torque NISSAN ALMERA N16 2001 Electronic Owner's Manual

InstallationNJEM0102S0202+When a stud bolt is pulled out, tighten it to the following torque:
: 18 - 21 N´m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
+Tighten the exhaust manifold mounting nuts in the following
procedure:
a) Tighten the nuts in the order specified in the figure.
b) Re-tighten the nuts 1 to 4.
EXHAUST MANIFOLD GASKETNJEM0102S03InstallationNJEM0102S0301Install the gasket so that the alignment protrusion faces the No. 4
port.
Disassembly and AssemblyNJEM0103
NEM379
TURBOCHARGERNJEM0103S01DisassemblyNJEM0103S0101After applying penetration lubricant (Lucen, etc.) to the mounting
nuts, check for the penetration of the lubricant, and then loosen the
nuts to remove.
EXHAUST MANIFOLD, TURBOCHARGERYD
Removal and Installation (Cont'd)
EM-112

CAUTION:
Do not disassemble or adjust the turbocharger body.
AssemblyNJEM0103S0102When a stud bolt is pulled out, tighten it to the following torque:
: 24 - 27 N´m (2.4 - 2.8 kg-m, 18 - 20 ft-lb)
JEM267G
InspectionNJEM0104EXHAUST MANIFOLDNJEM0104S01Check the distortion on the mounting surface in the six directions
using a straightedge and a feeler gauge.
Limit: 0.3 mm (0.012 in)
TURBOCHARGERNJEM0104S02
SEM269G
CAUTION:
When the compressor wheel, turbine wheel, or rotor shaft is
damaged, remove all the fragments and foreign matter left in
the following passages in order to prevent a secondary failure:
Suction side: Between turbocharger and air cleaner
Exhaust side: Between turbocharger and catalytic con-
verter
EXHAUST MANIFOLD, TURBOCHARGERYD
Disassembly and Assembly (Cont'd)
EM-113

Removal and InstallationNJEM0099
YEM014
PREPARATIVE WORKNJEM0099S01Remove engine cover.
YEM015
ROCKER COVERNJEM0099S02RemovalNJEM0099S0201Loosen holding bolts in the reverse order of that shown in the fig-
ure and remove.
CAUTION:
Do not remove mass damper on top. If damper must be
removed, remove all traces of old locking sealant from threads
of bolts and holes, and apply new locking sealant on the bolts
before tightening.
InstallationNJEM0099S0202+Tighten holding bolts in the numerical order shown in the fig-
ure.
+Re-tighten to the same torque in the same order as above.
ROCKER COVERYD
Removal and Installation
EM-116

CAMSHAFT VISUAL CHECKNJEM0065S02Check camshaft for scratches, seizure and wear.
JEM161G
CAMSHAFT RUNOUTNJEM0065S031. Place V-blocks on a work bench and support camshaft at No.
1 and No. 5 journal.
2. Set dial gauge perpendicularly at camshaft No. 3 journal.
3. Turn camshaft by hand in one direction and read runout on dial
gauge.
Runout (Total indicator reading):
Limit 0.02 mm (0.0008 in)
4. If it exceeds the limit, replace camshaft.
SEM549A
CAMSHAFT CAM HEIGHTNJEM0065S041. Measure camshaft cam height.
Standard cam height:
Intake
39.505 - 39.695 mm (1.5553 - 1.5628)
Exhaust
39.905 - 40.095 (1.5711 - 1.5785)
Cam wear limit:
0.2 mm (0.008 in)
2. If wear is beyond the limit, replace camshaft.
JEM162G
CAMSHAFT JOURNAL CLEARANCENJEM0065S051. Install camshaft bracket and tighten bolts to the specified
torque.
2. Measure inner diameter of camshaft bearing.
Standard inner diameter:
No. 1: 30.500 - 30.521 mm (1.2008 - 1.2016 in)
No. 2, 3, 4, 5: 24.000 - 24.021 mm (0.9449 - 0.9457 in)
SEM012A
3. Measure outer diameter of camshaft journal.
Standard outer diameter:
No. 1: 30.435 - 30.455 mm (1.1982 - 1.1990 in)
No. 2, 3, 4, 5: 23.935 - 23.955 mm (0.9423 - 0.9431 in)
4. If clearance exceeds the limit, replace camshaft and/or cylin-
der head.
Camshaft journal clearance:
Standard
No.1-5:0.045 - 0.086 mm (0.0018 - 0.0034 in)
Limit
0.045 - 0.086 mm (0.0018 - 0.0034 in)
CYLINDER HEADYD
Inspection (Cont'd)
EM-122

SEM316A
CRANKSHAFTNJEM0073S071. 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):
Standard
0.003 mm (0.0001 in)
Limit
0.005 mm (0.0002 in)
Taper (A þ B):
Standard
0.003 mm (0.0001 in)
Limit
0.005 mm (0.0002 in)
JEM212G
3. Measure crankshaft runout at No. 3 (center) journal.
Runout (Total indicator reading):
Standard 0.05 mm (0.0020 in)
Limit 0.10 mm (0.0039 in)
JEM214G
MAIN BEARING HOUSING INNER DIAMETERNJEM0073S15+Without installing main bearings, install main bearing caps,
and tighten bolts to the specified torque.
+Measure the inner diameter of main bearing housing with a
bore gauge.
Standard:
66.654 - 66.681 mm (2.6242 - 2.6252 in) dia.
+If the measurement is out of the specified range, replace cyl-
inder block and main bearing caps.
JEM213G
BEARING CLEARANCENJEM0073S08+Use either of the following two methods, however, method ªAº
gives more reliable results and is preferable.
Method A (Using bore gauge & micrometer)
Main bearingNJEM0073S08011. Install main bearings to the cylinder block and bearing cap, and
tighten the bolts to the specified torque. Then, measure the
inner diameter of the main bearings.
Oil clearance = Bearing ID ± Crankshaft journal OD
Standard: 0.039 - 0.066 mm (0.0015 - 0.0026 in)
CYLINDER BLOCKYD
Inspection (Cont'd)
EM-148

62.951 - 62.959
(2.4784 - 2.4787)2+Bearing grade No.
+Bearing thickness
+Oil clearance
+Identification colorSTD 2
1.824 - 1.828
(0.0718 - 0.0720)
0.039 - 0.066
(0.0015 - 0.0026)
GreenSTD 3
1.828 - 1.832
(0.0720 - 0.0721)
0.039 - 0.066
(0.0015 - 0.0026)
YellowSTD 4
1.832 - 1.836
(0.0721 - 0.0723)
0.039 - 0.066
(0.0015 - 0.0026)
Blue
3. When the specified oil clearance is not obtained with standard
size main bearings, use undersized bearings.
+When an undersized bearing is used, measure the inner diam-
eter of the bearing while the bearing is installed. Grind crank-
shaft journal so that the specified oil clearance is obtained.
JEM216G
Undersize bearing
Unit: mm (in)
Size Thickness
US 0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769)
CAUTION:
When grinding the crankshaft journal to use an undersize
bearing, avoid damaging the fillet R.
AEM027
Connecting Rod Bearing (Big end)NJEM0073S08021. 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 connecting rod.
Inner diameter:
Standard 55.000 - 55.013 mm (2.1654 - 2.1659 in)
AEM034
4. Measure outer diameter ªDpº of each crankshaft pin journal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance=CþDp
Standard: 0.031 - 0.061 mm (0.0012 - 0.0024 in)
6. If it exceeds the standard, replace bearing.
CYLINDER BLOCKYD
Inspection (Cont'd)
EM-150

Standard dimension R:
1.5 - 1.7 mm (0.0591 - 0.0669 in)
EM142
Method B (Using plastigage)
CAUTION:
+Do not turn crankshaft or connecting rod while plastigage
is being inserted.
+When bearing clearance exceeds the specified limit,
ensure that the proper bearing has been installed. If incor-
rect bearing clearance exists, use a thicker or undersized
main bearing to ensure specified clearance.
SEM502G
MAIN BEARING CRUSH HEIGHTNJEM0073S16+When the bearing cap is removed after being tightened to the
specified torque with main bearings installed, the tip end of
bearing must protrude.
Standard: There must be crush height.
+If the standard is not met, replace main bearings.
JEM219G
MAIN BEARING CAP BOLT DEFORMATIONNJEM0073S17+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 where
specified, measure at the point as d2.
+Calculate the difference between d1 and d2.
Limit: 0.13 mm (0.0051 in)
SEM673E
CONNECTING ROD BUSHING CLEARANCE (SMALL
END)
NJEM0073S091. Measure inner diameter ªCº of bushing.
Inner diameter ªCº:
Standard 28.026 - 28.038 mm (1.1034 - 1.1039 in)
2. Measure outer diameter ªDpº of piston pin.
Outer diameter ªDpº:
Standard 27.994 - 28.000 mm (1.1021 - 1.1024 in)
3. Calculate connecting rod bushing clearance.
Connecting rod bushing clearance=CþDp
Standard: 0.026 - 0.044 mm (0.0010 - 0.0017 in)
CYLINDER BLOCKYD
Inspection (Cont'd)
EM-152

JEM224G
4. Install main bearings and thrust bearings.
a. Remove debris, dust, and oil from the locations on the cylin-
der block and main bearing caps where bearings are installed.
b. Install thrust bearing on each side of cylinder block No. 3
housing.
+Install thrust bearings with oil groove facing in the direction of
the crankshaft arm (outside).
JEM213G
c. Be sure to install main bearings in the correct direction.
+Make sure those with oil holes or oil grooves are mounted on
the cylinder block side, and those without oil holes or oil
grooves are on the main cap side.
+Before installing, apply engine oil on the front (inner) surfaces
of bearings. Do not apply oil to the back surfaces, but thor-
oughly clean them.
+Align stopper notches on bearings and install.
+Check the oil holes on cylinder block and those on bearings
are aligned.
JEM225G
5. Install crankshaft to cylinder block.
+Make sure crankshaft rotates smoothly by hand.
6. Install main bearing caps.
+Identify main bearing caps by the punched mark. Install
correctly, matching the journal No. on the bearing cap and the
journal, with the front mark facing forward.
+Main bearing caps are commonly processed with the cylinder
block. Therefore, caps and cylinder block should be replaced
as a set.
JEM200G
JEM226G
7. Check the main bearing cap bolts for deformation.
Refer to EM-152, ªMAIN BEARING CAP BOLT DEFORMA-
TIONº.
8. Tighten the main bearing cap bolts according to the following
procedure:
a. Apply engine oil to the threaded part and seat surface of each
bolt.
b. Tighten to 25 to 30 N´m (2.5 to 3.1 kg-m, 18 to 22 ft-lb) in the
numerical order shown in the figure.
c. Put alignment marks (with paint) on each bolt and the main
bearing cap, all in the same direction. (when using a protrac-
tor)
d. Then, tighten 90É to 95É [target: 90É].
+Always use either an angle wrench (SST) or protractor
during angular tightening. Avoid tightening based on
visual checks alone.
+After tightening bolts to specified torque, make sure that crank-
shaft rotates smoothly.
+Check crankshaft end play. Refer to EM-143, ªCRANKSHAFT
END PLAYº.
9. Check the outer diameter of connecting rod bolts. Refer to
EM-153, ªCONNECTING ROD BOLT DEFORMATIONº.
10. Install piston to connecting rod.
CYLINDER BLOCKYD
Assembly (Cont'd)
EM-155

JEM233G
16. Install rear oil seal retainer.
+Apply a continuous bead of specified liquid gasket (Refer to
EM-76, ªLiquid Gasket Application Procedureº.) on locations
shown in the figure.
JEM234G
17. Install pilot bushing.
+Force fit with the drift [approx. 19 mm (0.75 in) dia.].
SEM513G
18. Install fuel injection pump bracket.
+Install insulator according to the shape of the block, and secure
by placing the bracket against the insulator. (Not installed on
some models)
+Align the bracket with the dowel pins on the block to install.
+The two bolts used for dowel pins have a longer shanks than
the other two.
+Check the protruding distance of the dowel pin for fuel injec-
tion pump.
Standard: 13.0 - 15.0 mm (0.512 - 0.591 in)
19. Install parts to the engine in the reverse order of disassembly.
+Tighten bolts securing brackets of auxiliary components (A/C
compressor, alternator) to the specified torque.
: 57 - 65 N´m (5.8 - 6.7 kg-m, 42 - 48 ft-lb)
20. Remove engine from engine stand in the reverse order of
assembly.
21. Install flywheel.
+Holding ring gear with ring stopper (SST), tighten securing
bolts with TORX-socket (size: Q8 E20, Commercial Service
Tool).
+Tighten bolts uniformly in a crisscross manner.
SEM500GA
REPLACEMENT OF PILOT BUSHINGNJEM0074S031. Remove pilot bushing using tool or suitable tool.
CYLINDER BLOCKYD
Assembly (Cont'd)
EM-157

SEF605X
+Do not operate fuel pump when there is no fuel in lines.
+Tighten fuel hose clamps to the specified torque.
SEF709Y
+Do not depress accelerator pedal when starting.
+Immediately after starting, do not rev up engine unneces-
sarily.
+Do not rev up engine just prior to shutdown.
SEF708Y
+When installing C.B. ham radio or a mobile phone, be sure
to observe the following as it may adversely affect elec-
tronic control systems depending on installation location.
1)Keep the antenna as far as possible from the electronic
control units.
2)Keep the antenna feeder line more than 20 cm (8 in) away
from the harness of electronic controls.
Do not let them run parallel for a long distance.
3)Adjust the antenna and feeder line so that the standing-
wave ratio can be kept smaller.
4)Be sure to ground the radio to vehicle body.
Wiring Diagrams and Trouble DiagnosisNJEC0006When you read Wiring diagrams, refer to the following:
+GI-12, ªHOW TO READ WIRING DIAGRAMSº
+EL-10, ªPOWER SUPPLY ROUTINGº for power distribution
circuit
When you perform trouble diagnosis, refer to the following:
+GI-31, ªHOW TO FOLLOW TEST GROUP IN TROUBLE
DIAGNOSISº
+GI-21, ªHOW TO PERFORM EFFICIENT DIAGNOSIS FOR
AN ELECTRICAL INCIDENTº
PRECAUTIONSQG
Engine Fuel & Emission Control System (Cont'd)
EC-19