NISSAN ALMERA N16 2003 Electronic Repair Manual

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c. Confirm mating marks stamped on intake and exhaust sprockets
are located as shown.
●If not, rotate crankshaft pulley as shown and align them.
d. Referring to mating marks on intake and exhaust camshaft
sprockets, put paint mating marks on timing chain links.
4. Set intake camshaft sprocket to most advanced position.
CAUTION:
Removal/installation of intake camshaft sprocket is required to maintain most advanced position
because of following reasons. Therefore, follow procedure exactly.
●Sprocket and vane (camshaft in front) rotate and become
offset within specific angle range.
●When engine is stationary, vane is located at most
retarded position. Vane is fixed to sprocket by internal
lock pin. Therefore, it does not rotate.
●If camshaft sprocket mounting bolts are turned under
above circumstance, lock pin will be damaged by lateral
load (shear stress). It may cause non-standard operation.
●Set intake camshaft sprocket to most advanced position as
follows.
NOTE:
“Rotating direction” means direction viewed from engine front side.
CAUTION:
Do not remove chain tensioner before performing this step.
a. Using a wrench, hold hexagonal part so that intake camshaft
does not move.
b. Using an air gun, apply air pressure to intake valve timing con-
trol solenoid valve advanced side oil passage on top surface of
No. 1 camshaft bracket.
●Keep applying air pressure until step “d” is completed.
CAUTION:
●Be careful not to damage oil passage from interference of
air gun tip.
●Thoroughly wipe off oil before applying air pressure.
When applying air pressure, cover around air gun using a rag. Wear protective glasses if neces-
sary.
MBIB0194E
MBIB0195E
MBIB0196E
Compression pressure
: 300 kPa (3.00 bar, 3.06 kg/cm
2 , 43.5 psi) or more
MBIB0197E

EM-34
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CAMSHAFT
c. Slowly turn intake camshaft in direction A (counterclockwise:
intake manifold side).
●Perform while applying air pressure.
CAUTION:
Be careful not to dislocate camshaft retaining spanner.
d. During above step, operating click (a sound indicating internal
lock pin is disengaged) is heard from inside of intake camshaft
sprocket. After hearing it, slowly turn intake camshaft in direction
B (clockwise: exhaust manifold side), and set to most advanced
position.
●Perform while applying air pressure.
●When vane rotates solely against sprocket, lock pin is disengaged even if operating click is not heard.
●If lock pin is not disengaged, apply vibration by jiggling the camshaft with a spanner.
●If lock pin is not disengaged with above step, hit intake camshaft in front by using plastic hammer.
e. The following status indicates that most advanced position is
achieved: vane starts rotating on its own, then sprocket also
starts rotating when camshaft is turned. When above status is
achieved, this step is complete.
●Most advanced position is confirmed when stopper pin groove
and lock pin breathing groove are aligned.
f. Stop air, insert stopper pin [approximately 3 mm (0.12 in) dia.,
length of inserted part is approximately 15 mm (0.59 in)] into
pinhole on camshaft sprocket to fix most advanced position.
NOTE:
In the figure, an Allen wrench [a/f 2.5 mm (0.091 in), short part:
approximately 20 mm (0.79 in), long part: approximately 50 mm
(1.97 in)] is used for stopper pin as an example.
CAUTION:
Load (spring reaction force) is not applied to stopper pin.
Pin is easily detached. Therefore, secure it with vinyl tape to
prevent detachment.
5. Remove chain tensioner.
●Remove in the following order.
a. Press plate down, and release stopper tab.
b. Insert plunger into tensioner body until it stops.
c. Secure plate by passing stopper pin (such as a hard wire)
through plate hole and body hole. (Plunger is also secured.)
d. Remove mounting bolts, and remove chain tensioner.
KBIA1414J
MBIB0198E
PBIC0966E
MBIB0201E

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6. While holding hexagonal part of camshaft with a spanner, loosen
mounting bolts and remove intake and exhaust camshaft
sprockets.
CAUTION:
●Be careful that tool does not interfere with A/C piping.
●Avoid securing camshaft at other than hexagonal part
and loosening mounting bolts by utilizing tension of tim-
ing chain.
●Handle intake camshaft sprocket, taking care of following.
CAUTION:
●Secure stopper pin with vinyl tape to prevent detach-
ment.
●Avoid dropping it or subjecting it to impact.
●Do not disassemble. (Do not loosen 3 bolts on front sur-
face.)
NOTE:
If stopper pin is detached and lock pin is engaged at most retarded position during removal, recover as
follows.
a. Reinstall stopper pin to intake camshaft, and tighten intake camshaft sprocket mounting bolts so that air
does not leak.
CAUTION:
Tightening torque for mounting bolts must be minimum so that air does not leak, preventing dam-
age on internal lock pin.
b. Apply air pressure to disengage lock pin, and turn vane to most advanced position. (This step can be per-
formed with timing chain removed.)
c. Reinstall stopper pin.
d. Remove intakecamshaft sprocket from camshaft.
7. Remove camshaft brackets.
●Loosen mounting bolts in several steps in reverse order
shown in figure.
8. Remove camshaft.
CAUTION:
Be careful not to damage signal plate on rear end of intake
camshaft and crankshaft.
9. Remove adjusting shims and valve lifters.
●Identify installation position of each valve. Arrange removed
valves so they cannot be mixed up.
INSTALLATION
1. Install valve lifters and adjusting shims.
●Install them in their original positions.
●Install adjusting shim with its stamped mark facing downward (valve lifter side).
EMD0826D
MBIB0202E
PBIC0969E

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2. Install camshaft.
●Intake and exhaust camshafts are distinguished by checking
difference between front and rear end shapes.
NOTE:
Some exhaust camshafts have a groove on the rear end.
●Install camshafts so that dowel pins on their front ends are
positioned as shown.
3. Install camshaft brackets.
●Completely remove any foreign material on back surfaces of
camshaft brackets and top surface of cylinder head.
●Referring to marks on top surfaces of camshaft brackets,
install them to their original positions and in their original
directions.
4. Tighten camshaft bracket mounting bolts as follows:
a. Different bolts are used depending on installation location. Refer
to following and install appropriate bolts.
b. First tighten bolts 9 through 12, then tighten bolts 1 through 8 in
numerical order.
c. Tighten in numerical order shown in figure.
d. Tighten again in numerical order shown in figure.
5. Install intake camshaft sprocket as follows.
●Before installation, make sure that stopper pin is inserted in intake camshaft sprocket.
NOTE:
Service parts are provided with pin inserted.
MBIB0204E
PBIC0967E
MBIB0206E
Bolt color:
1 to 10 in figure : black (reamer bolt)
11 and 12 in figure : gold
: 2.0 N·m (0.2 kg-m, 18 in-lb)
: 5.9 N·m (0.6 kg-m, 52 in-lb)
: 9.0 - 11.8 N·m (0.92 - 1.2 kg-m, 80 - 104 in-lb)
PBIC0969E

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CAUTION:
Stopper pin is easily detached. Secure it with vinyl tape to prevent detachment.
a. Install timing chain by aligning its mating mark (marked when
timing chain is removed) with mark on camshaft sprocket.
●Align dowel pin on camshaft front surface and pinhole on
sprocket backside, then install.
b. While holding hexagonal part of camshaft with a spanner,
tighten intake camshaft sprocket mounting bolts.
●Make sure that stopper pin is not detached.
6. Install exhaust camshaft sprocket as follows.
a. Install timing chain by aligning its mating mark (marked when
timing chain is removed) with mark on camshaft sprocket.
●Align dowel pin on camshaft front surface and pinhole on
sprocket, then install.
b. While holding hexagonal part of camshaft with a spanner,
tighten exhaust camshaft sprocket mounting bolts.
NOTE:
Tightening torque is different from intake side tightening torque.
c. Make sure that mating marks on intake/exhaust camshaft
sprockets and mating mark on timing chain are aligned.
7. Install chain tensioner.
●Hold plate and plunger with a stopper pin, then install them.
●After installation, remove stopper pin and release plunger.
●Make sure again that mating marks on intake/exhaust cam-
shaft sprockets and mating mark on timing chain are aligned.
MBIB0208E
MBIB0209E
MBIB0210E
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8. Remove stopper pin from intake camshaft sprocket.
9. Slowly turn crankshaft pulley clockwise to set intake camshaft
sprocket to most retarded position.
●Sprocket begins turning after crankshaft does. Once sprocket
starts turning, keep turning crankshaft until the vane (cam-
shaft) also begins turning. Most retarded position should now
be achieved.
●Most retarded position is confirmed when stopper pin groove
is at a clockwise offset from lock pin breathing groove.
●While turning crankshaft slightly more counterclockwise, con-
firm that lock pin is engaged when vane and sprocket turn
together.
10. Install cylinder head front cover.
●Apply liquid gasket (Use Genuine Liquid Gasket or equiva-
lent) continuously as shown in figure.
●Install it by aligning dowel pin on cylinder head.
11. Check and adjust valve clearance. Refer to EM-42, "
Va l v e
Clearance" .
12. From this step, install in the reverse order of removal.
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INSPECTION AFTER REMOVAL
Camshaft Runout
●Place a V-block on a surface plate to support No. 2 and No. 5
journals on camshaft.
CAUTION:
Do not support No. 1 journal (camshaft sprocket mounting
side), because its diameter is different from that of the other
4 journals.
●Set a dial gauge vertically onto journal No. 3.
●Rotate the camshaft in one direction by hand and read indication
on the gauge.
●A half of reading value is actual bend.
Camshaft Cam Height
●Measure with a micrometer.
Camshaft Journal Clearance
Outer Diameter of Camshaft Journal
●Measure with a micrometer.
Inner Diameter of Camshaft Bracket
●Tighten camshaft bracket bolts to the specified torque.
●Using an inside micrometer, measure inner diameter of the cam-
shaft bracket.
Calculation of Camshaft Journal Clearance
(Oil clearance) = (Camshaft bracket inner diameter) - (Camshaft journal outer diameter) Standard : 0.02 mm (0.0008 in) or less
MBIB0215E
Intake : 40.217 - 40.407 mm (1.5833 - 1.5908 in)
Exhaust : 38.965 - 39.155 mm (1.5341 - 1.5415 in)
MBIB0216E
Standard
No. 1
: 27.935 - 27.955 mm (1.0998 - 1.1006 in) dia.
No. 2 to No. 5
: 23.935 - 23.955 mm (0.9423 - 0.9431 in) dia.
MBIB0217E
Standard
No. 1
: 28.000 - 28.021 mm (1.1024 - 1.1032 in) dia.
No. 2 to No. 5
: 23.985 - 24.006 mm (0.9443 - 0.9451 in) dia.
MBIB0218E

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●If outside the standard, refer to standard of each unit part and replace camshaft or cylinder head as appro-
priate.
NOTE:
Camshaft bracket is machined with cylinder head. Replace them as cylinder head assembly.
Camshaft End play
●Position a dial gauge onto front end of camshaft in thrust direc-
tion. Read indication of dial gauge while moving camshaft back
and forth (axial direction).
●If outside the standard, replace camshaft with new one. Then
measure it again.
●If still outside the standard, replace cylinder head with new one.
Camshaft Sprocket Runout
●Using a dial gauge, measure camshaft sprocket runout.
Valve Lifter and Adjusting Shim (Shim type)
Check surfaces of valve lifter and shim for cracks and wear.
Valve Lifter Clearance
Outer Diameter of Valve LifterStandard
No. 1
: 0.045 - 0.086 mm (0.0018 - 0.0028 in)
No. 2 to No. 5
: 0.030 - 0.071 mm (0.0012 - 0.0028 in)
Standard
Intake : 0.070 - 0.143 mm (0.0028 - 0.0056 in)
Exhaust : 0.115 - 0.188 mm (0.0045 - 0.0074 in)
MBIB0219E
Limit:
Intake : 0.2 mm (0.008 in)
Exhaust : 0.15 mm (0.0059 in)
PBIC0930E
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●Measure outer diameter with a micrometer.
Valve Lifter Hole Diameter
●Using an inside micrometer, measure valve lifter hole diameter
on cylinder head.
Calculation of Valve Lifter Clearance
(Clearance) = (Valve lifter hole inner diameter) - (Valve lifter outer diameter)
●If outside the standard, refer to standard of each OD and hole ID and then replace valve lifter or cylinder
head as appropriate.
Valve Lifter (Shimless type)
●Check if surface of valve lifter has any wear or cracks.
Valve Lifter Clearance
Outer Diameter of Valve Lifter
●Measure outer diameter of valve lifter.Standard : 29.960 - 29.975 mm (1.1795 - 1.1801 in) dia.
MBIB0220E
Standard : 30.000 - 30.021 mm (1.1811 - 1.1819 in) dia.
MBIB0221E
Standard : 0.025 - 0.061 mm (0.0010 - 0.0024 in)
KBIA0182E
Valve lifter outer diameter (Intake and exhaust)
: 29.960 - 29.975 mm (1.1795 - 1.1801 in) dia.
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Valve Lifter Hole Diameter
●Using inside micrometer, measure diameter of valve lifter hole of
cylinder head.
Calculation of Valve Lifter Clearance
(Valve lifter clearance) = (hole diameter of valve lifter) – (outer diam-
eter of valve lifter).
●When out of specified range, referring to each specification of outer and inner diameter, replace either or
both valve lifter and cylinder head.
Valve ClearanceEBS00LQC
INSPECTION
●The following procedure is applicable when: Components related to camshafts or valves are removed,
installed, or replaced. Drivability concerns (poor starting, poor idling, noise) are caused by valve clearance
aging.
1. Warm up engine, and stop.
2. Remove RH splash cover (integrated with undercover).
3. Remove rocker cover. Refer to EM-29, "
ROCKER COVER" .
4. Turn crankshaft pulley clockwise (viewed from front) to align yel-
low paint with timing indicator.
5. At this point, confirm that both intake and exhaust cam noses on
No. 1 cylinder face outward. (No. 1 cylinder is at TDC of its com-
pression stroke.)
●If not, turn crankshaft pulley more.
NOTE:
Or, valves to be checked when No. 4 cylinder is at TDC of its
compression stroke can be checked first following step 8.
6. Referring to figure, measure valve clearances of valves with × in
table below using a thickness gauge.Standard (Intake and exhaust)
: 30.000 - 30.021 mm (1.1811 - 1.1819 in) dia.
Standard (Intake and exhaust)
: 0.025 - 0.061 mm (0.0010 - 0.0024 in)
SEM867E
MBIB0222E
Cylinder No.1 No.2 No.3 No.4
Valve INT EXH INT EXH INT EXH INT EXH
No. 1 cylinder at
TDC of its compres-
sion stroke××× ×
MBIB0223E
MBIB0224E