engine NISSAN ALMERA N15 1995 Service Manual

ENGINEREMOVAL
SEM237F
5

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N'm (kg-m, ft-Ib)

* :Located atfront cover.

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44•54 (4.5 •5.5, 33•40)

MIT models
~44.54
(4.5 .5.5, 33.40)

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44-54

o
(4.5-5.5,

10
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33•40)

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/$1

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44•54

" / (4.5•5.5,

33 -40)
9

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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]
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83.5 •93.3
(8.51 -9.51,
61.6 •68.8)

f]
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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

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

Punchmarksideup
(if mark ispresent.)
SEM965E CYLINDER
BLOCK @KJ
Assembly (Coni'd)

3. Set piston ringsasshown.

CAUTION:
• When piston ringsarenotreplaced, makesurethatpiston
rings aremounted intheir original position.
• When piston ringsarebeing replaced andnopunch mark
is present, pistonringscanbemounted witheither sideup.
For Europe andIsrael models
Engine
front

Q

Oil
ring
expander
tf
V

;l

Top and second ring
Punch marksideup
(if mark ispresen!.)

.::::::::J
c::
Oil ring
expander
*c:

Engine
il

front
~ •
Top ring
• Oil ring
~ upperrail

IJ

/') Oilring
~ ~lower rail
SEM160B
SEM208F
Top ring
Oil ring

~ It
upper rail

!J

~.Oil ring
lower rail
SEM200F Except
forEurope andIsrael models
#5

#4 ~

Oil hole #3 ~-'U
~"\)~ ~
~~
Oilgroove
SEM366E
CRANKSHAFT

1. Set main bearings intheir proper positions oncylinder
block andmain bearing cap.

• Confirm thatcorrect mainbearings areused. Referto
"Inspection" (EM-52).
• Apply engine oiltobearing surfaces.
EM-56

IdentificationNo.

\ca
p
\

NO.1
t.:?

Enginefront

SEM420C CYLINDER
BLOCK
Assembly (Cont'd)

•

Front
Pistonringcompressor

SEM293C
2.
Install crankshaft andmain bearing capsandtighten bolts
to the specified torque.

• Apply newengine oiltobolt threads andseat surface.
• Prior totightening bearingcapbolts, placebearing capin
its proper position byshifting crankshaft inthe axial direc-
tion.
• Tighten bearing capbolts gradually intwo orthree stages.
Start withcenter bearing andmove outward sequentially.
• After securing bearingcapbolts, makesurecrankshaft
turns smoothly byhand.

3. Measure crankshaft endplay.

Crankshaft endplay:
Standard:
0.060 -0.180 mm(0.0024 -0.0071 in)
Limit: 0.3 mm (0.012 in)
If beyond thelimit, replace thrustbearing witha

new one.

4. Install connecting rodbearings inconnecting rodsandcon-
necting rodcaps.

• Confirm thatcorrect bearings areused. Referto
"Inspection" (EM-52).
• Install bearings sothat oilhole inconnecting rodaligns with
oil hole ofbearing.
• Apply engine oiltobolt threads andbearing surfaces.

5. Install pistons withconnecting rods.
a. Install themintocorresponding cylinderswithTool.

• Becareful nottoscratch cylinder wallbyconnecting rod.
• Arrange sothat front mark onpiston headfaces toward
front ofengine.
• Apply engine oiltopiston ringsandsliding surface ofpis-
ton.
EM-57

OUTERCOMPONENT PARTS

•

SEM231F

SEC.
130-140-150-210-211-221

~ __to:J
13•16 (1.3 -1.6, 9.12)

to:J
16•21 (1.6. 2.1,12. 15)
to:J

20•29

(2.0 •3.0,

14 .22)

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41-52 (4.2 -5.3, 30-38)

~---- D_?

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~~~ 0
-t::;-.....~ /,
0

to:J
21-26 ./"

(2.1. 2.7, ,./"~/'
12 -1~)
fs\
19-~~7

~ to:J
16•21
Q

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18. 21 ,
to:J
45_60 (1.6-2.1, 0
Ii]
6.3 _8.3
(1.8 •2.1, (4.6•6.1, 12•15)
1
(0.64•0.85,

to:J
16•19 13-15)
to:J
16•21 33•44)
(1.6 -1.9, (1.6-2.1,
to:J
16•21

12 -14)

12•15)

t"J
16•,.
f"-~
t"J
15•21
r::!
*
H
...----4lJ

~~'. '1~
J
r \~ ~~'..,:;
1,
~Q.
/¥i-;:
--'Il

1il3.7 -5.0
J~
--A)
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16-21
~11V>/

(0.38 _0.51, A~ - (1.6.2.1,12•15)\...,//
~to:J
20.29(2.0-3.0, 14-22)
33.0 •44.3)
Y
&'/-
:f~l
to:J
20•26 (2.0 •2.7, 14-20)

to:J :
N'm (kg-m, fl-Ib)
to:J
16-21 (1.6 -2.1, 12-15)~/

Ii] :
N'm (kg-m, in-Ib) •

~ :Apply
liquidgasket.
*:
Refer toLC section
("Thermostat", "ENGINECOOLING SYSTEM").

G)
Oilfiller cap
@

Oilcatcher
@

Thermostat

@
Rocker cover
@

Oilfilter
@

Water inlet

@
PCVvalve
@

Water pipeassembly
@

Starter motor

@
Camshaft
positionsensor,igni-
@

Thermal transmitter
@

Power steering oilpump
tion coiland power transistor

@
Engine coolant temperature adjusting
bar
built intodistributor
sensor
@

Power
steering oilpump

@
Intake manifold supports

@
Thermostat housing bracket

@
Knock sensor

@
Airrelief plug

rJ)
Oilfilter bracket

EM-59

COMPRESSIONPRESSURE

Measurement ofCompression Pressure

1. Warm upengine.
2. Turn ignition switchoff.
3. Release fuelpressure.
Refer to"Releasing FuelPressure" inEC section.
4. Remove allspark plugs.
5. Disconnect distributorcoilconnector.

20
mm (0.79
In)dls.

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

SEM387C6.
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 speed.
Compression pressure:kPa(bar, kg/cm
2,
psi)/300 rpm
Standard 1,226 (12.26, 12.5,178)
Minimum 1,030 (10.30, 10.5,149)
Difference limitbetween cylinders
98 (0.98, 1.0,14)

10. Ifcompression inone ormore cylinders islow:
a. Pour asmall amount ofengine oilinto cylinders through
spark plugholes.
b. Retest compression.
• If
adding oilhelps compression, pistonringsmaybeworn
or damaged.
If
so, replace pistonringsafterchecking pis-
ton.
• Ifpressure stayslow,avalve maybesticking orseating
improperly. Inspectandrepair valveandvalve seat.Refer
to
50S.
If
valve orvalve seatisdamaged excessively,
replace them.
• There isleakage pastthegasket surface ifthe following is
observed. Compression intwo adjacent cylinders islow and
adding oildoes notimprove compression.
If
so, replace
cylinder headgasket.

EM-62