NISSAN ALMERA N16 2003 Electronic Repair Manual
Manufacturer: NISSAN, Model Year: 2003, Model line: ALMERA N16, Model: NISSAN ALMERA N16 2003Pages: 3189, PDF Size: 54.76 MB
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11. Remove the piston and connecting rod assembly.
●Before removing the piston and connecting rod assembly,
check the connecting rod si NISSAN ALMERA N16 2003 Electronic Repair Manual CYLINDER BLOCK
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11. Remove the piston and connecting rod assembly.
●Before removing the piston and connecting rod assembly,
check the connecting rod si](/img/5/57350/w960_57350-150.png)
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11. Remove the piston and connecting rod assembly.
●Before removing the piston and connecting rod assembly,
check the connecting rod side clearance. Refer to EM-84,
"CONNECTING ROD SIDE CLEARANCE" .
a. Position the crankshaft pin corresponding to the connecting rod
to be removed onto the bottom dead center.
b. Remove the connecting rod cap.
c. Using a hammer handle or similar tool, push the piston and con-
necting rod assembly out to the cylinder head side.
12. Remove the connecting rod bearings.
CAUTION:
●When removing them, note the installation position. Keep them in the correct order.
13. Remove the piston rings form the piston.
●Before removing the piston rings, check the piston ring side
clearance. Refer to EM-85, "
PISTON RING SIDE CLEAR-
ANCE" .
●Use a piston ring expander (commercial service tool).
CAUTION:
●When removing the piston rings, be careful not to dam-
age the piston.
●Be careful not to damage piston rings by expanding them
excessively.
14. Remove the piston from the connecting rod as follows:
a. Using a snap ring pliers, remove the snap ring.
b. Heat piston to 60 to 70°C (140 to 158°F) with drier or equivalent.
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c. Push out piston pin with stick of outer diameter approximately 17
mm (0.67 in).
15. Remove main bearing cap bolts.
●Loosen main bearing cap bolts in several steps NISSAN ALMERA N16 2003 Electronic Repair Manual EM-74
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c. Push out piston pin with stick of outer diameter approximately 17
mm (0.67 in).
15. Remove main bearing cap bolts.
●Loosen main bearing cap bolts in several steps](/img/5/57350/w960_57350-151.png)
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c. Push out piston pin with stick of outer diameter approximately 17
mm (0.67 in).
15. Remove main bearing cap bolts.
●Loosen main bearing cap bolts in several steps in reverse
order shown in the figure, and remove them.
●Measure crankshaft side clearance before loosening main
bearing cap bolts. Refer to EM-84, "
CRANKSHAFT SIDE
CLEARANCE" .
16. Remove main bearing caps.
●Using main bearing cap bolts as shown, remove center main
bearing cap while shaking it back-and-forth.
●To remove front and rear main bearing caps, lever them off
using screwdriver or similar tool. Or, using a plastic hammer,
tap them back-and-forth.
CAUTION:
Using shop cloth or wooden block, protect oil pan mount-
ing surface on cylinder block, so that mounting surface is
not damaged.
PBIC0262E
SEM933F
EMD0879D
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17. Remove crankshaft.
CAUTION:
●When placing crankshaft on ground, be careful not to
damage signal plate.
●Never remove signal plate un NISSAN ALMERA N16 2003 Electronic Repair Manual CYLINDER BLOCK
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17. Remove crankshaft.
CAUTION:
●When placing crankshaft on ground, be careful not to
damage signal plate.
●Never remove signal plate un](/img/5/57350/w960_57350-152.png)
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17. Remove crankshaft.
CAUTION:
●When placing crankshaft on ground, be careful not to
damage signal plate.
●Never remove signal plate unless it is necessary.
NOTE:
If it is removed, positioning dowel pin (dowel pins for crankshaft
and signal plate are specified as a single set) must be rein-
stalled.
18. Remove main bearing and thrust bearing from cylinder block and main bearing cap.
CAUTION:
Check mounting positions, and store them without mixing them up.
19. Remove baffle plate.
ASSEMBLY
1. Blow air sufficiently through engine coolant passage of cylinder block, oil passage, crank case and cylin-
der bore to remove foreign objects.
2. Install oil jet for timing chain lubrication.
●Face its flat surface upward, and push it as far as it will go.
3. Install baffle plate.
4. Install the main bearings and the thrust bearings.
a. Remove dust, dirt, and oil on the bearing mating surfaces of the
cylinder block and the lower cylinder block.
b. Install the thrust bearings to the both sides of the No. 3 journal
housing on the cylinder block.
●Install the thrust bearings with the oil groove facing the crank-
shaft arm (outside).
c. Install the main bearings paying attention to the direction.
●The main bearing with an oil hole and groove goes on the cyl-
inder block. The one without them goes on the lower cylinder
block.
●Main bearings (cylinder block side) for journal No. 1 and for
No. 2 to No. 5 are different.
●Before installing the bearings, apply engine oil to the bearing
surface (inside). Do not apply oil to the back surface, but thor-
oughly clean it.
●When installing, align the bearing stopper to the notch.
●Ensure the oil holes on cylinder block and those on the corre-
sponding bearing are aligned.
SEM928F
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5. Install the signal plate to the crankshaft.
a. Position crankshaft and signal plate using a positioning dowel
pin, and tighten mounting bolts.
b. Remove dowel pin. NISSAN ALMERA N16 2003 Electronic Repair Manual EM-76
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5. Install the signal plate to the crankshaft.
a. Position crankshaft and signal plate using a positioning dowel
pin, and tighten mounting bolts.
b. Remove dowel pin.](/img/5/57350/w960_57350-153.png)
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5. Install the signal plate to the crankshaft.
a. Position crankshaft and signal plate using a positioning dowel
pin, and tighten mounting bolts.
b. Remove dowel pin.
CAUTION:
Be sure to remove dowel pin.
NOTE:
●Dowel pins of crankshaft and signal plate are provided as a
set for each.
●If dowel pin is not available (when crankshaft and signal plate
are reused), use M6 bolt [length under head: 10 mm (0.39 in)
or longer] as its substitute.
6. Install the crankshaft to the cylinder block.
●While turning the crankshaft by hand, check that it turns smoothly.
7. Install main bearing cap.
●Main bearing cap is identified by identification paint No. made
on it before it is removed.
●Install it with arrow facing to front.
NOTE:
Main bearing cap cannot be replaced as a single part, because it
is machined together with cylinder block.
8. Tighten main bearing bolts in several steps in numerical order
shown in the figure.
●Apply engine oil onto thread and seat of mounting bolt.
●After tightening bolts to specified torque, make sure that
crankshaft rotates smoothly.
●Check crankshaft side clearance. Refer to EM-84, "CRANK-
SHAFT SIDE CLEARANCE" .
9. Install piston to connecting rod.
a. Using snap ring pliers, install snap ring to groove of piston rear side.
●Install with chamfered side facing piston pin side. Refer to EM-70, "Disassembly and Assembly" .
b. Install piston to connecting rod.
●Using hot-air blower, heat piston to 60 to 70°C (140 to 158°F) so that piston pin can be easily inserted
by hand. Insert piston pin into piston and connecting rod from front side of piston.
●Assemble so that front mark on piston head and oil hole in
connecting rod are positioned as shown in the figure.
c. Install snap ring to front side of piston.
●Refer to step “a” to install snap ring.
●After installation, make sure that connecting rod moves
smoothly.
PBIC0265E
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10. Install piston rings with piston ring expander (commercial ser-
vice tool).
CAUTION:
●Be careful not to damage piston.
●When instal NISSAN ALMERA N16 2003 Electronic Repair Manual CYLINDER BLOCK
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10. Install piston rings with piston ring expander (commercial ser-
vice tool).
CAUTION:
●Be careful not to damage piston.
●When instal](/img/5/57350/w960_57350-154.png)
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10. Install piston rings with piston ring expander (commercial ser-
vice tool).
CAUTION:
●Be careful not to damage piston.
●When installing top ring, be careful not to break end gap
step.
●Position end gaps of each piston ring to piston front mark as
shown in figure, then install rings.
●Install top ring with stamp mark side facing upward.
11. Install the connecting rod bearings to the connecting rod and the
connecting rod cap.
●When installing the connecting rod bearings, apply engine oil
to the bearing surface (inside). Do not apply oil to the back
surface, but thoroughly clean it.
●When installing, align the connecting rod bearing stopper pro-
trusion with the notch of the connecting rod to install.
●Check the oil holes on the connecting rod and those on the
corresponding bearing are aligned.
12. Install the piston and connecting rod assembly to the crankshaft.
●Position the crankshaft pin corresponding to the connecting
rod to be installed onto the bottom dead center.
●Apply engine oil sufficiently to the cylinder bore, piston and
crankshaft pin.
●Match the cylinder position with the cylinder No. on the con-
necting rod to install.
●Using a piston ring compressor, install the piston with the front
mark on the piston crown facing the front of the engine.
CAUTION:
Be careful not to damage the crankshaft pin, resulting from
an interference of the connecting rod big end.
13. Install the connecting rod cap.
●Match the stamped cylinder number marks on the connecting
rod with those on the cap to install.
PBIC0977E
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14. Tighten connecting rod nuts with the following procedure.
a. Lubricate connecting rod bolts and seat of nuts with new engine
oil.
b. Tighten to a torque of 13.72 - 1 NISSAN ALMERA N16 2003 Electronic Repair Manual EM-78
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14. Tighten connecting rod nuts with the following procedure.
a. Lubricate connecting rod bolts and seat of nuts with new engine
oil.
b. Tighten to a torque of 13.72 - 1](/img/5/57350/w960_57350-155.png)
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14. Tighten connecting rod nuts with the following procedure.
a. Lubricate connecting rod bolts and seat of nuts with new engine
oil.
b. Tighten to a torque of 13.72 - 15.68 N·m (1.4 - 1.5 kg-m, 10.2 -
11.5 ft-lb)
c. Turn all nuts another 35 to 40 degrees (Target: 35 degrees).
CAUTION:
Always use angle wrench (special service tool). Avoid tight-
ening based on visual check alone.
●After tightening nuts, make sure that crankshaft rotates
smoothly.
●Check connecting rod side clearance. Refer to EM-84, "CONNECTING ROD SIDE CLEARANCE" .
15. Install rear oil seal.
●Use an oil seal drift (commercial service tool) to press it in. At
this time, be careful not to cause any scratches or burrs on
circumference of oil seal.
●Press oil seal into rear oil seal retainer until it does not project
from end.
16. Install rear oil seal retainer.
●Apply continuous bead of liquid gasket to parts shown in fig-
ure.
●Install rear oil seal retainer by aligning it with dowel pins on
cylinder block.
17. Install rear plate.
SEM943F
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18. Install flywheel or drive plate.
●Install drive plate in direction shown in figure.
●Fix crankshaft with ring gear stopper (special service NISSAN ALMERA N16 2003 Electronic Repair Manual CYLINDER BLOCK
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18. Install flywheel or drive plate.
●Install drive plate in direction shown in figure.
●Fix crankshaft with ring gear stopper (special service](/img/5/57350/w960_57350-156.png)
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18. Install flywheel or drive plate.
●Install drive plate in direction shown in figure.
●Fix crankshaft with ring gear stopper (special service tool).
●Tighten mounting bolts diagonally in several steps.
19. Install oil level gauge guide.
●Press it in with punch mark for installing instruction in direction
shown in figure.
●Apply locking agent to pressed position.
20. Install knock sensor.
●Install sensor with connector facing lower right by 45° as
shown.
CAUTION:
●If any impact by dropping is applied to the knock sensor,
replace it with new one.
●Make sure that there is no foreign material on the cylin-
der block mating surface and the back surface of the
knock sensor.
●Do not tighten the mounting bolts while holding the con-
nector.
●Make sure that the knock sensor does not interfere with other parts.
21. Install crankshaft position sensor (POS).
●Tighten bolt after fully inserting crankshaft position sensor (POS) into cylinder block.
22. Tighten accessory brackets to the following tightening torque.
23. Assemble in the reverse order of disassembly.
PBIC0595E
PBIC0596E
Power steering pump bracket:
: 16.7 - 23.5 N·m (1.7 - 2.4 kg-m, 13 - 17 ft-lb)
Alternator air conditioner compressor bracket:
: 33.3 - 46.1 N·m (3.4 - 4.7 kg-m, 25 - 34 ft-lb)
PBIC0597E
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How to Select Piston and Bearing
EBS00LQN
DESCRIPTION
*For the service parts, the grade for fitting cannot be selected between a piston pin and a connecting NISSAN ALMERA N16 2003 Electronic Repair Manual EM-80
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How to Select Piston and Bearing
EBS00LQN
DESCRIPTION
*For the service parts, the grade for fitting cannot be selected between a piston pin and a connecting](/img/5/57350/w960_57350-157.png)
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How to Select Piston and Bearing
EBS00LQN
DESCRIPTION
*For the service parts, the grade for fitting cannot be selected between a piston pin and a connecting rod.
(Only 0 grade is available.) The information at the shipment from the plant is described as a reference.
●The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
●For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
●For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
HOW TO SELECT PISTON
When New Cylinder Block is Used
●Check the cylinder bore grade (1,2 or 3) on rear lower surface of
cylinder block, and select a piston of the same grade.
●QG15DE
Selection points Selection parts Selection items Selection methods
Between cylinder block to
crankshaftMain bearingMain bearing grade (bearing
thickness)Determined by match of cylin-
der block bearing housing
grade (inner diameter of hous-
ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Between crankshaft to connect-
ing rodConnecting rod bearingConnecting rod bearing grade
(bearing thickness)Connecting rod bearing grade
= crankshaft pin grade (outer
diameter of pin). No grade
exists for inner diameter to con-
necting rod large end.
Between cylinder block to pis-
tonPiston and piston pin assembly
The piston is available together
with piston pin as an assembly.Piston grade (piston outer
diameter)Piston grade = cylinder bore
grade (inner diameter of bore)
*Between piston to connecting
rod———
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●QG18DE
When Cylinder Block is Reused
1. Measure the cylinder block bore inner diameter.
2. Determine the bore grade by comparing the measurement NISSAN ALMERA N16 2003 Electronic Repair Manual CYLINDER BLOCK
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●QG18DE
When Cylinder Block is Reused
1. Measure the cylinder block bore inner diameter.
2. Determine the bore grade by comparing the measurement](/img/5/57350/w960_57350-158.png)
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●QG18DE
When Cylinder Block is Reused
1. Measure the cylinder block bore inner diameter.
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner
diameter of the “Piston Selection Table”. Select the piston of the same grade.
Piston Selection Table
QG15DE
Unit: mm (in)
QG18DE
Unit: mm (in)
CAUTION:
No stamp mark is only applied to piston side.
NOTE:
●The piston is available together with piston pin as an assembly.
●The piston pin (piston pin bore) grade is provided only for the parts installed at the plant. For service parts,
no grades can be selected. (Only 0 grade is available.)
HOW TO SELECT CONNECTING ROD BEARING
When New Connecting Rod and Crankshaft are Used
●Compare the pin diameter grade (0, 1 or 2) of the crankshaft on
front surface with the values of the selection table of connecting
rod bearing.
NOTE:
There is no grading for connecting rod big end.
When Crankshaft and Connecting Rod are Reused
1. Confirm connecting rod big end inner diameter is within the standard.
2. Measure the pin outer diameter of the crankshaft.
YEM056
Grade number (Mark) 1 2 (or no punching) 3
Inner diameter of cylinder bore73.600 - 73.610
(2.8976 - 2.8980)73.610 - 73.620
(2.8980 - 2.8984)73.620 - 73.630
(2.8984 - 2.8988)
Outer diameter of piston73.575 - 73.585
(2.8966 - 2.8970)73.585 - 73.595
(2.8970 - 2.8974)73.595 - 73.605
(2.8974 - 2.8978)
Grade number (Mark) 1 2 (or no punching) 3
Inner diameter of cylinder bore80.000 - 80.010
(3.1496 - 3.1500)80.010 - 80.020
(3.1500 - 3.1504)80.020 - 80.030
(3.1504 - 3.1508)
Outer diameter of piston79.965 - 79.975
(3.1482 - 3.1486)79.975 - 79.985
(3.1486 - 3.1490)79.985 - 79.995
(3.1490 - 3.1494)
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3. Find measured dimension in “Crankshaft pin outer diameter” column in selective-fit service parts table,
and select connecting rod bearing of same grade nu NISSAN ALMERA N16 2003 Electronic Repair Manual EM-82
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3. Find measured dimension in “Crankshaft pin outer diameter” column in selective-fit service parts table,
and select connecting rod bearing of same grade nu](/img/5/57350/w960_57350-159.png)
EM-82
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3. Find measured dimension in “Crankshaft pin outer diameter” column in selective-fit service parts table,
and select connecting rod bearing of same grade number.
Connecting Rod Bearing Selection Table
Unit: mm (in)
Undersize Bearings Usage Guide
●When the specified oil clearance is not obtained with standard size connecting rod bearings, use under-
size (US) bearings.
●When using undersize bearing, measure the bearing inner diameter with bearing installed, and grind the
crankshaft pin so that the oil clearance satisfies the standard.
Bearing undersize table
Unit: mm (in)
CAUTION:
In grinding the crankshaft pin to use undersize bearings, keep
the fillet R (All crankshaft pins).
HOW TO SELECT MAIN BEARING
When New Cylinder Block and Crankshaft are Used
1. Apply main bearing housing grade (0, 1 or 2) on bottom of cylin-
der block banks to row in main bearing selection table.
Connecting rod big end ID 43.000 - 43.013 (1.6929 - 1.6934)
Crankshaft pin OD Grade (punched) 0 (no punching)
39.968 - 39.974
(1.5735 - 1.5738)0
●Bearing grade No.
●Bearing thickness
●Oil clearance
●Identification colorSTD 0
1.503 - 1.506 (0.0592 - 0.0593)
0.014 - 0.039 (0.0006 - 0.0015)
Black
39.962 - 39.968
(1.5733 - 1.5735)1
●Bearing grade No.
●Bearing thickness
●Oil clearance
●Identification colorSTD 1
1.506 - 1.509 (0.0593 - 0.0594)
0.014 - 0.039 (0.0006 - 0.0015)
Red
39.956 - 39.962
(1.5731 - 1.5733)2
●Bearing grade No.
●Bearing thickness
●Oil clearance
●Identification colorSTD 2
1.509 - 1.512 (0.0594 - 0.0595)
0.014 - 0.039 (0.0006 - 0.0015)
Green
Size Thickness
US 0.08 (0.0031) 1.542 - 1.546 (0.0607 - 0.0609)
US 0.12 (0.0047) 1.562 - 1.566 (0.0615 - 0.0617)
US 0.25 (0.0098) 1.627 - 1.631 (0.0641 - 0.0642)
PBIC0491E
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