NISSAN ALMERA N16 2003 Electronic Repair Manual

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 CHECKNJEM0067S02Measure 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 CHECKNJEM0067S03After 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-3,
“Liquid Gasket Application Procedure”.) 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.
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
CYLINDER HEADYD
Installation (Cont’d)
EM-57

JEM149G
JEM166G
CYLINDER HEAD INSTALLATIONNJEM0067S05Tighten 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 180° to 185° [target: 180°] (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 90° to 95° [target: 90°] (angular tightening).
7. Tighten another 90° to 95° [target: 90°] (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 INSTALLATIONNJEM0067S06To 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-58

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. Tightento12to13N·m(1.2to1.4kg-m,9to10ft-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-59,
“Valve Clearance”.
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.
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
CYLINDER HEADYD
Installation (Cont’d)
EM-59

JEM178G
3. Check only those valves shown in the figure.
Crank positionValve
No. 1 No. 2 No. 3 No. 4
INT EXH INT EXH INT EXH INT EXH
No. 1 TDC
(Compression
stroke)
JEM179G
Using a feeler gauge, measure clearance between valve lifter
and camshaft.
Record any valve clearance measurements which are out of
specification. They will be used later to determine the required
replacement adjusting shim.
Valve clearance for checking (Cold):
Intake
0.24 - 0.32 mm (0.0094 - 0.0126 in)
Exhaust
0.26 - 0.34 mm (0.0102 - 0.0134 in)
JEM180G
4. Rotate crankshaft clockwise by one turn to set the No. 4 pis-
ton to TDC on the compression stroke.
5. Check only those valves shown in the figure.
Crank positionValve
No. 1 No. 2 No. 3 No. 4
INT EXH INT EXH INT EXH INT EXH
No. 4 TDC
(Compression
stroke)
JEM181G
ADJUSTINGNJEM0068S02Adjust valve clearance while engine is cold.
1. Turn crankshaft, to position cam lobe on camshaft of valve that
must be adjusted upward.
2. Place Tool (A) around camshaft as shown in figure.
Before placing Tool (A) (SST), rotate notch toward center
of cylinder head (See figure.), to simplify shim removal
later.
CAUTION:
Be careful not to damage cam surface with Tool (A).
SEM497G
3. Rotate Tool (A) (See figure.) so that valve lifter is pushed down.
CYLINDER HEADYD
Valve Clearance (Cont’d)
EM-60

SEM498G
4. Place Tool (B) (SST) between camshaft and the edge of the
valve lifter to retain valve lifter.
CAUTION:
Tool (B) must be placed as close to camshaft bracket as
possible.
Be careful not to damage cam surface with Tool (B).
5. Remove Tool (A).
JEM555G
6. Blow air into the hole to separate adjusting shim from valve
lifter.
To avoid engine oil spills, wipe off oil fully beforehand.
Wear safety goggles, etc. during work if necessary.
JEM556G
SEM145D
JEM184G
7. Remove adjusting shim using a small screwdriver and a mag-
netic finger.
8. Determine replacement adjusting shim size following formula.
Using a micrometer determine thickness of removed shim.
Calculate thickness of new adjusting shim so valve clearance
comes within specified values.
R = Thickness of removed shim
N = Thickness of new shim
M = Measured valve clearance
Intake:
N=R+[M−0.28mm(0.0110in)]
Exhaust:
N=R+[M−0.30mm(0.0118in)]
Shims are available in 33 sizes from 2.10 mm (0.0827 in)
to 2.74 mm (0.1079 in), in steps of 0.02 mm (0.0008 in).
Select new shim with thickness as close as possible to calcu-
lated value.
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
CYLINDER HEADYD
Valve Clearance (Cont’d)
EM-61

SEM552G
9. Install new shim using a suitable tool.
Install with the surface on which the thickness is stamped
facing down.
10. Place Tool (A) as mentioned in steps 2 and 3.
11. Remove Tool (B).
12. Remove Tool (A).
13. Recheck valve clearance.
Valve clearance:
Unit: mm (in)
Cold Hot* (reference data)
Intake 0.24 - 0.32 (0.009 - 0.013) 0.274 - 0.386 (0.011 - 0.015)
Exhaust 0.26 - 0.34 (0.010 - 0.013) 0.308 - 0.432 (0.012 - 0.017)
*: Approximately 80°C (176°F)
CYLINDER HEADYD
Valve Clearance (Cont’d)
EM-62

Removal and InstallationNJEM0069
SEM554G
WARNING:
Situate vehicle on a flat and solid surface.
Place chocks at front and back of rear wheels.
Do not remove engine until exhaust system has com-
pletely cooled off. Otherwise, you may burn yourself
and/or fire may break out in fuel line.
For safety during subsequent steps, the tension of wires
should be slackened against the engine.
Before removing front axle from transaxle, place safety
stands under designated front supporting points. Refer to
GI-46, “Garage Jack and Safety Stand”.
Be sure to hoist engine and transaxle in a safe manner.
For engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG.
CAUTION:
When lifting engine, be careful not to strike adjacent parts,
especially the following: Accelerator wire casing, brake
lines, and brake master cylinder.
In hoisting the engine, always use engine slingers in a
safe manner.
In removing drive shaft, be careful not to damage grease
seal of transaxle.
Before separating engine and transaxle, remove the
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
ENGINE ASSEMBLYYD
Removal and Installation
EM-63

crankshaft position sensor (TDC sensor) from the assem-
bly.
Always pay extra attention not to damage edge of crank-
shaft position sensor (TDC sensor) or ring gear teeth.
REMOVALNJEM0069S011. Remove engine undercover, and hood for hoisting.
2. Drain coolant from both cylinder block and radiator. Refer to
LC-43, “Changing Engine Coolant”.
3. Remove the following parts:
Battery
RH and LH front wheels
RH and LH splash covers (combined with undercover)
Auxiliary belts
Alternator
Alternator brackets
Radiator and cooling fan
Engine cover
Air ducts and air cleaner case
LH side of engine room:
4. Disconnect all harnesses and grounds that are connected to
components on vehicle.
5. Disconnect vacuum hose on vacuum pump side.
6. Disconnect fuel feed and fuel return hoses on engine side.
Immediately put blind plugs into the openings to prevent
fuel from flowing out.
7. Disconnect heater hose. Plug opening of hose to prevent cool-
ant from flowing out.
RH side of engine room:
8. Remove air conditioner compressor from brackets and move
it toward vehicle side. Secure compressor on vehicle side with
rope.
Vehicle underside:
9. Remove exhaust front tube.
10. Disconnect two hoses from power steering pump and plug to
stop fluid.
11. Remove M/T control rod and support rod.
12. Remove ABS wheel sensor, and temporarily hang brake cali-
per with rope on vehicle side.
13. Remove RH and LH drive shafts.
YEM024
14. Install engine slingers to cylinder head.
: 30 - 37 N·m (3.0 - 3.8 kg-m, 22 - 27 ft-lb)
Use engine slingers and securing bolts of the specified
service parts.
15. Lift up vehicle to appropriate level where work can be per-
formed efficiently. Using two transmission jacks, securely sup-
port engine oil pan and bottom surface of transaxle.
ENGINE ASSEMBLYYD
Removal and Installation (Cont’d)
EM-64

SEM189G
Make sure that support is stable with the use of safety
blocks.
16. Install hooks of lifting chain into engine slingers and tighten
chain so that engine still remains on transmission jacks with-
out being lifted up.
17. Remove engine mount insulator RH.
18. Remove through-bolt of engine mount insulator LH.
19. Remove bolts securing center member at front and rear.
JEM190G
20. Carefully lower transmission jacks in accordance with the low-
ering pace of the hoist, and remove engine and transaxle
assembly from vehicle.
While working, check that no parts of engine assembly
interfere with adjacent parts on the vehicle.
While working, make sure that parts requiring disconnec-
tion are not left connected, and that no parts interfere with
vehicle.
To prevent vehicle from falling down, perform operation
carefully so that the center of gravity of the vehicle will not
shift.
21. Remove center member.
Before starting removal operation, first place the assem-
bly on a level surface and securely support the bottom
surface with wood blocks. Using a hoist, lift engine
slingers, and make sure the assembly is stable.
22. Separate engine and transaxle.
INSTALLATIONNJEM0069S02Install in the reverse order of removal, observing the following:
While installing, be careful to keep mount insulators free of oil
smear and damage.
When parts require specified installation directions/positions,
install by using the identifying marks indicating up or front.
While keeping the mount insulators free of twists or distortions,
start tightening from the through-bolt on the engine mount
insulator LH. This mount is used as the reference position.
GI
MA
LC
EC
FE
CL
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
ENGINE ASSEMBLYYD
Removal and Installation (Cont’d)
EM-65

ComponentsNJEM0070
SEM510GA
CYLINDER BLOCKYD
Components
EM-66