NISSAN ALMERA N15 1995 Service Manual

SEM145D
VALVE
CLEARANCE
[QKJ
Adjusting (Cont'd)

3. Rotate Tool(A)(See figure.) sothat valve lifterispushed
down.
4. Place Tool(8)between camshaft andvalve liftertoretain
valve lifter.

CAUTION:

• 'Tool (B)must beplaced asclose tocamshaft bracketas
possible.
• Becareful nottodamage camsurface with'Tool (B).
5. Remove Tool(A).
6. Remove adjusting shimusing asmall screwdriver anda
magnetic finger.
7. Determine replacement adjustingshimsizefollowing for-
mula.
• Using amicrometer determinethicknessofremoved shim.
• Calculate thicknessofnew adjusting shimsovalve clear-
ance comes within
specified
values.
R
=
Thickness ofremoved shim
N
=
Thickness ofnew shim
M
=
Measured valveclearance
Intake:
N
=
R
+
[M -0.37 mm(0.0146 in)]
Exhaust:
N
=
R
+
[M -0.40 mm(0.0157 in)]
Shims areavailable in50 sizes from2.00mm(0.0787 in)to2.98
mm (0.1173 in),insteps of0.02 mm(0.0008 in).
• Select newshim withthickness asclose aspossible tocal-
culated value.

Shim Type A
Indicate
T
=
2.68
mm
(0.1055 In)
Type B
SEM104FEM-42

VALVECLEARANCE
[]K]

Adjusting (Cont'd)

8. Install newshim using asuitable tool.

• Install withthesurface onwhich thethickness isstamped
facing down.

9. Place Tool(A)asmentioned insteps 2and 3.
10. Remove Tool(B).
11. Remove Tool(A).
12. Recheck valveclearance.

Valve clearance:
Unit:mm(in)
For adjusting Forchecking
Cold'
Hot (referencedata) Hot
Intake 0.32
-0.40 0.25
-0.33
0.21-0.49
(0.013 -0.016)
(0.010-0.013) (0.008-0.019)
Exhaust 0.37
-0.45 0.32-0.40 0.30-0.58
(0.015 -0.018) (0.013-0.016) (0.012-0.023)
': At atemperature ofapproximately 20"C(68"F)
Whenever valveclearance areadjusted tocold specifications, checkthatthe
clearances satisfyhotspecifications andadjust againifnecessary.
EM-43
•

ENGINEREMOVAL
SEM237F
5

to.J :
N'm (kg-m, ft-Ib)

* :Located atfront cover.

to.J

44•54 (4.5 •5.5, 33•40)

MIT models
~44.54
(4.5 .5.5, 33.40)

~ I
)-<~
to.J
44-54

o
(4.5-5.5,

10
~;:J
33•40)

('.~

V~)
/$1

'v1( ./'"
L
[OJ
44•54

" / (4.5•5.5,

33 -40)
9

ffit"J

44-54 (4.5 -5.5. 33-40)

d
GA15DE andGA16DE withVTe
except forAustralia

u~

SEC.
112

@(For Europe)

(1)
Engine frontmounting

@
Cylinder headfrontmounting
bracket

@
Engine frontmounting bracket

@
Engine rearmounting bracket
@

Transaxle mounting

@
Transaxle mountingbracket

(f)
Engine rearmounting

@
Dynamic damper(AfTmodels)
@

Center member

@J
Buffer rodbracket

@
Buffer rod

EM-44

ENGINEREMOVAL

WARNING:
a. Situate vehicle onaflat and solid surface.
b. Place chocks atfront andback ofrear wheels.
c. Donot remove engineuntilexhaust systemhascompletely
cooled off.
Otherwise, youmay burn yourself and/orfiremay break out
in fuel line.
d. For safety during subsequent steps,thetension ofwires
should beslackened againsttheengine.
e. Before disconnecting fuelhose, release fuelpressure from
fuel line.
Refer to"Releasing FuelPressure" inEC section.
f. Besure tohoist engine andtransaxle inasafe manner.
g. For engines notequipped withengine slingers, attach
proper slingers andbolts described inPARTS CATALOG.
CAUTION:
• When liftingengine, besure toclear surrounding parts.
Take special careforaccelerator wirecasing, brakelines
and brake master cylinder.
• Inhoisting theengine, alwaysuseengine slingers inasafe
manner.
• Inremoving driveshaft, becareful nottodamage grease
seal oftransaxle.
Engine cannotberemoved separately fromtransaxle. Remove
engine withtransaxle.

Removal

1. Drain water.
2. Remove hood.
3. Remove battery.
4. Remove reservoir tankandbracket.
5. Remove drivebelts.
6. Remove alternator, compressor andpower steering oil
pump fromengine.

Power steering pumpdoesnotneed tobe disconnected from
power steering tubes.

7. Remove thefollowing parts:
• Right andleftfront tires
• Under covers
• Splash covers
• Brake caliper assembly

~: 72-97 N'm (7.3•9.9 kg-m, 53•72 ft-Ib)
Brake hosedoes notneed tobe disconnected frombrake cali-
per assembly.
Never depress brakepedal.

• Disconnect tie-rodballjoint (RH
&
LH).

~: 29-39 N'm (3.0-4.0 kg-m, 22-29 ft-Ib)

• RH
&
LH drive shaft

When removing driveshaft, becareful nottodamage transaxle
side grease seal.

EM-45
•

ENGINEREMOVAL
mJ

Removal (Cont'd)

• Disconnect controlrodand support rodfrom transaxle.
(M/T

models)
Control rod:

to:J:
14-18 N.m (1.4-1.8 kg-m, 10-13 ft-Ib)
Support rod:

to:J:
35-47 N.m (3.6-4.8 kg-m, 26-35 ft-Ib)

• Disconnect controlcablefromtransaxle.
(A/Tmodels)

• Center member
• Front exhaust tube
• Stabilizer
• Cooling fan
• Radiator
• Cylinder headfrontmounting bracket
• Remove airduct anddisconnect wires,harness, pipes,
hoses andsoon.
8. Lift upengine slightly anddisconnect orremove allengine
mountings.

When liftingengine, becareful nottohit itagainst adjacent
parts, especially againstbraketubesandbrake master cylin-
der.

9. Remove enginewithtransaxle asshown.

Installation
When installing theengine, adjusttheheight ofbuffer rodas
shown. (ForM/T)

• Installation isthe reverse orderofremoval.

EM-46

CYLINDERBLOCK

SEC. 110.120

ij]
6.3•8.3
(0.641 •0.851, 55.6-73.9)

I]
to;J
83.5 •93.3
(8.51 -9.51,
61.6 •68.8)

f]
to.J
93.3 •103.1 (9.51-10.51, 68.8-76.0)

to;J :
N.
m
(kg-m, ft-Ib)
~ :N.m (kg-m, in-Ib)
~ :Apply liquidgasket.

f] :
Lubricate withnew engine oil.

SEM238F
•

CD
Oillevel gauge guide

@
Cylinder block

@
Rear oilseal retainer

@
Rear oilseal

@
Rear plate

@
Flywheel

(J)
Rear lower plate

@
Drive plate
*: Applies toGA 16DE without VTC,14DE.
@

Drain plug

@)
Buffer plate

@
Topring

@
2ndring (Only Europe models*)

@
Oilring

@
Piston

@
Snap ring

@
Piston pin

EM-47
@

Connecting rod

@
Connecting rodbearing

@)
Connecting rodcap

@l
Key

@
Main bearing

@
Thrust bearing

@
Crankshaft

@
Main bearing cap

CYLINDERBLOCK
CAUTION:
• When installing slidingparts(bearings, pistons,etc.),lubri-
cate contacting surfaceswithnewengine oil.
• Place removed partssuchasbearings andbearing capsin
their proper orderanddirection.
• When installing connecting rodnuts, andmain bearing cap
bolts, apply newengine oiltothreads andseating surfaces.
Disassembly
PISTON ANDCRANKSHAFT

1. Place engine onawork stand.
2. Drain coolant andoil.
3. Remove timingchain.
Refer to"Removal" in"TIMING CHAIN"(EM-20).
4 Remove pistonswithconnecting rods.
• When disassembling pistonandconnecting rod,remove
snap ringfirst, thenheat piston to60 to70°C (140to158°F)
or use piston pinpress stand atroom temperature.
5. Loosen mainbearing capinnumerical orderasshown in
the figure.
6. Remove bearingcaps,mainbearings andcrankshaft.

• Before removing bearingcaps,measure crankshaft end
play.
• Bolts should beloosened intwo orthree steps.
AEM023 Inspection
PISTON ANDPISTON PINCLEARANCE

1. Measure innerdiameter ofpiston pinhole "dp".

Standard diameter
"dp":

18.987 -18.999
mm
(0.7475 -0.7480
in)

EM-48

I

Micrometer
AEM024CYLINDER
BLOCK ~

Inspection (Conl'd)

2. Measure outerdiameter ofpiston pin"Op".
Standard diameter "Op":
18.989 -19.001 mm(0.7476 -0.7481 in)
3. Calculate pistonpinclearance.
dp -Op
=
-0.004 to0mm (-0.0002 to0in)
If itexceeds theabove value, replace pistonassembly with

pin.

•

NG
Ring
Measuring point Feeler
gauge
SEM8228 PISTON
RINGSIDECLEARANCE

Side clearance:
Top ring
0.040 -0.080 mm(0.0016 -0.0031 in)
2nd ring (Only Europe models)
0.030 -0.070 mm(0.0012 -0.0028 in)
Max. limitofside clearance:
0.2 mm (0.008 in)
If out ofspecification, replacepistonand/or pistonringassem-
bly.

PISTON RINGENDGAP

End gap:
Top ring
0.20 -0.35 mm(0.0079 -0.0138 in)
2nd ring (Only Europe models)
0.37 -0.52 mm(0.0146 -0.0205 in)
Oil ring
0.20 -0.60 mm(0.0079 -0.0236 in)
Max. limitofring gap:
1.0 mm (0.039 in)
If out ofspecification, replacepistonring.Ifgap exceeds max-
imum limitwithnewring, rebore cylinder anduseoversize
piston andpiston rings.
Refer toSOS (EM-161).
• When replacing thepiston, checkthecylinder blocksurface
for scratches orseizure. Ifscratches orseizure isfound,
hone orreplace thecylinder block.

CONNECTING RODBEND ANDTORSION

Bend: Limit 0.15mm(0.0059 in)
per 100 mm (3.94 in)length
Torsion: Limit 0.3mm (0.012 in)
per 100 mm (3.94 in)length
If itexceeds thelimit, replace connecting rodassembly.

EM-49

SEM003FCYLINDER
BLOCK
Inspection (Cont'd)
Feeler gauge Straightedge
SEM102F

I
I

,

,

!

,

A

X-V
B
Unit:
mm
(In)

SEM166DA CYLINDER
BLOCKDISTORTION ANDWEAR

1. Clean upperfaceofcylinder blockandmeasure thedistor-
tion.
Limit: 0.10 mm(0.0039 in)

2. Ifout ofspecification, resurface
it.

The resurfacing limitisdetermined bycylinder headresur-
facing inengine.

Amount ofcylinder headresurfacing is
"A".

Amount ofcylinder blockresurfacing is
"B".

The maximum limitisas follows:

A
+
B
= 0.2 mm (0.008 in)
Nominal cylinderblockheight
from crankshaft center:
213.95 -214.05 mm(8.4232 .8.4271 in)

3. Ifnecessary, replacecylinder block.

PISTON- TO-BORE CLEARANCE

1. Using abore gauge, measure cylinderboreforwear, out-
of-round andtaper.

Standard innerdiameter:
GA16DE 76.000-76.030 mm(2.9921 -2.9933 in)
GA14, 15DE73.600 -73.630 mm(2.8976 -2.8988 in)
Wear limit:
0.2 mm (0.008 in)

If itexceeds thelimit, rebore allcylinders. Replacecylinder
block ifnecessary.

Out-of-round (X-Y) standard:
0.015 mm(0.0006 in)
Taper (A-B) standard:
0.01 mm(0.0004 in)
EM-50

Cylinderbore
grade number
No. 4
Cylinder block
SEM426C CYLINDER
BLOCK
[]K]

Inspection (Cont'd)

2. Check forscratches andseizure. Ifseizure isfound, hone
it.
• Ifcylinder blockorpiston isreplaced, matchpiston grade
with grade number oncylinder blocklower surface.
3. Measure pistonskirtdiameter.
Piston diameter "A":
Refer toSDS (EM-161).
Measuring point"a"(Distance fromthebottom):
Refer toSDS (EM-161).
4. Check thatpiston-to-bore clearanceiswithin specification.
Piston-to-bore clearance"B":
0.015 -0.035 mm(0.0006 -0.0014 in)
5. Determine pistonoversize according toamount ofcylinder
wear.
Oversize pistonsareavailable forservice. RefertoSDS (EM-
161).
6. Cylinder boresizeisdetermined byadding piston-to-bore
clearance topiston diameter "A".
Rebored sizecalculation:
D=A+B-C
where,

0:
Bored diameter
A: Piston diameter asmeasured
B: Piston-to-bore clearance
C: Honing allowance 0.02mm(0.0008 in)
7. Install mainbearing capsandtighten boltstothe specified
torque. Thiswillprevent distortion ofcylinder bores.
8. Cut cylinder bores.
• When anycylinder needsboring, allother cylinders must
also bebored.
• Donot cuttoo much outofcylinder boreatatime. Cutonly
0.05 mm(0.0020 in)orso indiameter atatime.
9. Hone cylinders toobtain specified piston-to-bore clearance.
10. Measure finishedcylinder boreforout-of-round andtaper.
• Measurement shouldbedone aftercylinder borecools
down.

EM-51
•