engine NISSAN ALMERA N15 1995 Service Manual

ENGINEMECHANICAL
SECTION
EM
CONTENTS
•

PRECAUTIONS
3

Parts Requiring AngularTightening 3
Liquid Gasket Application Procedure 3
PREPARATION 4
Special Service Tools 4
Commercial ServiceTools 8
GA
OUTER COMPONENT PARTS 9
COMPRESSION PRESSURE 15
Measurement ofCompression Pressure 15
OIL PAN 16
Removal 16
installation 17
TIMING CHAIN
18

Removal. 20
Inspection 23
Installation 23
OIL SEAL REPLACEMENT 30
CYLINDER HEAD 32
Removal 34
Disassembly 34
Inspection 34
Assembly 40
Installation 40
VALVE CLEARANCE 41
Checking 41
Adjusti ng 41
ENGINE REMOVAL .44
Removal 45
Ins taIIat ion " 46
CYLINDER BLOCK 47
Disassembly 48
Inspection 48
Assembly 55
SR

OUTER COMPONENT PARTS 59
COMPRESSION PRESSURE 62
Measurement ofCompression Pressure 62
OIL PAN
63

Removal 63
Installation ,66
TIMING CHAIN 68
Removal 69
Inspection 73
Installation ,73
OIL SEAL REPLACEMENT 82
ACCEL-DRUM UNIT 84
CYLINDER HEAD
85

Removal 86
Disassembly 86
Inspection 88
Assembly 93
Installation , 97
ENGINE REMOVAL 98
RemGval 99
Installation "100
CYLINDER BLOCK 101
Disassembly 102
Inspection , 102
Assembly 109
CD
OUTER COMPONENT PARTS
113

COMPRESSION PRESSURE 115
OIL PAN 118
Removal 118
Installation 118

CONTENTS(Conl'd.)
TIMING BELT
120
Camshaft TimingBelt 120
Injection PumpTiming Belt 124

OIL SEAL REPLACEMENT
126

CYLINDER HEAD 128

Removal 129
Disassembly 129
Inspection 130
Assembly 136
Installation 137

ENGINE REMOVAL
140

CYLINDER
BLOCK 143
Preparation 144
Disassembly 144
Inspection 145
Assembly 152
GA

SERVICE DATAANDSPECIFICATIONS
(505)
155
General Specifications ,155
Inspection andAdjustment. 156

SR
SERVICE DATAANDSPECIFICATIONS
(505)
163
General Specifications 163
Inspection andAdjustment. 163

CD
SERVICE DATAANDSPECIFICATIONS
(50S)
171
Inspection andAdjustment.. 171

Innerside
SEM164F PRECAUTIONS
Parts Requiring AngularTightening

• Use anangle wrench forthe final tightening ofthe follow-
ing engine parts:
(1) Cylinder headbolts
(2) Main bearing capbolts (SRengine only)
(3) Connecting rodcap nuts (SRand CDengine)
• Donot use atorque valueforfinal tightening. •
• The torque values forthese partsareforapreliminary step.
• Ensure threadandseat surfaces areclean andcoated with
engine oil.

Liquid Gasket Application Procedure

a. Use ascraper toremove alltraces ofold liquid gasket from
mating surfaces andgrooves. Also,completely cleananyoil
from these areas.
b. Apply acontinuous beadofliquid gasket tomating surfaces.
(Use Genuine LiquidGasket orequivalent.)
• For oilpan, besure liquid gasket diameter is4.0 to5.0
mm (0.157 to0.197 in)for SR engine. Besure liquid
gasket diameter is3.5 to4.5 mm (0.138 to0.177 in)for
GA and CDengine.
• For areas except oilpan, besure liquid gasket diame-
ter is2.0 to3.0 mm (0.079 to0.118 in).
c. Apply liquidgasket toinner surface aroundholeperimeter
area.
d. Assembly shouldbedone within 5minutes aftercoating.
e. Wait atleast 30minutes beforerefilling engineoiland
engine coolant.

EM.3

PREPARATION
Special Service Tools

Engine
Tool number
Description application
Tool name

GA
SRCD
ST0501S000 When
overhauling engine
Engine standassem-
bly
G)
ST05011000
Engine stand

XX
X

@
ST05012000
Base

NT042

KV10106500

~
When
overhauling engine
Engine standshaft

X

NT028

KV10115300

~
When
overhauling engine
Engine sub-attach-
ment
X

NTOO8

Engine attachment When
overhauling engine
assembly
G)
KV10106500
Engine attach-
ment
X

@
KV10113300
Sub-attachment

NT029
G)
KV10108101 Whenoverhauling engine
Engine attach-
ment
KV10106500
1

~

Engine
stand

X

shaft
or

@
KV10102500
Engine stand
shaft
NT366

ST10120000

b
Loosening
andtightening
Cylinder headbolt

~~
cylinder
headbolt
wrench
a;13 (0.51) dia.

XX

b: 12 (0.47)
c: 10 (0.39)
NT583
C

Unit:mm(in)

EM.4

PREPARATION
Special Service Tools(Cont'd)

Engine
Tool number
Description application
Tool name
GASRCD
KV10116200 Disassemblingand
Valve spring
assemblingvalve
compressor mechanism

•

CD

KV10115900

XX

Attachment

NT022

KV101092S0 Disassemblingand
Valve spring
assemblingvalve
compressor mechanism

0

CD
KV10109210
0

Compressor
X

@
KV10109220
Adapter

NT021

KV10115600 Installingvalveoilseal
Valve oilseal drift

c
d
SideA SideB

-HaP
a:

20 (0.79) 20(0.79)

XX

Side A
b:13 (0.51) 14.2(0.559)

(Side(Side

a
c:
10.3 (0.406)
11
(0.43)

A)A)

d: 8(0.31) 8(0.31)
e
f

e:10.7 (0.421) 10.7(0.421)

f:
5(0.20) 5(0.20)

NT603
Unit:
mm(in)
KV10107902

~
Removing
valveoilseal
Valve oilseal puller

CD
KV10116100
Valve oilseal

XXX

puller adapter

I~

\
./

'...:_.~---/

NT605

KV10115700 Adjustingshims
Dial gauge stand

0
X

NT012

KV101151 SO
Changingshims
Lifter stopper set

@t
l

:~

CD

KV10115110
Camshaft pliers

as

J

@

KV10115120
X

Lifter stopper

F
&)

NT041
EM-5

PREPARATION
Special Service Tools(Cont'd)

Engine
Tool number
Description application
Tool name

GA
SRCD
EM03470000

~
Installing
pistonassembly
Piston ringcompres- into
cylinder bore
sor
X
X
X

NT044

KV10107400 Disassembling
and
Piston pinpress assembling
pistonpin
stand
G)
KV10107310
Center shaft
@ ST13040020
Stand
X
X

@ ST13040030
Spring
@ KV10107320
Cap

@
ST13040050
Drift
NT013

KV10109300* Removing
andinstalling
Pulley holder
0

camshaftsprocket

X

a
a:
68 mm (2.68
in)

b b:8mm (0.31
in)dia.

NT628

ED19600000* Measuring
compression
Compression gauge pressure
set

X

p'

NT626

KV11100300* Loosening
andtightening
Nozzle holdersocket

(J
injector
nozzle

X

NT563

KV10111100

~
Removing
oilpan
Seal cutter

X
X
X

NT046

WS39930000 Pressingthetube ofliquid
Tube presser gasket

XXX

NT052

*: Special toolorcommercial equivalent

EM-6

Toolnumber
Tool name Description
PREPARATION
Special Service Tools(Cont'd)

Engine
application

GA SRCD
KV10112100

Angle wrench

ST16610001*
Pilot bushing puller

KV11102900*

Pulley puller

KV101056S0*

Ring gear stopper

G) KV10105630

Adapter

@ KV10105610

Plate assembly
NT014
NT045
NT647
NT617
Tightening
boltsforbear-
ing cap, cylinder head,
etc.
Removing pilotbushing
Removing injectionpump
pulley
Preventing crankshaft
from rotating
a:
3(0.12)
b: 6.4 (0.252)

c:
2.8 (0.110)
d: 6.6 (0.260)

e:
107 (4.21)

f:
14 (0.55)

g:
20 (0.79)

h: 14 (0.55) dia.

Unit: mm(in)
x

x

x
X

X

x

*:
Special toolorcommercial equivalent

EM-7

PREPARATION
Commercial ServiceTools

Engine
Tool name Description application

GA
SRCD
Spark plugwrench

0
Removing
andinstalling

Q
spark
plug

XX

16
mm

(0.63
In)

NT047

Valve seatcutter set

~
Finishing
valveseat
dimensions

XX

X

NT048

Piston ringexpander

~
Removing
andinstalling
piston ring

X
X
X

NT030

Valve guidedrift Removingandinstalling

'~
valve
guide

SR
Intake
&
Exhaust

XX

a
=
9.5
mm
(0.374 in)dia.
b
=
5.0
mm
(0.197 in)dia.

GA
Inlake
&
Exhaust
a
=
9.5
mm
(0.374 In)dla.

NT015
b

=
5.5
mm
(0.217 in)dla.

Valve guide reamer
Reaming
valve
guide
G)

or hole foroversize valve

~
guide

@

d,
\J
SR

Intake
&
Exhausl

XX

d,
=
6.0
mm
(0.236 in)dia.

@
d,

=
10.175
mm
(0.4006 in)
dia.

GA
Intake
&
Exhausl
d,
=
5.5
mm
(0.217 in)dia.
d,
=
9.685
mm
(0.3813 in)

NT016
dia.

Front oilseal drift
Installingfrontoilseal

XX

a
=
75
mm
(2.95 In)dla.

NT049
b

=
45
mm
(1.77 in)dia.

Rear oilseal drift
Installingrearoilseal

X
X

a
=
110
mm
(4.33 In)dla.

NT049
b
=
80
mm
(3.15 in)dia.

EM-8

OUTERCOMPONENT PARTS

tOJ:
N.m (kg-m, ft-Ib)

iii :
N'm (kg-m, in-Ib)
Tighten innumerical order.
Engine

A

Iront
y

*
Throttle bodyboltstightening procedure

1) Tighten allbolts to9to 11 N.m (0.9 to
1.1
kg-m, 6.5to8.0 fl-Ib)
2) Tighten allbolts to18 to22 N'm (1.8to2.2 kg-m, 13to16 ft-Ib)
Tighten innumerical order.

GA16DE
WITHOUT VTe,14DE AND15DE

SEC. 140-147-163-164
GA15DE

SEM220F

CD
Throttle position sensor
@ Mass airflow sensor

@
IACV-AAC valve
@ IACV-FICD solenoidvalve
@ Throttle body @
Engine coolant temperature
sensor

IJ)
Airrelief plug

@
Injector
@ Injector tube
@l

Pressure regulator

@
EGR valve (GA15DE

M/T
model only)
@ Intake manifold
@ IACV-AAC valve(GA15DE
engine models only)

EM-10

COMPRESSIONPRESSURE

20
mm
(O.79 In)dls.

Use compressor testerwhose end(rubber
portion) isless than 20mm (0.79 in)dia.
Otherwise, itmay becaught bycylinder
head during removal.

SEM387CMeasurement
ofCompression Pressure

1. Warm upengine.
2. Turn ignition switchoff.
3. Cut fuel line.
Release fuelpressure.
Refer to"Releasing FuelPressure" inEC section. •
4. Remove allspark plugs.
5. Disconnect distributorcentercable.
6. Attach acompression testertoNO.1 cylinder.
7. Depress accelerator pedalfullytokeep throttle valvewide
open.
8. Crank engine andrecord highest gaugeindication.
9. Repeat themeasurement oneach cylinder asshown above.

• Always useafully-charged batterytoobtain specified
engine revolution.
Compression pressure:
Unit:kPa(bar, kg/cm
2,
psi)/rpm
Compression Differencelimit
ratio
Standard
Refer toSOS Minimum
betweencylin-
(EM-155). ders
9.5 1,324
(13.24, 1,128(11.28,
13.5, 192)/350 11.5,164)/350
9.8 1,353
(1353, 1,157(11.57, 98(0.98, 1.0,14)/
13.8, 196)/350 11.8,168)/350
350
9.9 1,373
(13.7, 14, 1,177(11.8,12,
199)/350 171)/350

10.
If
compression inone ormore cylinders islow:
a. Pour asmall amount ofengine oilinto cylinders through
spark plugholes.
b. Re-test compression,

• Ifadding oilhelps compression, pistonringsmaybeworn
or damaged. Ifso, replace pistonringsafterchecking pis-
ton.
• Ifpressure stayslow,avalve maybesticking orseating
improperly. Inspectandrepair valveandvalve seat.Refer
to SOS (EM-156, 159).Ifvalve orvalve seatisdamaged
excessively, replacethem.
• Ifcompression stayslowintwo cylinder thatarenext to
each other:
The cylinder headgasket maybeleaking, or
both cylinders mayhave valve component damage.
Inspect andrepair asnecessary.
EM-15