NISSAN ALMERA N16 2003 Electronic Repair Manual

CYLINDER BLOCK
EM-83
[QG]
C
D
E
F
G
H
I
J
K
L
MA
EM
2. Apply journal diameter grade (0, 1 or 2) on crankshaft front to
column in main bearing selection table.
3. Select main bearing (STD 0 - 4) at the point where selected row
and column meet in following main bearing selection table.
When Cylinder Block and Crankshaft are Reused
1. Measure dimension of main bearing housing on cylinder block.
2. Find measured dimension in “Cylinder block main bearing housing inner diameter” row in following main
bearing selection table.
3. Measure crankshaft journal diameter.
4. Find measured dimension in “Crankshaft journal outer diameter” column in following main bearing selec-
tion table.
5. Select main bearing (STD 0 - 4) at the point where selected row and column meet in following main bear-
ing selection table.
Main Bearing Selection Table
Unit: mm (in)
Use Undersize Bearing Usage Guide
●Use undersize (US) bearing when oil clearance with standard size main bearing is not within specification.
●When using undersize (US) bearing, measure the bearing inner diameter with bearing installed, and grind
journal until oil clearance falls within specification.
PBIC0607E
Connecting block main bearing housing ID53.644 - 53.652
(2.1120 - 2.1123)53.652 - 53.660
(2.1123 - 2.1126)53.660 - 53.668
(2.1126 - 2.1129)
Crankshaft journal
ODGrade
(punched)012
49.956 - 49.964
(1.9668 - 1.9671)0
●Bearing grade No.
●Bearing thickness
●Oil clearance
●Identification colorSTD 0
1.826 - 1.830
(0.0719 - 0.0720)
0.020 - 0.044
(0.0008 - 0.0017)
BlackSTD 1
1.830 - 1.834
(0.0720 - 0.0722)
0.020 - 0.044
(0.0008 - 0.0017)
RedSTD 2
1.834 - 1.838
(0.0722 - 0.0724)
0.020 - 0.044
(0.0008 - 0.0017)
Green
49.948 - 49.956
(1.9665 - 1.9668)1
●Bearing grade No.
●Bearing thickness
●Oil clearance
●Identification colorSTD 1
1.830 - 1.834
(0.0720 - 0.0722)
0.020 - 0.044
(0.0008 - 0.0017)
RedSTD 2
1.834 - 1.838
(0.0722 - 0.0724)
0.020 - 0.044
(0.0008 - 0.0017)
GreenSTD 3
1.838 - 1.842
(0.0724 - 0.0725)
0.020 - 0.044
(0.0008 - 0.0017)
Ye l l o w
49.940 - 49.948
(1.9661 - 1.9665)2
●Bearing grade No.
●Bearing thickness
●Oil clearance
●Identification colorSTD 2
1.834 - 1.838
(0.0722 - 0.0724)
0.020 - 0.044
(0.0008 - 0.0017)
GreenSTD 3
1.838 - 1.842
(0.0724 - 0.0725)
0.020 - 0.044
(0.008 - 0.0017)
Ye l l o wSTD 4
1.842 - 1.846
(0.0725 - 0.0727)
0.020 - 0.044
(0.0008 - 0.0017)
Blue

EM-84
[QG]
CYLINDER BLOCK
Bearing undersize table
Unit: mm (in)
CAUTION:
Keep fillet R when grinding crankshaft journal in order to use
undersize bearing (All journals).
Inspection After DisassemblyEBS00LQO
CRANKSHAFT SIDE CLEARANCE
●Using a dial gauge, measure the clearance between the thrust
bearings and the crankshaft arm when the crankshaft is moved
fully forward or backward.
●If the measured value exceeds the limit, replace the thrust bear-
ings, and measure again. If it still exceeds the limit, replace the
crankshaft also.
CONNECTING ROD SIDE CLEARANCE
●Measure side clearance between connecting rod and crankshaft
arm with feeler gauge.
●If the measured value exceeds the limit, replace the connecting
rod bearings, and measure again. If it still exceeds the limit,
replace the crankshaft also.
PISTON AND PISTON PIN CLEARANCE
Inner Diameter of Piston Pin
●Measure the inner diameter of piston pin bore with an inside
micrometer.
Size Thickness
US 0.25 (0.0098) 1.960 - 1.964 (0.0722 - 0.0773)
US 0.50 (0.0197) 2.085 - 2.089 (0.0821 - 0.0822)
PBIC0491E
Standard : 0.060 - 0.260 mm (0.0024 - 0.0102 in)
Limit : 0.3 mm (0.012 in)
PBIC0608E
Standard : 0.200 - 0.470 mm (0.0079 - 0.0185 in)
Limit : 0.5 mm (0.020 in)
PBIC0609E
Standard:
QG15DE : 18.987 - 18.999 mm (0.7475 - 0.7480 in)
QG18DE : 18.993 - 18.999 mm (0.7478 - 0.7480 in)
PBIC0116E

CYLINDER BLOCK
EM-85
[QG]
C
D
E
F
G
H
I
J
K
L
MA
EM
Outer Diameter of Piston Pin
●Measure outer diameter of piston pin with a micrometer.
Piston and Piston Pin Clearance
(Piston pin clearance) = (Piston pin bore diameter) – (Outer diameter of piston pin)
●If clearance exceeds specification, replace either or both of piston/piston pin assembly and connecting rod
assembly with reference to specification of each parts.
●Refer to piston selection table to replace piston/piston pin assembly, refer to EM-80, "HOW TO SELECT
PISTON" .
NOTE:
●Regarding marks on piston head, refer to EM-80, "HOW TO SELECT PISTON" .
●Piston pin hole (piston pin) grade are provided only for the parts
installed at the plant. For service parts, no grades can be
selected. (Only 0 grade is available.)
PISTON RING SIDE CLEARANCE
●Measure side clearance of piston ring and piston ring groove
with feeler gauge.Standard : 18.989 - 19.001 mm (0.7476 - 0.7481 in)
PBIC0117E
Standard:
QG15DE : − 0.004 to 0 mm (− 0.0002 to 0 in)
QG18DE : 0.002 - 0.006 mm (0.0001 - 0.0002 in)
PBIC0591E
PBIC0610E

EM-86
[QG]
CYLINDER BLOCK
QG15DE
QG18DE
●If out of specification, replace piston and/or piston ring assembly.
PISTON RING END GAP
●Check if inner diameter of cylinder bore is within specification.
Refer to EM-88, "
PISTON TO CYLINDER BORE CLEARANCE"
.
●Insert piston ring until middle of cylinder with piston, and mea-
sure gap.
●If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylin-
der and use oversized piston and piston ring.
CONNECTING ROD BEND AND TORSION
●Check with connecting rod aligner.Standard:
Top ring : 0.045 - 0.080 mm (0.0018 - 0.0031 in)
2nd ring : 0.030 - 0.070 mm (0.0012 - 0.0028 in)
Oil ring : 0.065 - 0.135 mm (0.0026 - 0.0053 in)
Limit:
Top ring : 0.110 mm (0.0043 in)
2nd ring : 0.100 mm (0.0039 in)
Standard:
Top ring : 0.040 - 0.080 mm (0.0016 - 0.0031 in)
2nd ring : 0.030 - 0.070 mm (0.0012 - 0.0028 in)
Oil ring : 0.045 - 0.155 mm (0.0018 - 0.0061 in)
Limit:
Top ring : 0.110 mm (0.0043 in)
2nd ring : 0.100 mm (0.0039 in)
Standard:
Top ring : 0.20 - 0.39 mm (0.0079 - 0.0154 in)
2nd ring : 0.32 - 0.56 mm (0.0126 - 0.0220 in)
Oil ring : 0.20 - 0.69 mm (0.0079 - 0.0272 in)
Limit:
Top ring : 0.54 mm (0.0213 in)
2nd ring : 0.67 mm (0.0264 in)
Oil ring : 0.95 mm (0.0374 in)
SEM822B
Bend:
Limit : 0.15 mm (0.0059 in) per 100 mm (3.94 in) length
Torsion:
Limit : 0.30 mm (0.0118 in) per 100 mm (3.94 in) length
SEM038F

CYLINDER BLOCK
EM-87
[QG]
C
D
E
F
G
H
I
J
K
L
MA
EM
●If it exceeds the limit, replace connecting rod assembly.
CONNECTING ROD BEARING (BIG END)
●Install the connecting rod cap without the connecting rod bearing
installed. After tightening the connecting rod bolt to the specified
torque, measure the connecting rod big end inner diameter
using an inside micrometer.
CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)
Inner Diameter of Connecting Rod (Small End)
●Measure inner diameter of bushing.
Outer Diameter of Piston Pin
●Measure outer diameter of piston pin.
Connecting Rod Bushing Oil Clearance (Small End)
(Connecting rod small end oil clearance) = (Inner diameter of connecting rod small end) – (Outer diameter of
piston pin)
●If the measured value exceeds the standard, replace the connecting rod assembly and/or piston and pis-
ton pin assembly.
SEM003F
Standard : 43.000 - 43.013 mm (1.6929 - 1.6934 in) dia.
PBIC0119E
Standard : 19.000 - 19.012 mm (0.7480 - 0.7485 in) dia.
PBIC0120E
Standard : 18.989 - 19.001 mm (0.7476 - 0.7481 in)
PBIC0117E
Standard : 0.005 - 0.017 mm (0.0002 - 0.0007 in)

EM-88
[QG]
CYLINDER BLOCK
●If replacing the piston and piston pin assembly, refer to the “Piston Selection Table” to select the piston
corresponding to the applicable bore grade of the cylinder block to be used. Refer to EM-80, "
HOW TO
SELECT PISTON" .
Factory installed parts grading:
●Service parts apply only to grade 0.
Unit: mm (in)
CYLINDER BLOCK DISTORTION
●Using a scraper, remove gasket on the cylinder block surface,
and also remove oil, scale, carbon, or other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter the oil or cool-
ant passages.
●Measure the distortion on the block upper face at some different
points in 6 directions.
●If out of the distortion limit, replace the cylinder block.
INNER DIAMETER OF MAIN BEARING HOUSING
●Install the main bearing caps with the main bearings removed,
and tighten the mounting bolts to the specified torque.
●Using a bore gauge, measure the inner diameter of the main
bearing housing.
●If out of the standard, replace the cylinder block and lower cylin-
der block assembly.
NOTE:
These components cannot be replaced as a single unit because
they were processed together.
PISTON TO CYLINDER BORE CLEARANCE
Inner Diameter of Cylinder Bore
●Using a bore gauge, measure cylinder bore for wear, out-of-
round and taper at 6 different points on each cylinder. (X and Y
directions at A, B and C) (Y is in longitudinal direction of engine)
Grade 0 1
Connecting rod small end inner diam-
eter19.000 - 19.006
(0.7480 - 0.7483)19.006 - 19.012
(0.7483 - 0.7485)
Piston pin outer diameter18.989 - 18.995
(0.7476 - 0.7478)18.995 - 19.001
(0.7478 - 0.7481)
Piston pin hole diameterQG15DE18.987 - 18.993
(0.7475 - 0.7478)18.993 - 18.999
(0.7478 - 0.7480)
QG18DE18.993 - 18.996
(0.7478- 0.7479)18.996 - 18.999
(0.7479 - 0.7480)
PBIC0591E
Limit : 0.1 mm (0.004 in)
PBIC0121E
Standard : 53.644 - 53.668 mm (2.1120 - 2.1129 in) dia.
PBIC0611E
PBIC0612E

CYLINDER BLOCK
EM-89
[QG]
C
D
E
F
G
H
I
J
K
L
MA
EM
●If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
hone or rebore the inner wall.
●An oversize piston is provided. When using an oversize piston, rebore the cylinder so that the clearance
of the piston cylinder satisfies the standard.
Outer Diameter of Piston
●Measure piston skirt diameter.
Piston to Cylinder Bore Clearance
●Calculate by outer diameter of piston skirt and inner diameter of cylinder (direction X, position B).
(Clearance) = (Inner diameter of cylinder) – (Outer diameter of piston skirt).
●If it exceeds the standard, replace piston/piston pin assembly.
Reboring Cylinder Bore
1. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter “A”.
2. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted
in final assembly.Standard inner diameter:
QG15DE : 73.600 - 73.630 mm (2.8976 - 2.8988 in) dia.
QG18DE : 80.000 - 80.030 mm (3.1496 - 3.1508 in) dia.
Wear limit:
0.2 mm (0.008 in)
Out-of-round (Difference between X and Y):
0.015 mm (0.0006 in)
Taper limit (Difference between A and C):
0.01 mm (0.0004 in)
Oversize (OS) : 0.25 mm (0.0098 in)
: 0.5 mm (0.0197 in)
PBIC0613E
QG15DE
Measuring
point: 43.6 mm (1.717 in) below piston head
upper edge
Standard : 73.575 - 73.605 mm (2.8966 - 2.8978 in)
dia.
QG18DE
Measuring
point: 42.3 mm (1.665 in) below piston head
upper edge
Standard : 79.965 - 79.995 mm (3.1482 - 3.1494 in)
dia.
PBIC0125E
QG15DE
Standard : 0.015 - 0.035 mm (0.0006 - 0.0014 in)
QG18DE
Standard : 0.025 - 0.045 mm (0.010 - 0.018 in)
Rebored size calculation: D = A + B - C
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston - to - bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 in)

EM-90
[QG]
CYLINDER BLOCK
3. Cut cylinder bores.
●When any cylinder needs boring, all other cylinders must also be bored.
●Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter
at a time.
4. Hone cylinders to obtain specified piston-to-bore clearance.
5. Measure finished cylinder bore for out-of-round and taper.
●Measurement should be done after cylinder bore cools down.
OUTER DIAMETER OF CRANKSHAFT JOURNAL
●Measure outer diameter of crankshaft journals.
OUTER DIAMETER OF CRANKSHAFT PIN
●Measure outer diameter of crankshaft pin.
OUT-OF-ROUND AND TAPER OF CRANKSHAFT
●Using a micrometer, measure the dimensions at 4 different
points shown in the figure on each journal and pin.
●Out-of-round is indicated by the difference in dimensions
between A and B at 1 and 2.
●Taper is indicated by the difference in dimension between 1 and
2 at A and B.
CRANKSHAFT RUNOUT
●Place a V-block on a precise flat table to support the journals on
the both end of the crankshaft.
●Place a dial gauge straight up on the No. 3 journal.
●While rotating the crankshaft, read the movement of the pointer
on the dial gauge. (Total indicator reading)Standard : 49.940 - 49.964 mm (1.9661 - 1.9671 in) dia.
Standard : 39.956 - 39.974 mm (1.5731 - 1.5738 in) dia.
PBIC0270E
Limit:
Out-of-round (A – B) : 0.005 mm (0.0002 in)
Taper (1 – 2) : 0.005 mm (0.0002 in)
PBIC0614E
Limit: : 0.10 mm (0.004 in)
PBIC0271E

CYLINDER BLOCK
EM-91
[QG]
C
D
E
F
G
H
I
J
K
L
MA
EM
OIL CLEARANCE OF CONNECTING ROD BEARING
Method of Measurement
●Install the connecting rod bearings to the connecting rod and the
cap, and tighten the connecting rod bolts to the specified torque.
Using a inside micrometer measure the inner diameter of con-
necting rod bearing.
(Oil clearance) = (Inner diameter of connecting rod bearing) – (Outer
diameter of crankshaft pin)
●If clearance cannot be adjusted within the standard, grind crank-
shaft pin and use undersized bearing. Refer to EM-81, "
HOW
TO SELECT CONNECTING ROD BEARING" .
Method of Using Plastigage
●Remove oil and dust on the crankshaft pin and the surfaces of
each bearing completely.
●Cut a plastigage slightly shorter than the bearing width, and
place it in crankshaft axial direction, avoiding oil holes.
●Install the connecting rod bearings to the connecting rod cap,
and tighten the connecting rod bolts to the specified torque.
CAUTION:
Never rotate the crankshaft.
●Remove the connecting rod cap and bearings, and using the
scale on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is same as that described in the method by
calculation.
OIL CLEARANCE OF MAIN BEARING
Method of Measurement
●Install the main bearings to the cylinder block and bearing cap. Measure the main bearing inner diameter
with the bearing cap bolt tightened to the specified torque.
(Oil clearance) = (Inner diameter of main bearing) – (Outer diameter of crankshaft journal)
●If the measured value exceeds the limit, select main bearings referring to the main bearing inner diameter
and crankshaft journal outer diameter, so that the oil clearance satisfies the standard. Refer to EM-82,
"HOW TO SELECT MAIN BEARING" .
Method of Using Plastigage
●Remove oil and dust on the crankshaft journal and the surfaces
of each bearing completely.
●Cut a plastigage slightly shorter than the bearing width, and
place it in crankshaft axial direction, avoiding oil holes.
●Tighten the main bearing bolts to the specified torque.
CAUTION:
Never rotate the crankshaft.
●Remove the bearing cap and bearings, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in “the method by calculation.”Standard : 0.014 - 0.039 mm (0.0006 - 0.0015 in)
Limit : 0.10 mm (0.0039 in)
PBIC0119E
EM142
Standard : 0.020 - 0.044 mm (0.0008 - 0.0017 in)
Limit : 0.1 mm (0.004 in)
EM142

EM-92
[QG]
CYLINDER BLOCK
CRUSH HEIGHT OF MAIN BEARING
●When the bearing cap is removed after being tightened to the
specified torque with main bearings installed, the tip end of bear-
ing must protrude.
●If the standard is not met, replace main bearings.
FLYWHEEL RUNOUT
●Measure deflection of contact surface with dial gauge.Standard : There must be crush height
SEM502G
Flywheel (M/T models)
Limit : 0.1 mm (0.004 in)
SEM931F