NISSAN ALMERA 2001 Service Manual

JEM206G
JEM207G
PISTON-TO-BORE CLEARANCENJEM0073S061. Using a bore gauge, measure cylinder bore in X and Y direc-
tions at A, B and C for wear, out-of-round and taper.
Cylinder bore inner diameter:
Standard
86.000 - 86.030 mm (3.3858 - 3.3870 in)
Wear limit
0.20 mm (0.0079 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder
block if necessary.
Out-of-round (X þ Y):
Limit 0.015 mm (0.0006 in)
Taper (AþBþC):
Limit 0.010 mm (0.0004 in)
2. Check for scratches and seizure. If seizure is found, hone it.
SEM258C
3. Measure piston skirt diameter.
Piston diameter ªAº:
Standard
85.920 - 85.950 mm (3.3827 - 3.3839 in)
Measuring point ªaº (Distance from the top):
58.0 mm (2.28 in)
4. Check that piston-to-bore clearance is within specification.
+Calculate the clearance by using outer diameter at piston skirt
and inner diameter of cylinder (direction of X, point B):
Piston-to-bore clearance = Cylinder bore ± Piston
diameter ªAº
Standard [at room temperature 20ÉC (68ÉF)]:
0.070 - 0.090 mm (0.0028 - 0.0035 in)
+If the value is out of the specified range, replace piston and
piston pin assembly.
JEM208G
+If cylinder block or pistons are replaced with new ones, select
piston as follows:
When using a new cylinder block:
+Identify the cylinder bore grade (No. 1, 2, or 3) on LH surface
at the rear of cylinder block and select a piston of the same
grade.
+The part No. of piston is specified together with the piston pin
as an assembly.
CYLINDER BLOCKYD
Inspection (Cont'd)
EM-147

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

Standard
0.003 mm (0.0001 in)
Limit
0.005 mm (0.0002 in)
JEM212G
3. Measure crankshaft runout at No. 3 (center) journal.
Runout (Total indicator reading):
Standard 0.05 mm (0.0020 in)
Limit 0.10 mm (0.0039 in)
JEM214G
MAIN BEARING HOUSING INNER DIAMETERNJEM0073S15+Without installing main bearings, install main bearing caps,
and tighten bolts to the specified torque.
+Measure the inner diameter of main bearing housing with a
bore gauge.
Standard:
66.654 - 66.681 mm (2.6242 - 2.6252 in) dia.
+If the measurement is out of the specified range, replace cyl-
inder block and main bearing caps.
JEM213G
BEARING CLEARANCENJEM0073S08+Use either of the following two methods, however, method ªAº
gives more reliable results and is preferable.
Method A (Using bore gauge & micrometer)
Main bearingNJEM0073S08011. Install main bearings to the cylinder block and bearing cap, and
tighten the bolts to the specified torque. Then, measure the
inner diameter of the main bearings.
Oil clearance = Bearing ID ± Crankshaft journal OD
Standard: 0.039 - 0.066 mm (0.0015 - 0.0026 in)
2. If the value is out of the specified range, select main bearings
to obtain the specified oil clearance, based on the measure-
ments of the main bearing housing inner diameter and crank-
shaft journal outer diameter.
CYLINDER BLOCKYD
Inspection (Cont'd)
EM-149

JEM208G
When using a new cylinder block and crankshaft:
1) Identify the bearing housing grade (No. 0, 1, or 2) on LH sur-
face at the rear of the cylinder block, and locate the applicable
grade on the ªGradeº row in the table below.
2) Identify the journal grade (No. 0, 1, or 2) on the front surface
of the crankshaft, and locate the applicable grade under the
ªGradeº column on the table.
3) The main bearing to be used (STD 0 to STD 4) can be located
in the cell where the row and column cross.
JEM215G
When re-using removed cylinder block and crankshaft:
1) Measure the inner diameter of cylinder block main bearing
housing.
2) Locate the applicable cell where the measurement falls, on
ªCylinder block main bearing housing IDº row on the table.
3) Measure the outer diameter of the crankshaft journal.
4) Locate the applicable cell where the measurement falls, under
ªCrankshaft journal ODº column on the table.
5) The main bearing to be used (STD 0 to STD 4) can be located
in the cell where the row and column cross.
Selective fitting for main bearing
Unit: mm (in)
Cylinder block main bearing housing ID66.654 - 66.663
(2.6242 - 2.6245)66.663 - 66.672
(2.6245 - 2.6249)66.672 - 66.681
(2.6249 - 2.6252)
Crankshaft journal
ODGrade
(punched)012
62.967 - 62.975
(2.4790 - 2.4793)0+Bearing grade No.
+Bearing thickness
+Oil clearance
+Identification colorSTD 0
1.816 - 1.820
(0.0715 - 0.0717)
0.039 - 0.066
(0.0015 - 0.0026)
BlackSTD 1
1.820 - 1.824
(0.0717 - 0.0718)
0.039 - 0.066
(0.0015 - 0.0026)
Red or BrownSTD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
Green
62.959 - 62.967
(2.4787 - 2.6790)1+Bearing grade No.
+Bearing thickness
+Oil clearance
+Identification colorSTD 1
1.820 - 1.824
(0.0717 - 0.0718)
0.039 - 0.066
(0.0015 - 0.0026)
Red or BrownSTD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
GreenSTD 3
1.828 - 1.832
(0.0720 - 0.0721)
0.039 - 0.066
(0.0015 - 0.0026)
Yellow
62.951 - 62.959
(2.4784 - 2.4787)2+Bearing grade No.
+Bearing thickness
+Oil clearance
+Identification colorSTD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
GreenSTD 3
1.828 - 1.832
(0.0720 - 0.0721)
0.039 - 0.066
(0.0015 - 0.0026)
YellowSTD 4
1.832 - 1.836
(0.0721 - 0.0723)
0.039 - 0.066
(0.0015 - 0.0026)
Blue
3. When the specified oil clearance is not obtained with standard
size main bearings, use undersized bearings.
+When an undersized bearing is used, measure the inner diam-
eter of the bearing while the bearing is installed. Grind crank-
shaft journal so that the specified oil clearance is obtained.
CYLINDER BLOCKYD
Inspection (Cont'd)
EM-150

JEM216G
Undersize bearing
Unit: mm (in)
Size Thickness
US 0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769)
CAUTION:
When grinding the crankshaft journal to use an undersize
bearing, avoid damaging the fillet R.
AEM027
Connecting Rod Bearing (Big end)NJEM0073S08021. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
Tighten bolts to the specified torque.
3. Measure inner diameter ªCº of connecting rod.
Inner diameter:
Standard 55.000 - 55.013 mm (2.1654 - 2.1659 in)
AEM034
4. Measure outer diameter ªDpº of each crankshaft pin journal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance=CþDp
Standard: 0.031 - 0.061 mm (0.0012 - 0.0024 in)
6. If it exceeds the standard, replace bearing.
JEM215G
When using a new crankshaft and connecting rods:
+Identify the pin diameter grade (No. 0, 1, or 2) on front surface
of crankshaft and select the connecting rod bearings of the
same grade.
+There is no grading for the inner diameter of the big end of the
connecting rod.
When re-using the removed crankshaft and connecting rods:
+Measure the inner diameter of the big end of the connecting
rod and make sure it is within the specified range.
+Measure the outer diameter of the crankshaft pin.
+Determine the crankshaft pin grade by comparing the mea-
surement with the values under the column ªCrankshaft pin
ODº of the table below. Choose the bearings of the same
grade.
CYLINDER BLOCKYD
Inspection (Cont'd)
EM-151

Selective fitting for connecting rod bearing
Unit: mm (in)
Connecting rod big end ID 55.000 - 55.013 (2.1654 - 2.1659)
Crankshaft pin OD Grade (punched) 0 (no punching)
51.968 - 51.974
(2.0460 - 2.0462)0+Bearing grade No.
+Bearing thickness
+Oil clearance
+Identification colorSTD 0
1.492 - 1.496
(0.0587 - 0.0589)
0.031 - 0.061
(0.0012 - 0.0024)
Black
51.961 - 51.968
(2.0457 - 2.0460)1+Bearing grade No.
+Bearing thickness
+Oil clearance
+Identification colorSTD 1
1.496 - 1.500
(0.0589 - 0.0591)
0.031 - 0.061
(0.0012 - 0.0024)
Brown
51.954 - 51.961
(2.0454 - 2.0457)2+Bearing grade No.
+Bearing thickness
+Oil clearance
+Identification colorSTD 2
1.500 - 1.504
(0.0591 - 0.0592)
0.031 - 0.061
(0.0012 - 0.0024)
Green
7. If clearance cannot be adjusted within the standard of any
bearing, grind crankshaft journal and use undersized bearing.
+When an undersized bearing is used, measure the inner diam-
eter of the bearing while the bearing is installed. Grind the pins
so that the specified oil clearance is obtained.
JEM216G
Undersize bearing
Unit: mm (in)
Size Thickness
US 0.08 (0.0031) 1.536 - 1.540 (0.0605 - 0.0606)
US 0.12 (0.0047) 1.556 - 1.560 (0.0613 - 0.0614)
US 0.25 (0.0098) 1.621 - 1.625 (0.0638 - 0.0640)
CAUTION:
When grinding the crankshaft journal to use an undersize
bearing, avoid damaging the fillet R.
Standard dimension R:
1.5 - 1.7 mm (0.0591 - 0.0669 in)
CYLINDER BLOCKYD
Inspection (Cont'd)
EM-152

EM142
Method B (Using plastigage)
CAUTION:
+Do not turn crankshaft or connecting rod while plastigage
is being inserted.
+When bearing clearance exceeds the specified limit,
ensure that the proper bearing has been installed. If incor-
rect bearing clearance exists, use a thicker or undersized
main bearing to ensure specified clearance.
SEM502G
MAIN BEARING CRUSH HEIGHTNJEM0073S16+When the bearing cap is removed after being tightened to the
specified torque with main bearings installed, the tip end of
bearing must protrude.
Standard: There must be crush height.
+If the standard is not met, replace main bearings.
JEM219G
MAIN BEARING CAP BOLT DEFORMATIONNJEM0073S17+Measure the outer diameter of threaded area, d1 and d2, at the
points specified in the figure.
+When the necked point is identified at a point other than where
specified, measure at the point as d2.
+Calculate the difference between d1 and d2.
Limit: 0.13 mm (0.0051 in)
SEM673E
CONNECTING ROD BUSHING CLEARANCE (SMALL
END)
NJEM0073S091. Measure inner diameter ªCº of bushing.
Inner diameter ªCº:
Standard 28.026 - 28.038 mm (1.1034 - 1.1039 in)
2. Measure outer diameter ªDpº of piston pin.
Outer diameter ªDpº:
Standard 27.994 - 28.000 mm (1.1021 - 1.1024 in)
3. Calculate connecting rod bushing clearance.
Connecting rod bushing clearance=CþDp
Standard: 0.026 - 0.044 mm (0.0010 - 0.0017 in)
Limit: 0.057 mm (0.0022 in)
If it exceeds the limit, replace connecting rod assembly and/or
piston set with pin.
CYLINDER BLOCKYD
Inspection (Cont'd)
EM-153

JEM220G
CONNECTING ROD BOLT DEFORMATIONNJEM0073S18+Install nuts to connecting rod bolts. Check that the nut can be
screwed smoothly on bolt threads by hand to the last thread
on the bolt.
+If the nut does not screw in smoothly, measure the outer diam-
eter of the bolt thread at the point specified in the figure.
+If a necked point is identified, measure at that point.
Standard: 8.90 - 9.00 mm (0.3504 - 0.3543 in) dia.
Limit: 8.75 mm (0. 3445 in) dia.
+If the measurement exceeds the limit, replace connecting rod
bolts and nuts.
AEM100
FLYWHEEL RUNOUTNJEM0073S11Runout (Total indicator reading):
FlywheelH
Less than 0.15 mm (0.0059 in)
CAUTION:
+The signal plate is built into the flywheel assembly. Be
careful not to damage the signal plate, especially the
teeth.
+Check the signal plate for deformation or cracks.
+Never place the flywheel assembly with the signal plate
facing down.
+Keep any magnetized objects away from the signal plate.
+Do not allow any magnetic materials to contact the signal
plate teeth.
JEM221G
OIL JETNJEM0073S19+Check nozzle for deformation or damage.
+Check oil passage for obstruction by blowing in air on nozzle
side.
+If abnormality is found, clean or replace.
JEM222G
OIL JET RELIEF VALVENJEM0073S20Using a clean resin rod, press down on the check valve inside relief
valve. Check for appropriate bounce/repulsion and smooth
operation.
CYLINDER BLOCKYD
Inspection (Cont'd)
EM-154

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

JEM213G
c. Be sure to install main bearings in the correct direction.
+Make sure those with oil holes or oil grooves are mounted on
the cylinder block side, and those without oil holes or oil
grooves are on the main cap side.
+Before installing, apply engine oil on the front (inner) surfaces
of bearings. Do not apply oil to the back surfaces, but thor-
oughly clean them.
+Align stopper notches on bearings and install.
+Check the oil holes on cylinder block and those on bearings
are aligned.
JEM225G
5. Install crankshaft to cylinder block.
+Make sure crankshaft rotates smoothly by hand.
6. Install main bearing caps.
+Identify main bearing caps by the punched mark. Install
correctly, matching the journal No. on the bearing cap and the
journal, with the front mark facing forward.
+Main bearing caps are commonly processed with the cylinder
block. Therefore, caps and cylinder block should be replaced
as a set.
JEM200G
JEM226G
7. Check the main bearing cap bolts for deformation.
Refer to EM-153, ªMAIN BEARING CAP BOLT DEFORMA-
TIONº.
8. Tighten the main bearing cap bolts according to the following
procedure:
a. Apply engine oil to the threaded part and seat surface of each
bolt.
b. Tighten to 25 to 30 N´m (2.5 to 3.1 kg-m, 18 to 22 ft-lb) in the
numerical order shown in the figure.
c. Put alignment marks (with paint) on each bolt and the main
bearing cap, all in the same direction. (when using a protrac-
tor)
d. Then, tighten 90É to 95É [target: 90É].
+Always use either an angle wrench (SST) or protractor
during angular tightening. Avoid tightening based on
visual checks alone.
+After tightening bolts to specified torque, make sure that crank-
shaft rotates smoothly.
+Check crankshaft end play. Refer to EM-144, ªCRANKSHAFT
END PLAYº.
9. Check the outer diameter of connecting rod bolts. Refer to
EM-154, ªCONNECTING ROD BOLT DEFORMATIONº.
10. Install piston to connecting rod.
CYLINDER BLOCKYD
Assembly (Cont'd)
EM-156