NISSAN ALMERA 2001 Service Manual

Removal and InstallationNJEM0099
SEM655G
PREPARATIVE WORKNJEM0099S01Remove engine cover.
JEM664G
ROCKER COVERNJEM0099S02RemovalNJEM0099S0201Loosen holding bolts in the reverse order of that shown in the fig-
ure and remove.
CAUTION:
Do not remove mass damper on top. If damper must be
removed, remove all traces of old locking sealant from threads
of bolts and holes, and apply new locking sealant on the bolts
before tightening.
InstallationNJEM0099S0202+Tighten holding bolts in the numerical order shown in the fig-
ure.
+Re-tighten to the same torque in the same order as above.
ROCKER COVERYD
Removal and Installation
EM-117

JEM248G
+Apply 3.0 mm (0.118 in) dia. of specified liquid gasket (Refer
to EM-77, ªLiquid Gasket Application Procedureº.) on locac-
tions shown in the figure.
ROCKER COVERYD
Removal and Installation (Cont'd)
EM-118

ComponentsNJEM0062
SEM504G
CYLINDER HEADYD
Components
EM-119

CAUTION:
+When installing camshafts, chain tensioners, oil seals, or
other sliding parts, lubricate contacting surfaces with new
engine oil.
+Apply new engine oil to threads and seat surfaces when
installing cylinder head, camshaft sprocket, crankshaft
pulley, and camshaft bracket.
+Attach tags to valve lifters so as not to mix them up.
RemovalNJEM0063PREPARATIVE WORKNJEM0063S011. Drain engine coolant. Refer to LC-44, ªChanging Engine Cool-
antº.
2. Remove exhaust manifold. Refer to EM-112, ªRemovalº.
3. Remove intake manifold. Refer to EM-108, ªRemovalº.
+Apply paint to camshaft sprockets for alignment during
installation.
JEM152G
CAMSHAFTNJEM0063S021. Remove the following parts:
+Rocker cover
+Vacuum pump and cylinder head rear cover assembly
+Spill tube
+High pressure injection nozzle assembly
+Secondary timing chain and associated parts
JEM159G
2. Remove camshaft sprockets.
+Holding the hexagonal part of the camshaft with a wrench
having 21 mm (0.83 in) width between facing flats, loosen the
bolt holding the camshaft sprocket.
JEM160G
3. Remove camshafts.
+Loosen bolts holding the camshaft bracket in several stages in
the reverse order of that shown in the figure, and remove them.
4. Remove adjusting shims and valve lifters.
+Confirm the correct location of each part removed. Store them
so they do not get mixed up.
+For re-installation, be sure to put mark on camshaft
bracket before removal.
CYLINDER HEADYD
Components (Cont'd)
EM-120

JEM149G
CYLINDER HEADNJEM0063S03+Loosen bolts in the reverse order of that shown in the figure
and remove them.
+Be careful not to damage the tips of glow plugs project-
ing out of the bottom surface of the cylinder head. To
avoid damage to glow plugs, either remove them
beforehand, or support cylinder head with wooden blocks
to create a space below the bottom surface.
DisassemblyNJEM0100
JEM150G
1. Remove adjusting shims and valve lifters. Confirm the correct
location of each part removed. Store them in order to avoid
mixing them up.
JEM151G
2. Remove valve collets.
+Compress valve spring with a valve spring compressor, and
remove valve collet with a magnet hand.
3. Remove valve spring retainers, and valve springs.
4. Push valve stem toward combustion chamber and remove
valve.
+Before removing valves, check valve guide clearance. Refer to
EM-124, ªVALVE GUIDE CLEARANCEº.
+Confirm the correct location of each valve. Store them so they
do not get mixed up.
CYLINDER HEADYD
Removal (Cont'd)
EM-121

JEM152G
+For the locations and arrangement of intake and exhaust
valves, refer to the figure.
JEM153G
5. Remove valve oil seals.
+Use a valve oil seal puller (SST) for removal.
6. Remove valve spring seats.
7. When removing valve seats, check valve seat contact. Refer
to EM-126.
8. Before removing valve guides, check valve guide clearance.
Refer to EM-124, ªVALVE GUIDE CLEARANCEº.
9. Remove glow plugs.
+To avoid damage, glow plugs should be removed only
when required.
+Handle with care to avoid applying shock. (When dropped
from approx. 100 mm (3.94 in) or higher, always replace
with a new one.)
SEM496G
InspectionNJEM0065CYLINDER HEAD DISTORTIONNJEM0065S01Clean surface of cylinder head.
Use a reliable straightedge and feeler gauge to check the flatness
of cylinder head surface.
Check along six positions shown in the figure.
Head surface flatness: Limit 0.04 mm (0.0016 in)
If beyond the specified limit, resurface or replace it.
The limit for cylinder head resurfacing is determined by the
cylinder block resurfacing.
Resurfacing limit:
Amount of cylinder head resurfacing is ªAº.
Amount of cylinder block resurfacing is ªBº.
The maximum limit: A+ B = 0.07 mm (0.0028 in)
After resurfacing cylinder head, check that camshaft rotates freely
by hand. If resistance is felt, cylinder head must be replaced.
Nominal cylinder head height:
153.9 - 154.1 mm (6.059 - 6.067 in)
CYLINDER HEADYD
Disassembly (Cont'd)
EM-122

CAMSHAFT VISUAL CHECKNJEM0065S02Check camshaft for scratches, seizure and wear.
JEM161G
CAMSHAFT RUNOUTNJEM0065S031. Place V-blocks on a work bench and support camshaft at No.
1 and No. 5 journal.
2. Set dial gauge perpendicularly at camshaft No. 3 journal.
3. Turn camshaft by hand in one direction and read runout on dial
gauge.
Runout (Total indicator reading):
Limit 0.02 mm (0.0008 in)
4. If it exceeds the limit, replace camshaft.
SEM549A
CAMSHAFT CAM HEIGHTNJEM0065S041. Measure camshaft cam height.
Standard cam height:
Intake
39.505 - 39.695 mm (1.5553 - 1.5628)
Exhaust
39.905 - 40.095 (1.5711 - 1.5785)
Cam wear limit:
0.2 mm (0.008 in)
2. If wear is beyond the limit, replace camshaft.
JEM162G
CAMSHAFT JOURNAL CLEARANCENJEM0065S051. Install camshaft bracket and tighten bolts to the specified
torque.
2. Measure inner diameter of camshaft bearing.
Standard inner diameter:
No. 1: 30.500 - 30.521 mm (1.2008 - 1.2016 in)
No. 2, 3, 4, 5: 24.000 - 24.021 mm (0.9449 - 0.9457 in)
SEM012A
3. Measure outer diameter of camshaft journal.
Standard outer diameter:
No. 1: 30.435 - 30.455 mm (1.1982 - 1.1990 in)
No. 2, 3, 4, 5: 23.935 - 23.955 mm (0.9423 - 0.9431 in)
4. If clearance exceeds the limit, replace camshaft and/or cylin-
der head.
Camshaft journal clearance:
Standard
No.1-5:0.045 - 0.086 mm (0.0018 - 0.0034 in)
Limit
0.045 - 0.086 mm (0.0018 - 0.0034 in)
CYLINDER HEADYD
Inspection (Cont'd)
EM-123

JEM163G
CAMSHAFT END PLAYNJEM0065S061. Install camshaft in cylinder head.
2. Measure camshaft end play.
Camshaft end play:
Standard
0.070 - 0.148 mm (0.0028 - 0.0058 in)
Limit
0.24 mm (0.0094 in)
+If the value exceeds the limit, replace camshaft and measure
again.
+If the measurement exceeds the limit again, replace cylinder
head.
JEM164G
CAMSHAFT SPROCKET RUNOUTNJEM0065S071. Install sprocket on camshaft.
2. Measure camshaft sprocket runout.
Runout (Total indicator reading):
Less than 0.15 mm (0.0059 in)
3. If it exceeds the limit, replace camshaft sprocket.
JEM155G
VALVE GUIDE CLEARANCENJEM0065S081. Check that valve stem diameter is within the specified range.
2. Push out valve approx. 25 mm (0.98 in) toward combustion
chamber. Swing valve in the direction of the dial gauge to
measure the runout.
+This inspection should be performed before removing valve
guides.
+Half of the runout reading on the dial gauge is the valve guide
clearance.
Standard:
Intake 0.020 - 0.053 mm (0.0008 - 0.0021 in)
Exhaust 0.040 - 0.073 mm (0.0016 - 0.0029 in)
3. If it exceeds the limit, check valve to valve guide clearance.
a. Measure valve stem diameter and valve guide inner diameter.
b. Check that clearance is within specification.
Valve to valve guide clearance limit:
Intake 0.08 mm (0.0031 in)
Exhaust 0.1 mm (0.004 in)
c. If it exceeds the limit, replace valve or valve guide.
CYLINDER HEADYD
Inspection (Cont'd)
EM-124

SEM008A
VALVE GUIDE REPLACEMENTNJEM0065S09+When a valve guide is removed, replace with an oversized [0.2
mm (0.008 in)] valve guide.
1. To remove valve guide, heat cylinder head to 110 to 130ÉC
(230 to 266ÉF) by soaking in heated oil.
SEM931C
2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2
US ton, 2.0 Imp ton) pressure] or hammer and suitable tool.
SEM932C
3. Ream cylinder head valve guide hole.
Valve guide hole diameter (for service parts):
10.175 - 10.196 mm (0.4006 - 0.4014 in)
JEM156G
4. Heat cylinder head to 110 to 130ÉC (230 to 266ÉF) and press
service valve guide onto cylinder head.
Projection ªLº:
10.4 - 10.6 mm (0.409 - 0.417 in)
5. Ream valve guide.
Finished size:
6.000 - 6.018 mm (0.2362 - 0.2369 in)
CYLINDER HEADYD
Inspection (Cont'd)
EM-125

SEM934C
JEM157G
VALVE SEATSNJEM0065S10+Before starting this check, confirm that the dimensions of valve
guides and valves are as specified.
+Apply red lead primer on contacting surfaces of valve seat and
of valve face to examine the conditions of contacting surfaces.
+Check that the paint on contacting surfaces is continuous
along the entire circumference.
+If there are abnormal indications, grind the valve and check the
contact again. If abnormal indications still persist, replace
valve seat.
SEM795A
REPLACING VALVE SEAT FOR SERVICE PARTSNJEM0065S111. Bore out old seat until it collapses. Boring should not continue
beyond the bottom face of the seat recess in cylinder head. Set
the machine depth stop to ensure this.
2. Ream cylinder head recess for service valve seat.
Oversize [0.5 mm (0.020 in)]:
Intake 30.500 - 30.516 mm (1.2008 - 1.2014 in)
Exhaust 29.500 - 29.516 mm (1.1614 - 1.1620 in)
Be sure to ream in circles concentric to the valve guide
center.
This will enable valve seat to fit correctly.
CYLINDER HEADYD
Inspection (Cont'd)
EM-126