NISSAN ALMERA N16 2001 Electronic Repair Manual

Piston, Piston Ring and Piston Pin=NJEM0034PISTONNJEM0034S01Unit: mm (in)
SEM882E
QG15DE QG18DE
Piston skirt
diameter ªAºStandardGrade No. 1 73.575 - 73.585 (2.8966 - 2.8970) 79.965 - 79.975 (3.1482 - 3.1486)
Grade No. 2 73.585 - 73.595 (2.8970 - 2.8974) 79.975 - 79.985 (3.1486 - 3.1490)
Grade No. 3 73.595 - 73.605 (2.8974 - 2.8978) 79.985 - 79.995 (3.1490 - 3.1494)
0.5 (0.002) oversize (service) 74.075 - 74.105 (2.9163 - 2.9175) 80.215 - 80.245 (3.1581 - 3.1592)*1
1.0 (0.039) oversize (service) 74.575 - 74.605 (2.9360 - 2.9372) 80.465 - 80.495 (3.1679 - 3.1691)*2
ªaº dimension 43.6 (1.717) 42.3 (1.665)
Piston pin hole inner diameter 18.987 - 18.999 (0.7475 - 0.7080) 18.993 - 19.005 (0.7478 - 0.7482)
Piston to bore clearance 0.015 - 0.035 (0.0006 - 0.0014) 0.025 - 0.045 (0.0010 - 0.0018)
*1: 0.25 (0.0098) oversize (service)
*2: 0.5 (0.002) oversize (service)
PISTON RINGNJEM0034S02Unit: mm (in)
QG15DE QG18DE
Limit
Standard
Side clearanceTop 0.045 - 0.080 (0.0018 - 0.0031) 0.040 - 0.080 (0.0016 - 0.0031) 0.110 (0.0043)
2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.100 (0.0039)
Oil 0.065 - 0.135 (0.0026 - 0.0053) 0.045 - 0.155 (0.0018 - 0.0061) Ð
End gapTop 0.20 - 0.30 (0.0079 - 0.0118) 0.53 (0.0209)
2nd 0.32 - 0.47 (0.0126 - 0.0185) 0.67 (0.0264)
Oil 0.20 - 0.60 (0.0079 - 0.0236) 0.95 (0.0374)
PISTON PINNJEM0034S03Unit: mm (in)
QG15DE QG18DE
Piston pin outer diameter 18.989 - 19.001 (0.7476 - 0.7481)
Piston pin to piston clearance þ0.004 to 0 (þ0.0002 to 0) 0.002 - 0.006 (0.0001 - 0.0002)
Piston pin to connecting rod bushing
clearanceStandard 0.005 - 0.017 (0.0002 - 0.0007)
Limit 0.023 (0.0009)
SERVICE DATA AND SPECIFICATIONS (SDS)QG
Piston, Piston Ring and Piston Pin
EM-73

Connecting RodNJEM0035Unit: mm (in)
Center distance140.45 - 140.55 (5.5295 - 5.5335)
Bend limit [per 100 (3.94)]0.15 (0.0059)
Torsion limit [per 100 (3.94)]0.3 (0.012)
Connecting rod bushing inner diameter* (small end) 19.000 - 19.012 (0.7480 - 0.7485)
Connecting rod big end inner diameter 43.000 - 43.013 (1.6929 - 1.6934)
Side clearanceStandard 0.200 - 0.470 (0.0079 - 0.0185)
Limit 0.5 (0.020)
*After installing in connecting rod
CrankshaftNJEM0036Unit: mm (in)
Main journal dia. ªDmºGrade No. 0 49.956 - 49.964 (1.9668 - 1.9671)
Grade No. 1 49.948 - 49.956 (1.9665 - 1.9668)
Grade No. 2 49.940 - 49.948 (1.9661 - 1.9665)
Pin journal dia. ªDpºGrade No. 0 39.968 - 39.974 (1.5735 - 1.5738)
Grade No. 1 39.962 - 39.968 (1.5733 - 1.5735)
Grade No. 2 39.956 - 39.962 (1.5731 - 1.5733)
Center distance ªrº43.95 - 44.05 (1.7303 - 1.7342)
Out-of-round (X þ Y)Standard Less than 0.003 (0.0001)
Limit Less than 0.005 (0.0002)
Taper (A þ B)Standard Less than 0.004 (0.0002)
Limit Less than 0.005 (0.0002)
Runout [TIR*]Standard Less than 0.04 (0.0016)
Limit Less than 0.05 (0.0020)
Free end playStandard 0.060 - 0.260 (0.0024 - 0.0102)
Limit 0.3 (0.012)
*: Total indicator reading
Main BearingNJEM0037STANDARDNJEM0037S01
Grade No. Thickness ªTº mm (in) Identification color
0 1.826 - 1.830 (0.0719 - 0.0720) Black
1 1.830 - 1.834 (0.0720 - 0.0722) Red
2 1.834 - 1.838 (0.0722 - 0.0724) Green
3 1.838 - 1.842 (0.0724 - 0.0725) Yellow
4 1.842 - 1.846 (0.0725 - 0.0727) Blue
UNDERSIZENJEM0037S02Unit: mm (in)
Thickness ªTº
0.25 (0.0098) 1.960 - 1.964 (0.0772 - 0.0773)
0.50 (0.0197) 2.085 - 2.089 (0.0821 - 0.0822)
SERVICE DATA AND SPECIFICATIONS (SDS)QG
Connecting Rod
EM-74

Connecting Rod BearingNJEM0038STANDARD SIZENJEM0038S01Unit: mm (in)
Grade No. Thickness Identification color or number
0 1.503 - 1.506 (0.0592 - 0.0593) Ð
1 1.506 - 1.509 (0.0593 - 0.0594) Brown
2 1.509 - 1.512 (0.0594 - 0.0595) Green
UNDERSIZENJEM0038S02Unit: mm (in)
Grade No. Thickness Identification color or number
0.08 (0.0031) 1.542 - 1.546 (0.0607 - 0.0609) Ð
0.12 (0.0047) 1.562 - 1.566 (0.0615 - 0.0617) Ð
0.25 (0.0098) 1.627 - 1.631 (0.0641 - 0.0642) Ð
Bearing ClearanceNJEM0039Unit: mm (in)
Main bearing clearanceStandard 0.020 - 0.044 (0.0008 - 0.0017)
Limit 0.1 (0.004)
Connecting rod bearing clearanceStandard 0.014 - 0.039 (0.0006 - 0.0015)
Limit 0.1 (0.004)
Miscellaneous ComponentsNJEM0040Unit: mm (in)
Flywheel runout [TIR*]Less than 0.15 (0.0059)
Drive plate runout [TIR*]Less than 0.2 (0.008)
Camshaft sprocket runout [TIR*] Less than 0.15 (0.0059)
*: Total indicator reading
SERVICE DATA AND SPECIFICATIONS (SDS)QG
Connecting Rod Bearing
EM-75

Parts Requiring Angular TighteningNJEM0047+Use an angle wrench for the final tightening of the following
engine parts:
a) Cylinder head bolts
b) Main bearing cap bolts
c) Connecting rod cap nuts
d) Crankshaft pulley bolt
+Do not use a torque value for final tightening.
+The torque value for these parts are for a preliminary step.
+Ensure thread and seat surfaces are clean and coated with
engine oil.
SEM164F
Liquid Gasket Application ProcedureNJEM00481.Use a scraper to remove all traces of old liquid gasket
from mating surfaces and grooves. Also, completely clean
any oil from these areas.
2.Apply a continuous bead of liquid gasket to mating sur-
faces. (Use Genuine Liquid Gasket or equivalent.)
+Be sure liquid gasket diameter is as specified.
AEM080
3.Apply liquid gasket around the inner side of bolt holes
(unless otherwise specified).
4.Assembly should be done within 5 minutes after coating.
5.Wait at least 30 minutes before refilling engine oil and
engine coolant.
PRECAUTIONSYD
Parts Requiring Angular Tightening
EM-76

Special Service ToolsNJEM0049
Tool number
Tool nameDescription
ST0501S000
Engine stand assembly
1 ST05011000
Engine stand
2 ST05012000
Base
NT042
Disassembling and assembling
KV10106500
Engine stand shaft
NT028
KV11105900
Engine sub-attachment
NT799
KV10115900 has been replaced with
KV10106500.
KV10115600
Valve oil seal drift
NT603
Installing valve oil seal
Use side A.
Side A
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia.
e: 10.7 (0.421)
f: 5 (0.20)
Unit: mm (in)
KV10107902
Valve oil seal puller
1 KV10116100
Valve oil seal puller
adapter
NT605
Removing valve oil seal
KV11103000
Injection pump drive gear
puller
NT676
PREPARATIONYD
Special Service Tools
EM-77

Tool number
Tool nameDescription
KV101056S0
Ring gear stopper
1 KV10105630
Adapter
2 KV10105610
Plate
NT617
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)
KV101151S0
Lifter stopper set
1 KV10115110
Camshaft pliers
2 KV10115120
Lifter stopper
NT041
Changing shims
ST16610001
Pilot bushing puller
NT045
Removing crankshaft pilot bushing
KV101111 0 0
Seal cutter
NT046
Removing steel oil pan and rear timing chain
case
WS39930000
Tube presser
NT052
Pressing the tube of liquid gasket
KV10112100
Angle wrench
NT014
Tightening bolts for bearing cap, cylinder
head, etc.
KV10109300
Pulley holder
NT628
a: 68 mm (2.68 in)
b: 8 mm (0.31 in) dia.
PREPARATIONYD
Special Service Tools (Cont'd)
EM-78

Tool number
Tool nameDescription
KV11106010
Hexagon wrench
NT801
a: 5 mm (Face to face)
b: 20 mm
KV11106020
Hexagon wrench
NT803
a: 6 mm (Face to face)
b: 20 mm
KV11106030
Positioning stopper pin
NT804
a: 6 mm dia.
b: 80 mm
KV11106040
TORX wrench
NT805
a: T70
b: 26 mm
Commercial Service ToolsNJEM0050
Tool name Description
Valve seat cutter set
NT048
Finishing valve seat dimensions
Piston ring compressor
NT044
Installing piston assembly into cylinder bore
Piston ring expander
NT030
Removing and installing piston ring
PREPARATIONYD
Special Service Tools (Cont'd)
EM-79

Tool name Description
TORX socket
NT807
Standard Universal
NT808
PREPARATIONYD
Commercial Service Tools (Cont'd)
EM-80

NJEM0051
NVH Troubleshooting Ð Engine NoiseNJEM0051S01Use the chart below to help you find the cause of the symptom.
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
Location of
noiseType of
noiseOperating condition of engine
Source of
noiseCheck itemReference
page Before
warm-upAfter
warm-upWhen
startingWhen
idlingWhen
racingWhile
driving
To p o f
engine
Rocker
cover
Cylinder
headTicking or
clickingC AÐA BÐTappet
noise+Valve clearance EM-133
Rattle C A Ð A B CCamshaft
bearing
noise+Camshaft journal
clearance
+Camshaft runoutEM-122,
122
Crankshaft
pulley
Cylinder
block
(Side of
engine)
Oil panSlap or
knockÐAÐB BÐPiston pin
noise+Piston and piston
pin clearance
+Connecting rod
bushing clearanceEM-144,
152
Slap or
rapAÐÐB B APiston slap
noise+Piston-to-bore
clearance
+Piston ring side
clearance
+Piston ring end
gap
+Connecting rod
bend and torsionEM-144,
145, 145,
146
Knock A B C B B BConnect-
ing rod
bearing
noise+Connecting rod
bushing clearance
(Small end)
+Connecting rod
bearing clearance
(Big end)EM-152,
150
Knock A B Ð A B CMain bear-
ing noise+Main bearing oil
clearance
+Crankshaft runoutEM-148,
148
Front of
engine
Timing
chain
coverTapping or
tickingAAÐBBBTiming
chain and
chain ten-
sioner
noise+Timing chain
cracks and wear
+Timing chain ten-
sioner operationEM-95, 93
Front of
engineSqueaking
or fizzingA BÐBÐCOther
drive belts
(Sticking
or slipping)+Drive belts deflec-
tion
EM-84
CreakingABABABOther
drive belts
(Slipping)+Idler pulley bearing
operation
Squall
CreakABÐBABWater
pump
noise+Water pump opera-
tionLC-39
A: Closely related B: Related C: Sometimes related Ð: Not related
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGYD
NVH Troubleshooting Ð Engine Noise
EM-81

NJEM0053
JEM111G
1. Warm up engine.
2. Turn ignition switch OFF.
3. Using CONSULT-II, make sure no error codes are indicated for
self-diagnosis items. Refer to EC-492, ªTrouble Diagnosis Ð
INDEXº.
+Do not disconnect CONSULT-II until the end of this operation;
it will be used to check engine rpm and for error detection at
the end of this operation.
4. Disconnect the negative battery terminal.
5. To prevent fuel from being injected during inspection, remove
fuel injection pump fuse [ENG CONT2 (20A)] from fuse box on
the left side of engine compartment.
6. Remove glow plugs from all the cylinders.
+Before removal, clean the surrounding area to prevent
entry of any foreign materials into the engine.
+Carefully remove glow plugs to prevent any damage or
breakage.
+Handle with care to avoid applying any shock to glow
plugs.
SEM112G
7. Install adapter (SST) to installation holes of glow plugs and
connect compression gauge for diesel engine.
: 18 - 21 N´m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
8. Connect battery negative terminal.
9. Set the ignition switch to ªSTARTº and crank. When gauge
pointer stabilizes, read compression pressure and engine rpm.
Repeat the above steps for each cylinder.
+Always use a fully-charged battery to obtain specified
engine speed.
Unit: kPa (bar, kg/cm2, psi)/rpm
Standard MinimumDifference limit between
cylinders
3,138 (31.38, 32.0, 455)/
2002,452 (24.52, 25.0, 356)/
200490 (4.90, 5.0, 71)/200
+When engine rpm is out of the specified range, check the spe-
cific gravity of battery liquid. Measure again under corrected
conditions.
+If engine rpm exceeds the limit, check valve clearance and
combustion chamber components (valves, valve seats, cylin-
der head gaskets, piston rings, pistons, cylinder bores, cylin-
der block upper and lower surfaces) and measure again.
10. Complete this operation as follows:
a. Turn the ignition switch to ªOFFº.
b. Disconnect battery negative terminal.
c. Install glow plugs.
MEASUREMENT OF COMPRESSION PRESSUREYD
EM-82