engine NISSAN ALMERA 2001 Service Manual

JEM116G
13. For Europe only, remove catalyst rear diffuser, EM-110, ªCata-
lystº.
14. Remove upper oil pan bolts in reverse order.
15. Remove four engine-to-transaxle bolts using a universal
socket. (Commercial Service Tool).
16. Remove upper oil pan.
a. Insert an appropriate size tool into the notch of upper oil pan.
+Be careful not to damage aluminum mating surface.
+Do not insert screwdriver, or oil pan flange will be
deformed.
b. Pry off upper oil pan by moving the tool up and down.
c. Remove upper oil pan.
+Be careful to prevent No. 15 and 16 blots from falling into
transaxle case.
JEM117G
InstallationNJEM00561. Install upper oil pan.
a. Use a scraper to remove old liquid gasket from mating sur-
faces.
+Also remove old liquid gasket from mating surface of cyl-
inder block, front cover and lower oil pan.
+Remove old liquid gasket from the bolt hole and thread.
SEM159F
b. Apply a continuous bead of liquid gasket to mating surface of
aluminum oil pan.
+Use Genuine Liquid Gasket or equivalent.
JEM118G
c. Apply Genuine Liquid Gasket or equivalent, to areas shown in
the figure.
+At the 8 bolt holes markedH, liquid gasket should be
applied on the rims of the holes.
+Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
or 4.5 to 5.5 mm (0.177 to 0.217 in) wide. (Be careful that
the diameter of the silicon bead is different around the
front.)
+Attaching should be done within 5 minutes after coating.
OIL PANYD
Removal (Cont'd)
EM-91

JEM116G
d. Install upper oil pan.
+Tighten bolts in numerical order.
+Bolt dimensions vary depending on the installation location.
Refer to the following and use appropriate bolts.
M6 x 30 mm: Bolt No. 15, 16
M8 x 25 mm: Bolt No. 3, 4, 9, 10
M8 x 60 mm: Bolt No. 1, 2, 5, 6, 7, 8, 11, 12, 13, 14
+The shank length under the bolt neck above is the length of the
threaded part (pilot portion not included).
+Wait at least 30 minutes before refilling engine oil.
2. Install the four engine-to-transaxle bolts. For tightening torque,
refer to MT-24, ªInstallationº.
3. Install oil pan cover.
4. Install air compressor bracket.
: 57 - 65 N´m (5.8 - 6.7 kg-m, 42 - 48 ft-lb)
5. Install drive belts.
6. Install center member.
7. Install front and rear engine mounting insulator nuts and bolts.
JEM119G
8. Install crankshaft position sensor (TDC sensor).
+Tighten bolt while positioning and setting the side surface of
the crankshaft position sensor (TDC sensor) sleeve against
the arc of the upper oil pan.
9. Install front exhaust tube and its support.
10. Install oil strainer.
SEM493G
11. Install lower oil pan.
a. Use a scraper to remove old liquid gasket from mating sur-
faces.
+Also remove old liquid gasket from mating surface of
upper oil pan.
SEM159F
b. Apply a continuous bead of liquid gasket to mating surface of
lower oil pan.
+Use Genuine Liquid Gasket or equivalent.
OIL PANYD
Installation (Cont'd)
EM-92

SEM494G
+Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide.
+Attaching should be done within 5 minutes after coating.
JEM114G
c. Install lower oil pan.
+Tighten in numerical order shown in the figure.
+Wait at least 30 minutes before refilling engine oil.
OIL PANYD
Installation (Cont'd)
EM-93

Secondary Timing ChainNJEM0093CAUTION:
+After removing timing chain, do not turn crankshaft and
camshaft separately, or valves will strike piston heads.
+When installing camshafts, chain tensioners, oil seals, or
other sliding parts, lubricate contacting surfaces with new
engine oil.
+Apply new engine oil to bolt threads and seat surfaces
when installing camshaft sprockets, crankshaft pulley,
and camshaft brackets.
+When removing the oil pans, oil pump assembly and tim-
ing chain from engine, first remove the crankshaft posi-
tion sensor (TDC sensor).
Be careful not to damage sensor edges.
+Do not spill engine coolant on drive belts.
JEM120G
REMOVALNJEM0093S01+For preparative work for removing/installing secondary timing
chain to remove/install fuel injection pump, refer to EC-618,
ªElectronic control fuel injection pumpº.
+To prepare for removing/installing secondary timing chain to
remove/install camshaft, refer to EM-120, ªCAMSHAFTº.
1. Drain engine oil.
2. Drain coolant by removing cylinder block drain plugs. Refer to
LC-44, ªChanging Engine Coolantº.
TIMING CHAINYD
Secondary Timing Chain
EM-94

JEM121G
3. Remove front chain case.
+Move power steering fluid reservoir tank from the bracket.
+Loosen fixing bolts in the reverse order of that shown in the
figure and remove them.
+Remove No. 6, 10, and 11 bolts with the rubber washer as
space is limited for pulling them out.
SEM514G
CAUTION:
+While front chain case is removed, cover openings to pre-
vent entry of foreign material into engine.
+Do not remove two mass dampers on the back of cover.
SEM515G
4. Set the No. 1 piston to TDC on its compression stroke.
+Turn crankshaft pulley clockwise so that the alignment mark
(punched mark) on each camshaft sprocket is positioned as
shown in the figure.
+No position indicator is provided on the crankshaft pulley.
+When installing, color coded links on the secondary tim-
ing chain can be used as alignment marks. Marking may
not be necessary for removal; however, make alignment
marks as required because the alignment mark on fuel
injection pump sprocket may not be easy to see.
JEM124G
5. Remove chain tensioner.
a. Push the plunger of chain tensioner and keep it pressed with
a push pin.
JEM125G
b. Using a hexagon-head wrench (face to face: 5 mm, SST),
remove bolts to remove chain tensioner.
TIMING CHAINYD
Secondary Timing Chain (Cont'd)
EM-95

REMOVALNJEM0094S011. Remove engine and transaxle assembly. Refer to EM-137,
ªENGINE ASSEMBLYº.
2. Remove transaxle from engine. Place engine onto engine
stand (SST). Refer to EM-141, ªCYLINDER BLOCKº, ªDisas-
semblyº.
3. Remove the following parts:
+Oil pan (upper and lower)
Refer to EM-89, ªOIL PANº.
+Oil filter bracket
Refer to LC-32, ªOil Filter Bracketº.
+Injection tube
Refer to EC-614, ªInjection Tube and Injection Nozzleº.
4. Remove secondary timing chain and associated parts.
Refer to EM-94, ªSecondary Timing Chainº.
5. When removing rear chain case, remove camshaft sprockets.
Refer to EM-120, ªCAMSHAFTº.
JEM131G
6. Remove crankshaft pulley.
a. Hold crankshaft pulley with the pulley holder (SST).
b. Loosen crankshaft pulley fixing bolt and pull out the bolt
approximately 10 mm (0.39 in).
JEM132G
c. Using pulley puller (SST), remove crankshaft pulley.
+Use two M6 bolts with approx. 60 mm (2.36 in) shank length
for securing crankshaft pulley.
JEM133G
7. Remove oil pump.
+Loosen bolts in the reverse order of that shown in the figure
and remove them.
+Use seal cutter (SST) etc. for removal.
8. Remove front oil seal from oil pump.
+Punch out the seal off from the back surface of the oil pump
using a flat-bladed screwdriver.
+Be careful not to damage the oil pump.
TIMING CHAINYD
Primary Timing Chain (Cont'd)
EM-100

JEM140G
1. Install rear chain case.
a. Apply a continuous bead of specified liquid gasket (Refer to
EM-77, ªLiquid Gasket Application Procedureº.) on locations
shown in the figure.
A: Apply bead so that it does not protrude into the oil passage.
B, C: Minimize overlapping area of bead, by start and end
areas of bead as shown in the figure. Apply so that the portion
marked * comes at an external location but cannot be viewed
externally after engine assembly.
D: Leave the start and end areas of the bead slightly protrud-
ing from the case surface.
JEM141G
b. Install four O-rings to the grooves of the cylinder block, fuel
injection pump bracket.
JEM138G
c. Install rear chain case.
+When installing, align the dowel pin with the pin hole.
d. Tighten bolts in the numerical order shown in the figure.
+Install the following four types of bolts, referring to the figure.
16 mm (0.63 in): Bolt No. 1, 2, 16, 17, 18, 19, 20, 21, 22
20 mm (0.79 in): Bolt No. 3, 4, 6, 9, 10, 11, 13, 14
25 mm (0.98 in): Bolt No. 12, 15
35 mm (1.38 in): Bolt No. 5, 7, 8
+The shank length under the bolt neck above is the length of
threaded part (pilot portion not included).
e. After tightening all the bolts, re-tighten in the same order.
TIMING CHAINYD
Primary Timing Chain (Cont'd)
EM-103

JEM137G
2. Install power steering pump.
3. Install fuel injection pump.
+Before installing, make sure the notch on the fuel injection
pump flange and the hole 6 mm (0.24 in) in diameter on the
pump body are aligned.
4. Install chain guide and tension guides.
5. Install crankshaft sprocket, aligning it with the crankshaft key
on the far side.
JEM136G
6. Install primary timing chain with fuel injection pump sprocket.
+When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on the chain.
+Install fuel injection pump sprocket washer with the surface
marked ªFº (front mark) facing the front of the engine.
7. Install timing chain onto power steering pump sprocket and
through chain guide.
JEM135G
8. Use the positioning stopper pin (SST) to hold the fuel injection
pump sprocket and install the bolt.
+Using a TORX wrench (SST), turn the pump shaft little by little
to adjust the position of the pump flange. Insert positioning
stopper pin (SST) into the hole 6 mm (0.24 in) in diameter on
the fuel injection pump sprocket so that the stopper pin goes
through the pump flange to the pump body. While the stopper
pin is in place, install the bolt.
JEM134G
9. Install timing chain slack guide.
10. Install chain tensioner.
+Push the plunger of the chain tensioner. While keeping plunger
pressed down with a push pin, etc., install the chain tensioner.
+After installation, pull out the push pin holding the plunger.
+Check again that the alignment marks on the sprockets
and the colored alignment marks on timing chain are
aligned.
JEM142G
11. Install front oil seal to oil pump.
+Using a suitable drift [62 mm (2.44 in) dia.], force fit the seal
until it hits the bottom.
+Do not touch lips of oil seal. Make sure seal surfaces are
free of foreign materials.
TIMING CHAINYD
Primary Timing Chain (Cont'd)
EM-104

JEM143G
12. Install chain case cover (for opening for power steering pump
removal/installation) to oil pump.
+Apply a continuous bead of specified liquid gasket (Refer to
EM-77, ªLiquid Gasket Application Procedureº.) as shown in
the figure.
+Apply liquid gasket on oil pump-side surface.
JEM144G
13. Install oil pump.
a. Apply a continuous bead of specified liquid gasket (Refer to
EM-77, ªLiquid Gasket Application Procedureº.) on locations
shown in the figure.
A: Leave the start and end areas of the bead slightly protrud-
ing from the surface.
B: Apply liquid gasket along upper end surface of oil pump.
JEM145G
b. Install oil pump drive spacer to crankshaft.
+Install with the front mark (punched mark) facing the front of
the engine.
c. Install O-ring into the groove of rear chain case.
JEM133G
d. Install oil pump.
+When installing, align the inner rotor in the direction of the two
facing flats of the oil pump drive spacer.
+When installing, align the dowel pin with the pin hole.
e. Tighten fixing bolts in the numerical order shown in the figure.
f. After tightening all the bolts, re-tighten in the same order.
JEM146G
14. Check gaps on upper oil pan mounting surface.
+Using straightedge and feeler gauge, measure gaps between
the locations of the following parts:
Standard:
Oil pump and rear chain case
±0.14 to 0.14 mm (±0.0055 to 0.0055 in)
Rear chain case and cylinder block
±0.25 to 0.13 mm (±0.0098 to 0.0051 in)
+If the measured value is out of the above range, install again.
TIMING CHAINYD
Primary Timing Chain (Cont'd)
EM-105

Removal and InstallationNJEM0109
SEM487GA
SEM565G
PREPARATIVE WORKNJEM0109S011. Drain engine coolant. Refer to LC-44, ªChanging engine cool-
antº.
2. Remove engine cover. Refer to the figure at left.
3. Remove injection tube.
4. Remove blow-by hose (on rocker cover side).
5. Remove or relocate fuel pipes.
6. Remove or relocate wires/harnesses and tubes/pipes.
INTAKE MANIFOLDYD
Removal and Installation
EM-107