used for dowel pins have a longer shanks than
the other two.
+Check the protruding distance of the dowel pin for fuel injec-
tion pump.
Standard: 13.0 - 15.0 mm (0.512 - 0.591 in)
19. Install parts to the engine in the reverse order of disassembly.
+Tighten bolts securing brackets of auxiliary components (A/C
compressor, alternator) to the specified torque.
: 57 - 65 N´m (5.8 - 6.7 kg-m, 42 - 48 ft-lb)
20. Remove engine from engine stand in the reverse order of
assembly.
21. Install flywheel.
+Holding ring gear with ring stopper (SST), tighten securing
bolts with TORX-socket (size: Q8 E20, Commercial Service
Tool).
+Tighten bolts uniformly in a crisscross manner.
SEM500GA
REPLACEMENT OF PILOT BUSHINGNJEM0074S031. Remove pilot bushing using tool or suitable tool.
CYLINDER BLOCKYD
Assembly (Cont'd)
EM-158

General SpecificationsNJEM0075
Cylinder arrangementIn-line 4
Displacement cm
3(cu in)2,184 (133.27)
Bore and stroke mm (in)86 x 94 (3.39 x 3.70)
Valve arrangementDOHC
Firing order1-3-4-2
Number of piston ringsCompression 2
Oil 1
Number of main bearings5
Compression ratio18.0
Compression PressureNJEM0076Unit: kPa (bar, kg/cm2, psi)/200 rpm
Compression pressureStandard 3,138 (31.4, 32.0, 455)
Minimum 2,452 (24.5, 25.0, 356)
Differential limit between cylinders 490 (4.9, 5.0, 71)
Belt DeflectionNJEM0111
Applied belt Belt specificationBelt deflection with 98 N (10 kg, 22 lb) force applied*
mm (in)
New AdjustedLimit for re-tighten-
ing
Air conditioner compressor belt HA type low edge belt4-5
(0.16 - 0.20)6-7
(0.24 - 0.28)8.5 (0.335)
Alternator & water pump beltHA type low-edge wide angle
belt9.0 - 10.5
(0.354 - 0.413)11.0 - 12.5
(0.433 - 0.492)16.5 (0.650)
*: When engine is cold.
Cylinder HeadNJEM0077Unit: mm (in)
Standard Limit
Head surface distortion Less than 0.03 (0.0012) 0.04 (0.0016)
JEM204G
SERVICE DATA AND SPECIFICATIONS (SDS)YD
General Specifications
EM-160

ValveNJEM0078VALVENJEM0078S01Unit: mm (in)
SEM188
Valve head diameter ªDºIntake 28.0 - 28.3 (1.102 - 1.114)
Exhaust 26.0 - 26.3 (1.024 - 1.035)
Valve length ªLºIntake 106.72 (4.2016)
Exhaust 106.36 (4.1874)
Valve stem diameter ªdºIntake 5.965 - 5.980 (0.2348 - 0.2354)
Exhaust 5.945 - 5.960 (0.2341 - 0.2346)
Valve seat angle ªaºIntake
45É15¢- 45É45¢
Exhaust
Valve margin ªTºIntake 1.38 (0.0543)
Exhaust 1.48 (0.0583)
Valve margin ªTº limitMore than 1.0 (0.039)
Valve stem end surface grinding limit Less than 0.2 (0.008)
VALVE CLEARANCENJEM0078S02Unit: mm (in)
Cold Hot* (reference data)
Intake 0.24 - 0.32 (0.009 - 0.013) 0.274 - 0.386 (0.011 - 0.015)
Exhaust 0.26 - 0.34 (0.010 - 0.013) 0.308 - 0.432 (0.012 - 0.017)
*: Approximately 80ÉC (176ÉF)
AVAILABLE SHIMSNJEM0078S03
Thickness mm (in) Identification mark
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
SERVICE DATA AND SPECIFICATIONS (SDS)YD
Valve
EM-161

Thickness mm (in) Identification mark
2.30 (0.0906) 2.30
2.32 (0.0913) 2.32
2.34 (0.0921) 2.34
2.36 (0.0929) 2.36
2.38 (0.0937) 2.38
2.40 (0.0945) 2.40
2.42 (0.0953) 2.42
2.44 (0.0961) 2.44
2.46 (0.0969) 2.46
2.48 (0.0976) 2.48
2.50 (0.0984) 2.50
2.52 (0.0992) 2.52
2.54 (0.1000) 2.54
2.56 (0.1008) 2.56
2.58 (0.1016) 2.58
2.60 (0.1024) 2.60
2.62 (0.1031) 2.62
2.64 (0.1039) 2.64
2.66 (0.1047) 2.66
2.68 (0.1055) 2.68
2.70 (0.1063) 2.70
2.72 (0.1071) 2.72
2.74 (0.1079) 2.74
SEM512G
VALVE SPRINGNJEM0078S04
Free height mm (in) Outer 42.3 (1.6654)
Pressure N (kg, lb) at height mm (in) Outer 366 (37.3, 82.2) at 24.82 (0.9772)
Out-of-square mm (in) Outer Limit 2.1 (0.083)
VALVE LIFTERNJEM0078S05Unit: mm (in)
Valve lifter outer diameter 29.960 - 29.975 (1.1795 - 1.1801)
SERVICE DATA AND SPECIFICATIONS (SDS)YD
Valve (Cont'd)
EM-162