engine NISSAN ALMERA N15 1995 Service Manual

Cylinderheadbolt

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

83 -93

(8.5 -9.5,
(Iii(~)

61.2 -68.6)

39 (4.0, 29)

o
N.m (0kg-m, 0ft-Ib)

SEM673DA
SEM678D CYLINDER
HEAD
Installation
1. Install cylinder headgasket.

• When replacing onlycylinder headgasket, installsame
grade gasket asthe one formerly used.
• When replacing orrepairing cylinderblock,piston, connect-
ing rod and crankshaft, selectgasket referring to"Selecting •
cylinder headgasket".
• Pay attention tothe direction ofthe cylinder headbolt
washer asshown inthe figure.

2. Install cylinder headandtighten cylinder headboltsaccord-
ing tothe following sequence.

Tightening procedure
• Apply engine oiltothreads andunderhead seatingfaceof
each bolt.

1.-
Tighten boltsinnumerical ordershown inthe figure follow-
ing steps below.

@
39N'm (4.0kg-m, 29ft-Ib)

@
83-93 N'm (8.5-9.5 kg-m, 61.2-68.6 ft-Ib)

@
Return to0N'm (0kg-m, 0ft-Ib)

@
39N'm (4.0kg-m, 29ft-Ib)

@
Tighten to75 -80°
If itis difficult tocheck tightening angleofbolt, tighten to83
to 93 N'm (8.5to9.5 kg-m, 61to69 ft-Ib).
2. Install rocker cover.
• Install rocker coverinthe sequence shownatleft.

EM-137

SEC.112 ENGINE
REMOVAL

~~ 44.54(4.5.5.5,33 -40)
~44 .54 (4.5 .5.5, 33.40) ~~
~ 44•54 (4.5 .5.5, 33•40)"\ ~
-~1J.
~1

~~' ~64.74,

_' 2
(6.5.7.5, / \
~ 47.54),/'
rJ44. 54(4.5.5.5,33 -40) ~\
'" ~~~44.54 \....

.- ,9
(4.5.5.5,
ttJJ 44-54 (4.5 •5.5, 33-40)
7
ttJJ64.75 ------~

@--."
('.5•7.5, 4~' \
y~

~~.~~ ~~f;fi\
~~~'~i':-l~"

k(j' --.
II!~o' ~

/'Oolk..,
ttJJ64.75 (6.5•7.5, 47•54) ~
~'o
@\
8,.'~

~- I
2
rJ64. 75(6.5 .7.5,47.54)..1"""-../
~2ft -."~
°
>

~44. 54
~@
ttJJ44.54(4.5 -5.5, 33. 40)
j~~~1 ~-/.~/

(4.5 -5.5, 33•40)
ti ~~
44•54
~'@
A

5~'
!-'~
~35'-4~.)5'~ ~/
,0
7

~ I~. '
.Vi
rJ44.54(4.5.5.5,33.40)

~ ~l
ttJJ44•54 (4.5 •5.5, 33•40)

~ 'l
o.o~

I...",;S'"
1.
..J'-;:7o
6
ttJJ44.54 (4.5 •5.5, 33•40)

~l \

'LrJ 44•54 (4.5 -5.5, 33•40)
ttJJ 44.54 (4.5 .5_5, 33.40)

rJ
N.m(kg-m. ft-Ibl

G)
Engine frontmounting

@
Engine mounting bracket

@
Gusset

@
Buffer rodbracket
@

Buffer rod

@
Center member

(J)
Transaxle mounting

@
Transaxle mountingbracket
SEM050F

@
Rolldamper

@)
Engine rearmounting

@
Engine rearmounting bracket

@
Dynamic damper

WARNING:
• Situate vehicle onaflat and solid surface.
• Place chocks atfront andback ofrear wheels.
• Donot remove engineuntilexhaust systemhascompletely
cooled off.Otherwise, youmay burn yourself and/orfire
may break outin.the fuel line.
• For safety during subsequent steps,thetension ofwires
should beslackened againsttheengine.
• Before removing frontaxlefrom transaxle, placesafety
stands underdesignated frontsupporting points.RefertoGI
section forlifting points andtowing.
• Besure tohoist engine andtransaxle inasafe manner.
• 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 transaxle
oil seal.

EM-140

Drainplug(Radiator)
SFA110A
SFA 1538
SEM534D ENGINE
REMOVAL

1. Remove engineundercovers andsplash covers.
2. Remove frontexhaust tube.
3. Drain coolant anddisconnect lowerwater hosefromradia-
tor.
4. Drain transaxle oil.
5. Disconnect electricalwiringfromcooling fan.
6. Remove powersteering mounting bolt. •
7. Drain coolant fromcylinder block.
8. Disconnect waterhoses andremove radiator.
9. Disconnect fueltubes andvacuum tubes.
10. Release powersteering beltadjusting nutand remove
power steering pumpfromengine.
Bind pump properly tothe vehicle.
11. Disconnect orremove electrical wiringwhere necessary.
12. Release clutchlevercable andaccelerator cable.
13. Remove speedometer pinionconnector fromtransaxle.
14. Remove frontwheels.
15. Remove brakecaliper mounting boltsandbind caliper prop-
erly tovehicle (coilspring) LH
&
RH.
16. Remove lowerballjoint nutsandrelease theupper hub
mounting bolts.
17. Release steering armballjoint using asuitable tool.
Remove driveshafts fromtransaxle.
1) RH: Split drive shaftcenter thrustbearing.
2) RH
&
LH: Remove hubmounting boltsandremove drive
shaft carefully fromtransaxle.
18. Mount suitable slingers tocylinder head.Fithoist with
studge andhoist engine torelease forceonengine mount-
ings.

EM-141

SEM535D
SEM536D ENGINE
REMOVAL

19. Remove enginemounting bracket.
20. Release transaxle shiftlinkages.
21. Release transaxle mounting.
22. Remove centermember fromchassis.
23. Remove enginewithtransaxle asshown.

EM-142

CYLINDERBLOCK

•

l(]~

83-93
(8.5 -9.5

61 -
69)

~

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

f] :
Lubricate withnewengine oil.

(]
~76-78 (7.8 -8.0, 56-58)

@f]-

o

o

@~~ ~

! ~
l"J
R,t" I.
"A,~mbly".

SEC.
110-120
SEM227F

CD
Piston
ring
(J)
Rear
plate
@
Main
bearing

@
Piston
@

Flywheel
@
Crankshaft

@
Piston
pin
@
Rear
oilseal
@

Main bearing

@
Connecting
rodbearing
@)

Rear oilseal retainer
@

Gusset

@
Connecting
rod
@

Gusset
@

Drain plug

@
Main
bearing cap
@

Cylinder block
@

Pilot bushing

EM-143

Unit:mm(in) 183.0(7.205)

SEM707DCYLINDER
BLOCK
Preparation

• Drill ahole intotheattachment (KV10108101).

Disassembly
PISTON ANDCRANKSHAFT

1. Place engine onawork stand.
2. Drain coolant andoil.
3. Remove timingbelt.
4. Remove waterpump.
5. Remove oilpan andoilpump.
6. Remove cylinder head.
7. Remove pistonswithconnecting rods.

When disassembling pistonandconnecting rod,heat piston to
60 to70°C (140to158°F) oruse piston pinpress standatroom
temperature.

Heater
SEM360D

8.Remove bearingcapand crankshaft.

Place thebearings andcaps intheir proper order.
Upper bearings (cylinderblockside)haveoilgroove.

Loosen innumerical order.
SEM564A
SEM291
9.
Remove pistonringswithatool.

EM-144

Measuringpoints
Warpage ofsurface:
Less than0.1mm (0.004 in)

SEM655ACYLINDER
BLOCK

Inspection (Cont'd)

CYLINDER BLOCKDISTORTION

Clean upperfaceofcylinder blockandmeasure thedistortion.
Limit:
0.10
mm
(0.0039
in)
If out ofspecification, resurfaceit.
The resurfacing limitofcylinder blockisdetermined bycylin-
der head resurfacing inan engine.

SEM008D
Amount
ofcylinder headresurfacing is"A".
Amount ofcylinder blockresurfacing is"B".
The maximum limitisas follows:

A + B=0.1
mm
(0.004
in)
If necessary, replacecylinder block.

~ Moving thebore gauge
as shown, takethe

//p'
minimum reading.
CYLINDER
BORE

1. Check forscratches orseizure. Ifseizure isfound, hone
bore.
2. Using abore gauge, measure cylinderboreforwear, out-
of-round ortaper.
Standard borediameter:

84.500 -84.550
mm
(3.3268 -3.3287
in)

Unit:mm(in)

If itexceeds thelimit, rebore allfour cylinders. Replacecylin-
der block ifnecessary.
If cylinder blockorpiston isreplaced, matchpiston gradewith
grade number oncylinder blockupper surface.

y

Unit mm(in)

SEM704DA
Bore
wear limit
Out-aI-round (X-Y) standard
Taper (A-B) standard
0.2
(0.008)
0.015 (0.0006)
0.010 (0.0004)
EM-150

SEM550
SEM703D CYLINDER
BLOCK
@[]

Inspection (Cont'd)

Using feeler gauge
1. Set piston andfeeler gauge withspring scale.
2. Measure extracting forcewhile pulling upscale slowly.
Feeler gaugeused:
0.05 -0.07 mm(0.0020 -0.0028 in)
Extracting force:
7.8 -14.7 N(0.8 -1.5 kg, 1.8-3.3 Ib)

Assembly
PISTON

• Numbers stampedonconnecting rodand capcorrespond to
each cylinder. Careshould betaken toavoid awrong com-
bination including bearingandconnecting roddirection.

KV101070S0
EM156
•
Install newsnap ringonone side ofpiston pinhole.
• When assembling pistonandconnecting rodwith piston pin,
heat piston tobetween 60and 80°C (140and176°F) and
install piston pinwith asuitable tool.
• Install newsnap ring.
• After assembling, ascertainthatpiston swings smoothly.
• Install
piston
ringswithasuitable tool.
Selective topring; When installing newtopring orreplacing
cylinder block,selecttopring toadjust ringgap.
Punch
marksideup

~r~~

~ Tetl~ntubesetposition

~ ,0

Ql
0

SEM251D
Top
ring grade No. Cylinder
boregrade
1,2,3

No mark 4,
5

S

SEM617
CRANKSHAFT

1. Set main bearings inthe proper position oncylinder block
and main bearing caps.
• Ifeither crankshaft, cylinderblockormain bearing isreused
again, itis necessary tomeasure mainbearing clearance.
• Upper bearings (cylinderblockside)haveoilgroove.
• Apply newengine oiltobearing surfaces.

EM-152

Enginefront1
t;J
SEM230F
~~~:::~"
IJ

~ 2ndring
SEM909 CYLINDER
BLOCK
[ill

Assembly (Cont'd)

2. Apply engine oiltomain bearing surfaces oncrankshaft
journal side.
3. Install crankshaft andmain bearing caps.

Main bearing capbolt:
~: 44-54 N'm (4.5-5.5 kg-m, 33-40 ft-Ib)

4. Tighten mainbearing capbolts.

• Arrange theparts sothat theindicated numbersonbearing •
caps areinarow from thefront ofengine.
• Tighten bearing capbolts gradually intwo orthree stages
and outwardly fromcenter bearing insequence.
• After securing bearingcapbolts, ascertain thatcrankshaft
turns smoothly.
• Apply newengine oiltothreads ofbearing capbolts.

5. Measure crankshaft freeendplay atcenter bearing.

Crankshaft freeendplay:
Standard 0.05 -0.18 mm(0.0020 -0.0071 in)
Limit 0.30 mm(0.0118 in)
PISTON WITHCONNECTING ROD

1. Install connecting rodbearings inthe connecting rodsand
connecting rodcaps.
• Confirm thatcorrect sizeofbearings isused.

Refer to"Inspection" (EM-147).

• Install thebearings sothat theoilhole inthe connecting rod
aligns withtheoilhole ofthe bearing.

• Apply engine oiltoconnecting rodbearing surfaces onthe
crankshaft journalside.

• Set piston ringsasshown.

EM-153

EM03470000orsuitable tool CYLINDER
BLOCK
lliJ

Assembly
(Conl'd)

2. Install pistons withconnecting rods.
• Install themintocorresponding cylinderusingTool.
• Becareful nottoscratch cylinder wallwithconnecting rod.
• Apply engine oiltocylinder wall,piston andbearing.
• Arrange sothat thefront mark onpiston headfaces tothe
front ofengine.
3. Install connecting rodbearing caps.
• Apply engine oiltothe thread ofconnecting rodbearing nut.
(1) Tighten connecting rodbearing nutto15:1:1 N'm(1.5:1:0.1
kg-m, 10.8:1:0.7ft-Ib).
(2) Then tighten anadditional 60
+_~'.
turns withanangular tight-
ening wrench.
~: 15:1:1 N'm(1.5:1:0.1 kg-m,10.8:1:0.7 ft-Ib)plus

60+'::;.
or

~: 37-45 N'm (3.8-4.6 kg-m, 27-33 ft-Ib)
4. Measure connecting rodside clearance.
Connecting rodside clearance (Bigendplay):
Limit
0.3
mm (0.012 in)

FLYWHEEL RUNOUT

Runout (Totalindicator reading):
Less than0.15mm(0.0059 in)

EM-154