NISSAN ALMERA N16 2001 Electronic Repair Manual

JEM163G
CAMSHAFT END PLAYNJEM0065S061. Install camshaft in cylinder head.
2. Measure camshaft end play.
Camshaft end play:
Standard
0.070 - 0.148 mm (0.0028 - 0.0058 in)
Limit
0.24 mm (0.0094 in)
+If the value exceeds the limit, replace camshaft and measure
again.
+If the measurement exceeds the limit again, replace cylinder
head.
JEM164G
CAMSHAFT SPROCKET RUNOUTNJEM0065S071. Install sprocket on camshaft.
2. Measure camshaft sprocket runout.
Runout (Total indicator reading):
Less than 0.15 mm (0.0059 in)
3. If it exceeds the limit, replace camshaft sprocket.
JEM155G
VALVE GUIDE CLEARANCENJEM0065S081. Check that valve stem diameter is within the specified range.
2. Push out valve approx. 25 mm (0.98 in) toward combustion
chamber. Swing valve in the direction of the dial gauge to
measure the runout.
+This inspection should be performed before removing valve
guides.
+Half of the runout reading on the dial gauge is the valve guide
clearance.
Standard:
Intake 0.020 - 0.053 mm (0.0008 - 0.0021 in)
Exhaust 0.040 - 0.073 mm (0.0016 - 0.0029 in)
3. If it exceeds the limit, check valve to valve guide clearance.
a. Measure valve stem diameter and valve guide inner diameter.
b. Check that clearance is within specification.
Valve to valve guide clearance limit:
Intake 0.08 mm (0.0031 in)
Exhaust 0.1 mm (0.004 in)
c. If it exceeds the limit, replace valve or valve guide.
CYLINDER HEADYD
Inspection (Cont'd)
EM-123

SEM008A
VALVE GUIDE REPLACEMENTNJEM0065S09+When a valve guide is removed, replace with an oversized [0.2
mm (0.008 in)] valve guide.
1. To remove valve guide, heat cylinder head to 110 to 130ÉC
(230 to 266ÉF) by soaking in heated oil.
SEM931C
2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2
US ton, 2.0 Imp ton) pressure] or hammer and suitable tool.
SEM932C
3. Ream cylinder head valve guide hole.
Valve guide hole diameter (for service parts):
10.175 - 10.196 mm (0.4006 - 0.4014 in)
JEM156G
4. Heat cylinder head to 110 to 130ÉC (230 to 266ÉF) and press
service valve guide onto cylinder head.
Projection ªLº:
10.4 - 10.6 mm (0.409 - 0.417 in)
5. Ream valve guide.
Finished size:
6.000 - 6.018 mm (0.2362 - 0.2369 in)
CYLINDER HEADYD
Inspection (Cont'd)
EM-124

SEM934C
JEM157G
VALVE SEATSNJEM0065S10+Before starting this check, confirm that the dimensions of valve
guides and valves are as specified.
+Apply red lead primer on contacting surfaces of valve seat and
of valve face to examine the conditions of contacting surfaces.
+Check that the paint on contacting surfaces is continuous
along the entire circumference.
+If there are abnormal indications, grind the valve and check the
contact again. If abnormal indications still persist, replace
valve seat.
SEM795A
REPLACING VALVE SEAT FOR SERVICE PARTSNJEM0065S111. Bore out old seat until it collapses. Boring should not continue
beyond the bottom face of the seat recess in cylinder head. Set
the machine depth stop to ensure this.
2. Ream cylinder head recess for service valve seat.
Oversize [0.5 mm (0.020 in)]:
Intake 30.500 - 30.516 mm (1.2008 - 1.2014 in)
Exhaust 29.500 - 29.516 mm (1.1614 - 1.1620 in)
Be sure to ream in circles concentric to the valve guide
center.
This will enable valve seat to fit correctly.
CYLINDER HEADYD
Inspection (Cont'd)
EM-125

JEM158G
SEM301G
3. Heat cylinder head to 110 to 120ÉC (230 to 248ÉF) by soaking
in heated oil.
4. Sufficiently cool valve seat with dry ice. Force fit valve seat into
cylinder head.
WARNING:
Do not touch cold valve seat with your bare hands.
5. Cut or grind valve seat using suitable tool to the specified
dimensions as shown in SDS (EM-163).
CAUTION:
Use the valve seat cutter properly. Securely gripping the cut-
ter handle with both hands, press the cutter down onto the
entire circumference of the contacting surface and finish cut-
ting at one time. Improper pressing of the cutter or cutting in
several steps may result in staged surface on the valve seat.
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition. Refer to EM-125, ªValve Seatsº.
JEM253G
8. Use a depth gauge to measure the distance between the
mounting surface of the cylinder head spring seat and the
valve stem end. If the distance is shorter than specified, repeat
step 5 above to adjust it. If it is longer, replace the valve seat
with a new one.
Valve seat resurface limit ªLº:
Intake 36.53 - 36.98 mm (1.4382 - 1.4559 in)
Exhaust 36.53 - 37.01 mm (1.4382 - 1.4571 in)
CYLINDER HEADYD
Inspection (Cont'd)
EM-126

SEM188A
VALVE DIMENSIONSNJEM0065S12Check dimensions of each valve. For dimensions, refer to SDS
(EM-160).
When valve head has been worn down to 0.5 mm (0.020 in) in
margin thickness, replace valve.
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or
less.
SEM288A
VALVE SPRINGNJEM0065S13SquarenessNJEM0065S13011. Measure dimension ªSº.
Out-of-square ªSº:
Limit 1.5 mm (0.059 in)
2. If it exceeds the limit, replace spring.
EM113
PressureNJEM0065S1302Check valve spring pressure at specified spring height.
Standard:
Installation height 32.82 mm (1.2921 in)
Installation load 168 - 186 N (17.13 - 18.97 kg, 37.8 -
41.8 lb)
Height during valve open 24.82 mm (0.9772 in)
Load with valve open 350 - 382 N (35.7 - 37.9 kg, 78.7
- 83.6 lb)
If it exceeds the standard, replace spring.
SEM960E
VALVE LIFTERNJEM0065S141. Check contact and sliding surfaces for wear or scratches.
SEM961E
2. Check diameter of valve lifter and valve lifter guide bore.
Valve lifter outer diameter:
29.960 - 29.975 mm (1.1795 - 1.1801 in)
CYLINDER HEADYD
Inspection (Cont'd)
EM-127

SEM867E
Lifter guide bore diameter:
30.000 - 30.021 mm (1.1811 - 1.1819 in)
Clearance between lifter and lifter guide:
Standard 0.025 - 0.061 mm (0.0010 - 0.0024 in)
+If the value is out of the range, replace valve lifter and/or cyl-
inder head, referring to the specified values for the outer diam-
eter and bore diameter.
JEM165G
AssemblyNJEM00661. Install valve oil seal.
+Using valve oil seal drift (SST), install so that the dimension
shown in the figure is obtained. The dimension in the figure
shows the dimension before the valve spring seat is installed.
+Different parts should be used depending on the valve oil seal
location. Identify by the rubber color.
For intake: Black
For exhaust: Brown
+Always use new valve oil seal.
+Before installing valve oil seal, install valve spring seat.
2. Install other valve component parts. Refer to ªDisassemblyº,
EM-120.
+After installing valve collets, tap valve stem tip with plastic
hammer to assure a proper fit.
CYLINDER HEADYD
Inspection (Cont'd)
EM-128

Installation=NJEM0067+Before installation, remove old liquid gasket from mating
surface of all liquid gasket applied parts.
SEM505G
CYLINDER HEAD GASKET SELECTIONNJEM0067S01+Select and install cylinder head gasket with appropriate thick-
ness according to the following procedure:
When replacing gasket alone:
+Install a gasket with the same thickness as that of the one
removed.
+Identify the thickness of gasket by the number of holes on the
RH side.
Gasket thickness*
mm (in)Number of holes
0.900 (0.0354) 1
0.925 (0.0364) 2
0.950 (0.0374) 3
0.975 (0.0384) 4
1.000 (0.0394) 5
1.025 (0.0404) 6
*: Measured with head bolts tightened
SEM507G
When the following parts have been repaired/replaced:
+With cylinder block upper surface and/or crankshaft pin journal
ground
+With cylinder block, pistons, connecting rods, and/or crank-
shaft replaced
1. Set piston at a point close to TDC.
2. Set a dial gauge at the location as shown in the figure. Turn-
ing crankshaft gradually, set the gauge scale to ª0º where the
piston protrusion is maximized.
3. Move the dial gauge stand so that the tip of dial gauge can
contact the cylinder block. Read the difference.
4. Measure at two locations per cylinder, that is eight locations for
four cylinders. Select gasket based on the maximum protru-
sion of eight measurements.
5. Measure front and rear at two locations for each cylinder and
calculate the mean value.
Among the four measured points for each cylinder, determine
the maximum protrusion value as the engine's piston protru-
sion value, and select and install a head gasket according to
the value.
+This SELECTION has been discontinued since June, 2000.
CYLINDER HEADYD
Installation
EM-129

Piston protrusion mm (in)Gasket thickness*
mm (in)Identification
Number of holes
Less than 0.255 (0.0100) 0.900 (0.0354) 1
Less than 0.255 - 0.280
(0.0100 - 0.0110)0.925 (0.0364) 2
Less than 0.280 - 0.305
(0.0110 - 0.0120)0.950 (0.0374) 3
Less than 0.305 - 0.330
(0.0120 - 0.0130)0.975 (0.0384) 4
Less than 0.330 - 0.355
(0.0130 - 0.0140)1.000 (0.0394) 5
More than 0.355 (0.0140) 1.025 (0.0404) 6
*: Measured with head bolts tightened
JEM171G
CYLINDER HEAD BOLT DEFORMATION CHECKNJEM0067S02+Measure the outer diameter of threaded area, d1 and d2, at the
points specified in the figure.
+When the necked point is identified at a point other than speci-
fied points, measure at the point as d1.
+Calculate the difference between d1 and d2. If the value
exceeds the limit, replace with new ones.
Limit: 0.15 mm (0.0059 in)
JEM172G
CYLINDER HEAD-TO-BLOCK DIFFERENCE CHECKNJEM0067S03+After installing cylinder head, measure dimension from the
front end surface of cylinder block to that of cylinder head.
Standard: 23.53 - 24.07 mm (0.9264 - 0.9476 in)
+If the difference is out of the range, check fitting of dowel pins
and cylinder head.
JEM167G
LIQUID GASKET APPLICATION ON REAR CHAIN CASENJEM0067S04Apply a continuous bead of specified liquid gasket (Refer to EM-76,
ªLiquid Gasket Application Procedureº.) on the surface shown in
the figure.
A: Apply bead so that it does not protrude into oil passage.
B: Minimize the overlapping area of the bead, with start and end
areas of bead as shown in the figure.
Apply so that the portion marked * comes at an external location
but cannot be viewed externally after engine is assembled.
CYLINDER HEADYD
Installation (Cont'd)
EM-130

JEM149G
JEM166G
CYLINDER HEAD INSTALLATIONNJEM0067S05+Tighten bolts in numerical order as shown in the figure accord-
ing to the following procedure:
1. Apply engine oil to bolt threads and seat surfaces.
2. Tighten bolts to 29 to 38 N´m (2.9 to 3.9 kg-m, 21 to 28 ft-lb).
3. Tighten 180É to 185É [target: 180É] (angular tightening).
4. Loosen completely to 0 N´m (0 kg-m, 0 in-lb) in the reverse
order of that shown in the figure.
5. Tighten bolts to 35 to 44 N´m (3.5 to 4.5 kg-m, 26 to 32 ft-lb).
6. Tighten 90É to 95É [target: 90É] (angular tightening).
7. Tighten another 90É to 95É [target: 90É] (angular tightening).
+When an angle wrench is not used, paint an alignment
mark on the head of cylinder head bolt and cylinder head
surface before tightening. Check the angle with a protrac-
tor.
GLOW PLUG INSTALLATIONNJEM0067S06+To avoid damage, glow plugs should be removed only
when required.
+Handle with care to avoid applying shock. (When dropped
from approx. 100 mm (3.94 in) or higher, always replace
with a new one.)
+Before installing, remove carbon depositing on mounting hole
of glow plug with a reamer.
JEM173G
CAMSHAFT INSTALLATIONNJEM0067S071. Install valve lifters and adjusting shims.
+Install in the correct locations (the same places as before
removal).
2. Install camshafts.
+Identify camshafts by the paint position and screw hole at the
rear end.
Camshaft RH: Paint is at position A without screw hole.
Camshaft LH: Paint is at position B with screw hole.
SEM516G
+Install so that knock pins are positioned in the directions shown
in the figure.
CYLINDER HEADYD
Installation (Cont'd)
EM-131

JEM175G
3. Install camshaft brackets.
+Install correctly, identifying brackets by the journal No. and
front mark on top surface.
JEM160G
4. Tighten bolts in the order shown in the figure according to the
following procedure:
a. Tighten to 2.0 N´m (0.2 kg-m, 17 in-lb).
+Make sure camshaft thrusting parts (on rear side) securely fit
in their mating parts on the cylinder head.
b. Tighten to 6 N´m (0.6 kg-m, 52 in-lb).
c. Tighten to 12 to 13 N´m (1.2 to 1.4 kg-m, 9 to 10 ft-lb).
5. Install camshaft sprockets.
+Camshaft sprockets are commonly used for RH and LH.
+Align camshaft sprocket and dowel pin on camshaft, and
install.
+Holding the hexagonal part of camshaft with a wrench, tighten
bolt securing camshaft sprocket.
6. Before installing spill tube after installing secondary timing
chain, check and adjust valve clearance. Refer to EM-132,
ªValve Clearanceº.
7. Hereafter, install in the reverse order of removal.
JEM176G
Valve ClearanceNJEM0068CHECKINGNJEM0068S01Check valve clearance while engine is cold and not running.
1. Set the No. 1 piston to TDC on its compression stroke.
+Turn crankshaft pulley clockwise so that the knock pin on cam-
shaft LH faces straight above. (No position indicator, etc. is
provided on the crankshaft pulley.)
JEM177G
2. Put an alignment mark with paint, etc. on the crankshaft pul-
ley and on the oil pump as an angle indicator.
CYLINDER HEADYD
Installation (Cont'd)
EM-132