NISSAN ALMERA N16 2001 Electronic Repair Manual

Removal and InstallationNJEM0024CAUTION:
+When installing sliding parts such as bearings and
pistons, apply engine oil on the sliding surfaces.
+Place removed parts, such as bearings and bearing caps,
in their proper order and direction.
+When installing connecting rod nuts and main bearing cap
bolts, apply new engine oil to threads and seating sur-
faces.
+Do not allow any magnetic materials to contact the signal
plate teeth of flywheel or drive plate, and rear plate.
+Remove the crankshaft position sensor (POS).
+Be careful not to damage sensor edges and single plate
teeth.
SEM927F
DisassemblyNJEM0025PISTON AND CRANKSHAFTNJEM0025S011. Place engine on a work stand.
2. Drain coolant and oil.
3. Remove timing chain.
Refer to EM-23.
SEM877B
4. Remove pistons with connecting rod.
+When disassembling piston and connecting rod, remove snap
ring first. Then heat piston to 60 to 70ÉC (140 to 158ÉF) or use
piston pin press stand at room temperature.
CAUTION:
+When piston rings are not replaced, make sure that piston
rings are mounted in their original positions.
+When replacing piston rings, if there is no punch mark,
install with either side up.
SEM165DB
5. Loosen main bearing caps in numerical order as shown in fig-
ure.
6. Remove bearing caps, main bearings and crankshaft.
+Before removing bearing caps, measure crankshaft end
play. Refer to EM-61.
+Bolts should be loosened in two or three steps.
CYLINDER BLOCKQG
Removal and Installation
EM-53

SEM928F
7. Remove signal plate from crankshaft.
AEM023
InspectionNJEM0026PISTON AND PISTON PIN CLEARANCENJEM0026S011. Measure inner diameter of piston pin hole ªdpº.
Standard diameter ªdpº:
QG18DE
18.993 - 19.005 mm (0.7478 - 0.7482 in)
QG15DE
18.987 - 18.999 mm (0.7475 - 0.7480 in)
AEM024
2. Measure outer diameter of piston pin ªDpº.
Standard diameter ªDpº:
18.989 - 19.001 mm (0.7476 - 0.7481 in)
3. Calculate piston pin clearance.
QG18DE
Dp þ dp: 0.002 - 0.006 mm (0.0001 - 0.0002 in)
QG15DE
Dp þ dp: þ0.004 to 0 mm (þ0.0002 to 0 in)
If it exceeds the above value, replace piston assembly with pin.
SEM024AA
PISTON RING SIDE CLEARANCENJEM0026S02Side clearance:
Refer to SDS, EM-73.
Max. limit of side clearance:
Refer to SDS, EM-73.
If out of specification, replace piston and/or piston ring assembly.
AEM096
PISTON RING END GAPNJEM0026S03End gap:
Refer to SDS, EM-73.
Max. limit of end gap:
Refer to SDS, EM-73.
If out of specification, replace piston ring. If gap exceeds maximum
limit with a new ring, rebore cylinder and use oversized piston and
piston rings.
Refer to SDS, EM-73.
+When replacing the piston, check the cylinder bore surface for
CYLINDER BLOCKQG
Disassembly (Cont'd)
EM-54

scratches or seizure. If scratches or seizure is found, hone or
replace the cylinder block.
SEM150B
CONNECTING ROD BEND AND TORSIONNJEM0026S04Bend:
Limit 0.15 mm (0.0059 in)
per 100 mm (3.94 in) length
Torsion:
Limit 0.3 mm (0.012 in)
per 100 mm (3.94 in) length
If it exceeds the limit, replace connecting rod assembly.
SEM003F
SEM486C
CYLINDER BLOCK DISTORTION AND WEARNJEM0026S05Clean upper surface of cylinder block.
Use a reliable straightedge and feeler gauge to check the flatness
of cylinder block surface. Check along six positions shown in fig-
ure.
Block surface flatness:
Standard Less than 0.03 mm (0.0012 in)
Limit 0.10 mm (0.004 in)
If out of specification, resurface it.
The limit for cylinder block resurfacing is determined by the amount
of cylinder head resurfacing.
SEM102F
Amount of cylinder head resurfacing is ªAº.
Amount of cylinder block resurfacing is ªBº.
The maximum limit is as follows:
A + B = 0.2 mm (0.008 in)
Nominal cylinder block height
from crankshaft center:
213.95 - 214.05 mm (8.4232 - 8.4271 in)
If necessary, replace cylinder block.
CYLINDER BLOCKQG
Inspection (Cont'd)
EM-55

SEM166D
SEM929F
PISTON-TO-BORE CLEARANCENJEM0026S061. Using a bore gauge, measure cylinder bore for wear, out-of-
round and taper.
Standard inner diameter:
Refer to SDS, EM-72.
Wear limit:
0.2 mm (0.008 in)
Out-of-round (X þ Y) standard:
Less than 0.015 mm (0.0006 in)
Taper (A þ B) standard:
Less than 0.01 mm (0.0004 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder
block if necessary.
2. Check for score and seizure. If seizure is found, hone it.
+If cylinder block or piston is replaced, match piston grade
with grade number on cylinder block lower surface.
SEM258C
3. Measure piston skirt diameter.
Piston diameter ªAº:
Refer to SDS, EM-73.
Measuring point ªaº (Distance from the top):
Refer to SDS, EM-73.
4. Check that piston-to-bore clearance is within specification.
Piston-to-bore clearance = cylinder bore measurement
ªBº þ Piston diameter ªAº:
Refer to SDS, EM-73.
5. Determine piston oversize according to amount of cylinder
wear.
Oversize pistons are available for service. Refer to SDS EM-73.
6. Cylinder bore size is determined by adding piston-to-bore
clearance to piston diameter ªAº.
Rebored size calculation:
D=A+BþC
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
7. Install main bearing caps and tighten bolts to the specified
torque. This will prevent distortion of cylinder bores.
8. Cut cylinder bores.
+When any cylinder needs boring, all other cylinders must
also be bored.
+Do not cut too much out of cylinder bore at a time. Cut
only 0.05 mm (0.0020 in) or so at a time.
9. Hone cylinders to obtain specified piston-to-bore clearance.
10. Measure finished cylinder bore for out-of-round and taper.
+Measurement should be done after cylinder bore cools
down.
CYLINDER BLOCKQG
Inspection (Cont'd)
EM-56

SEM316A
CRANKSHAFTNJEM0026S071. Check crankshaft main and pin journals for score, wear or
cracks.
2. With a micrometer, measure journals for taper and out-of-
round.
Out-of-round (X þ Y):
Less than 0.003 mm (0.0001 in)
Taper (A þ B):
Less than 0.004 mm (0.0002 in)
SEM346D
3. Measure crankshaft runout.
Runout (Total indicator reading):
Less than 0.04 mm (0.0016 in)
SEM366E
BEARING CLEARANCENJEM0026S08+Use Method A or Method B. Method A is preferred because it
is more accurate.
Method A (Using bore gauge and micrometer)
Main bearingNJEM0026S08011. Set main bearings in their proper positions on cylinder block
and main bearing cap.
SEM683G
2. Install main bearing cap to cylinder block.
Tighten all bolts in correct order in two or three stages. Refer
to EM-61.
3. Measure inner diameter ªAº of each main bearing.
AEM026
4. Measure outer diameter ªDmº of each main journal in crank-
shaft.
5. Calculate main bearing clearance.
Main bearing clearance = A þ Dm
Standard: 0.020 - 0.044 mm (0.0008 - 0.0017 in)
Limit: 0.1 mm (0.004 in)
If it exceeds the limit, replace bearing.
If clearance cannot be adjusted within standard of any bearing,
grind crankshaft journal and use undersized bearing.
CYLINDER BLOCKQG
Inspection (Cont'd)
EM-57

SEM588A
When grinding crank pin and crank journal:
+Grind until clearance is within specified standard bearing
clearance.
+Fillets should be finished as shown in the figure. R: 2.3 -
2.5 mm (0.091 - 0.098 in)
Refer to SDS, EM-75 for standard bearing clearance and
available spare parts.
SEM930F
6. If the crankshaft is replaced, select thickness of main bearings
as follows:
a. Grade number of each cylinder block main journal is punched
on the respective cylinder block. These numbers are punched
in either Arabic or Roman numerals.
AEM172
SEM194C
b. Grade number of each crankshaft main journal is punched on
the respective crankshaft. These numbers are punched in
either Arabic or Roman numerals.
c. Select main bearing with suitable thickness according to the
following table.
Main bearing grade color:
Crankshaft main jour-
nal grade numberCylinder block main journal grade number
012
0 Black Brown or Red Green
1 Brown or Red Green Yellow
2 Green Yellow Blue
For example:
Cylinder block main journal grade number: 1
Crankshaft main journal grade number: 2
Main bearing grade number=1+2=Yellow
AEM027
Connecting rod bearing (Big end)NJEM0026S08021. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
Tighten bolts to the specified torque.
3. Measure inner diameter ªCº of each bearing.
CYLINDER BLOCKQG
Inspection (Cont'd)
EM-58

AEM028
4. Measure outer diameter ªDpº of each crankshaft pin journal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance=CþDp
Standard: 0.014 - 0.039 mm (0.0006 - 0.0015 in)
Limit: 0.1 mm (0.004 in)
If it exceeds the limit, replace bearing.
If clearance cannot be adjusted using any standard bearing
grade, grind crankshaft journal and use undersized bearing.
Refer to step 5, EM-57.
SEM437CA
+If a new bearing, crankshaft or connecting rod is replaced,
select connecting rod bearing according to the following table.
Connecting rod bearing grade number:
These numbers are punched in either Arabic or Roman numerals.
Crankshaft pin journal grade number Connecting rod bearing grade color
0Ð
1 Brown
2 Green
EM142
Method B (Using Plastigage)
CAUTION:
+Do not turn crankshaft or connecting rod while Plastigage
is being inserted.
+If incorrect bearing clearance exists, use a thicker or
undersized main bearing to ensure specified clearance.
AEM029
CONNECTING ROD BUSHING CLEARANCE (SMALL
END)
NJEM0026S091. Measure inner diameter ªCº of bushing.
AEM030
2. Measure outer diameter ªDpº of piston pin.
3. Calculate connecting rod bushing clearance.
Connecting rod bushing clearance=CþDp
Standard:
0.005 - 0.017 mm (0.0002 - 0.0007 in)
Limit:
0.023 mm (0.0009 in)
If it exceeds the limit, replace connecting rod assembly or
connecting rod bushing and/or piston pin.
CYLINDER BLOCKQG
Inspection (Cont'd)
EM-59

SEM062A
REPLACEMENT OF CONNECTING ROD BUSHING
(SMALL END)
NJEM0026S101. Drive in small end bushing until it is flush with end surface of
rod.
Be sure to align the oil holes.
2. Ream the bushing so that clearance with piston pin is within
specification.
Clearance between connecting rod bushing and piston
pin:
0.005 - 0.017 mm (0.0002 - 0.0007 in)
SEM931F
FLYWHEEL/DRIVE PLATE RUNOUTNJEM0026S12Runout (Total indicator reading):
Flywheel (M/T models)
Less than 0.15 mm (0.0059 in)
Drive plate (A/T models)*
Less than 0.2 mm (0.008 in)
*Measuring points: Approximately 115 mm (4.53
in) from crankshaft center
CAUTION:
+Do not allow any magnetic materials to contact the ring
gear teeth and rear plate.
+Do not resurface flywheel. Replace as necessary.
SEM166B
AssemblyNJEM0027PISTONNJEM0027S011. Install new snap ring on one side of piston pin hole.
SEM932F
2. Heat piston to 60 to 70ÉC (140 to 158ÉF) and assemble piston,
piston pin, connecting rod and new snap ring.
+Align the direction of piston and connecting rod.
+Numbers stamped on connecting rod and cap correspond
to each cylinder.
+After assembly, make sure connecting rod swings
smoothly.
CYLINDER BLOCKQG
Inspection (Cont'd)
EM-60

SEM522G
3. Set piston rings as shown.
CAUTION:
+When piston rings are not replaced, make sure that piston
rings are mounted in their original position.
+Install new piston rings either side up if there is no punch
mark.
SEM160B
+Align piston rings so that end gaps are positioned as
shown.
SEM934F
SEM366E
SEM420C
CRANKSHAFTNJEM0027S021. Install signal plate to crankshaft.
2. Set main bearings in their proper positions on cylinder block
and main bearing cap.
+Confirm that correct main bearings are selected by using
Method A or Method B. Refer to EM-57.
+Apply new engine oil to bearing surfaces.
CYLINDER BLOCKQG
Assembly (Cont'd)
EM-61

SEM933F
3. Install crankshaft and main bearing caps and tighten bolts to
the specified torque.
+Apply new engine oil to the bolt thread and seat surface.
+Prior to tightening bearing cap bolts, shift crankshaft back
and forth to properly seat the bearing caps.
+Tighten bearing cap bolts gradually in two or three stages.
Start with center bearing and move outward as shown in
figure.
+After securing bearing cap bolts, make sure crankshaft
turns smoothly by hand.
SEM116F
4. Measure crankshaft end play.
Crankshaft end play:
Standard
0.060 - 0.260 mm (0.0024 - 0.0102 in)
Limit
0.3 mm (0.012 in)
If beyond the limit, replace thrust bearing with new ones.
SEM168D
5. Install connecting rod bearings in connecting rods and con-
necting rod caps.
+Confirm that correct bearings are used. Refer to EM-58.
+Install bearings so that oil hole in connecting rod aligns
with oil hole of bearing.
+Apply new engine oil to bolt threads and bearing surfaces.
SEM942F
6. Install pistons with connecting rods.
a. Install them into corresponding cylinders with Tool.
+Make sure connecting rod does not scratch cylinder wall.
+Make sure connecting rod bolts do not scratch crankshaft
pin journals.
+Arrange so that front mark on piston head faces engine.
+Apply new engine oil to piston rings and sliding surface
of piston.
SEM943F
b. Install connecting rod caps.
Apply new engine oil to bolt threads and nut seating surfaces.
Tighten connecting rod cap nuts in the following procedure:
+Tighten to 13.72 to 15.68 N´m (1.399 to 1.599 kg-m, 10.120
to 11.566 ft-lb).
+Turn nuts to 35É to 40É degrees clockwise with an angle
wrench. If an angle wrench is not available, tighten nuts to
23 to 28 N´m (2.3 to 2.9 kg-m, 17 to 21 ft-lb).
CYLINDER BLOCKQG
Assembly (Cont'd)
EM-62