NISSAN ALMERA N16 2003 Electronic Repair Manual

Va l v eNJEM0078VA L V ENJEM0078S01Unit: mm (in)
SEM188
Valve head diameter “D”Intake 28.0 - 28.3 (1.102 - 1.114)
Exhaust 26.0 - 26.3 (1.024 - 1.035)
Valve length “L”Intake 106.72 (4.2016)
Exhaust 106.36 (4.1874)
Valve stem diameter “d”Intake 5.965 - 5.980 (0.2348 - 0.2354)
Exhaust 5.945 - 5.960 (0.2341 - 0.2346)
Valve seat angle “α”Intake
45°15′- 45°45′
Exhaust
Valve margin “T”Intake 1.38 (0.0543)
Exhaust 1.48 (0.0583)
Valve margin “T” limitMore than 1.0 (0.039)
Valve stem end surface grinding limit Less than 0.2 (0.008)
VALVE CLEARANCENJEM0078S02Unit: 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)
AVAILABLE SHIMSNJEM0078S03
Thickness mm (in) Identification mark
2.10 (0.0827) 2.10
2.12 (0.0835) 2.12
2.14 (0.0843) 2.14
2.16 (0.0850) 2.16
2.18 (0.0858) 2.18
2.20 (0.0866) 2.20
2.22 (0.0874) 2.22
2.24 (0.0882) 2.24
2.26 (0.0890) 2.26
2.28 (0.0898) 2.28
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SERVICE DATA AND SPECIFICATIONS (SDS)YD
Valve
EM-87

Thickness mm (in) Identification mark
2.30 (0.0906) 2.30
2.32 (0.0913) 2.32
2.34 (0.0921) 2.34
2.36 (0.0929) 2.36
2.38 (0.0937) 2.38
2.40 (0.0945) 2.40
2.42 (0.0953) 2.42
2.44 (0.0961) 2.44
2.46 (0.0969) 2.46
2.48 (0.0976) 2.48
2.50 (0.0984) 2.50
2.52 (0.0992) 2.52
2.54 (0.1000) 2.54
2.56 (0.1008) 2.56
2.58 (0.1016) 2.58
2.60 (0.1024) 2.60
2.62 (0.1031) 2.62
2.64 (0.1039) 2.64
2.66 (0.1047) 2.66
2.68 (0.1055) 2.68
2.70 (0.1063) 2.70
2.72 (0.1071) 2.72
2.74 (0.1079) 2.74
SEM512G
VALVE SPRINGNJEM0078S04
Free height mm (in) Outer 42.3 (1.6654)
Pressure N (kg, lb) at height mm (in)
Outer350 - 382 (35.7 - 37.9, 78.7 - 83.6) at 24.82
(0.9772)
Out-of-square mm (in) Outer Limit 2.1 (0.083)
SERVICE DATA AND SPECIFICATIONS (SDS)YD
Valve (Cont’d)
EM-88

VALVE LIFTERNJEM0078S05Unit: mm (in)
Valve lifter outer diameter 29.960 - 29.975 (1.1795 - 1.1801)
Lifter guide inner diameter 30.000 - 30.021 (1.1181 - 1.1819)
Clearance between lifter and lifter guide 0.025 - 0.061 (0.0010 - 0.0024)
VALVE GUIDENJEM0078S06Unit: mm (in)
JEM156G
Standard Service
Valve guide Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029)
Valve guide Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369)
Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014)
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Standard Limit
Stem to guide clearanceIntake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031)
Exhaust 0.040 - 0.073 (0.0016 - 0.0029) 0.1 (0.004)
Valve deflection limit0.15 (0.0059)
Projection length10.4 - 10.6 (0.4094 - 0.4173)
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SERVICE DATA AND SPECIFICATIONS (SDS)YD
Valve (Cont’d)
EM-89

Valve SeatNJEM0079Unit: mm (in)
SEM546G
JEM253G
Standard Service
Cylinder head seat recess diameter (D)Intake 30.000 - 30.016 (1.1181 - 1.1817) 30.500 - 30.516 (1.2008 - 1.2014)
Exhaust 29.000 - 29.016 (1.1417 - 1.1424) 29.500 - 29.516 (1.1614 - 1.1620)
Valve seat interference fitIntake 0.064 - 0.100 (0.0025 - 0.0039)
Exhaust 0.064 - 0.096 (0.0025 - 0.0038)
Valve seat outer diameter (d)Intake 30.080 - 30.100 (1.1842 - 1.1850) 30.580 - 30.600 (1.2039 - 1.2047)
Exhaust 29.080 - 29.096 (1.1449 - 1.1455) 29.580 - 29.596 (1.1646 - 1.1652)
SERVICE DATA AND SPECIFICATIONS (SDS)YD
Valve Seat
EM-90

Height (h)Intake 7.0 - 7.1 (0.276 - 0.280) 6.60 - 6.70 (0.2598 - 0.2638)
Exhaust 6.7 - 6.8 (0.264 - 0.268) 6.3 - 6.4 (0.248 - 0.252)
Depth (H)Intake 8.83 - 9.13 (0.3476 - 0.3594)
Exhaust 9.06 - 9.36 (0.3567 - 0.3685)
Depth (L)Intake 36.53 - 36.98 (1.4382 - 1.4559)
Exhaust 36.53 - 37.01 (1.4382 - 1.4571)
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SERVICE DATA AND SPECIFICATIONS (SDS)YD
Valve Seat (Cont’d)
EM-91

Camshaft and Camshaft Bearing=NJEM0080Unit: mm (in)
Standard Limit
Camshaft journal to bearing clearance 0.045 - 0.086 (0.0018 - 0.0034) 0.045 - 0.086 (0.0018 - 0.0034)
Inner diameter of camshaft bearingNo. 1
30.500 - 30.521 (1.2008 - 1.2016)
No. 2, 3, 4, 5
24.000 - 24.021 (0.9449 - 0.9457)—
Outer diameter of camshaft journalNo. 1
30.435 - 30.455 (1.1982 - 1.1990)
No. 2, 3, 4, 5
23.935 - 23.955 (0.9423 - 0.9431)—
Camshaft runout [TIR*] — 0.02 (0.0008)
Camshaft sprocket runout [TIR*] Less than 0.15 (0.0059) —
Camshaft end play 0.070 - 0.148 (0.0028 - 0.0058) 0.24 (0.0094)
*: Total indicator reading
EM671
Cam height “A”Intake 39.505 - 39.695 (1.5553 - 1.5628)
Exhaust 39.905 - 40.095 (1.5711 - 1.5785)
Wear limit of cam height0.15 (0.0059)
Valve timing
EM120
Unit: degree
abcde f
Valve timing 224 212 2 30 –2 46
SERVICE DATA AND SPECIFICATIONS (SDS)YD
Camshaft and Camshaft Bearing
EM-92

Cylinder BlockNJEM0081Unit: mm (in)
JEM207G
Surface flatnessStandardLess than 0.03 (0.0012)
Limit0.04 (0.0016)
Cylinder bore Inner diameterStandardGrade No. 1 86.000 - 86.010 (3.3858 - 3.3862)
Grade No. 2 86.010 - 86.020 (3.3862 - 3.3866)
Grade No. 3 86.020 - 86.030 (3.3866 - 3.3870)
Wear limit 0.07 (0.0028)
Out-of-round (X − Y)Less than 0.015 (0.0006)
Taper (A−B−C)Less than 0.010 (0.0004)
Main journal inner
diameter grade
(Without bearing)Grade No. 0
Grade No. 1
Grade No. 266.654 - 66.663 (2.6242 - 2.6245)
66.663 - 66.672 (2.6245 - 2.6249)
66.672 - 66.681 (2.6249 - 2.6252)
Difference in inner
diameter between
cylindersLimitLess than 0.05 (0.0020)
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SERVICE DATA AND SPECIFICATIONS (SDS)YD
Cylinder Block
EM-93

Piston, Piston Ring and Piston Pin=NJEM0082AVAILABLE PISTONNJEM0082S01Unit: mm (in)
SEM882E
Piston skirt diameter “A” StandardGrade No. 1 85.920 - 85.930 (3.3827 - 3.3831)
Grade No. 2 85.930 - 85.940 (3.3831 - 3.3835)
Grade No. 3 85.940 - 85.950 (3.3835 - 3.3839)
0.25 (0.0098) oversize (Service) 86.170 - 86.200 (3.3925 - 3.3937)
0.50 (0.0197) oversize (Service) 86.420 - 86.450 (3.4024 - 3.4035)
“a” dimension58.0 (2.28)
Piston pin hole diameter27.997 - 28.005 (1.1022 - 1.1026)
Piston clearance to cylinder block 0.070 -0.090 (0.0028 - 0.0035)
PISTON RINGNJEM0082S02Unit: mm (in)
Standard Limit
Side clearanceTop 0.120 - 0.180 (0.0047 - 0.0071) 0.2 (0.008)
2nd 0.050 - 0.090 (0.0020 - 0.0035) 0.1 (0.004)
Oil ring 0.030 - 0.070 (0.0012 - 0.0028) —
End gapTop 0.20 - 0.35 (0.0079 - 0.0138) 1.0 (0.039)
2nd 0.39 - 0.54 (0.0154 - 0.0213) 1.0 (0.039)
Oil 0.25 - 0.37 (0.0098 - 0.0146) 0.87 (0.0343)
PISTON PINNJEM0082S03Unit: mm (in)
Piston pin outer diameter27.994 - 28.000 (1.1021 - 1.1024)
Interference fit of piston pin to piston 0.002 - 0.006 (0.0001 - 0.0002)
Piston pin to connecting rod bushing clearanceStandard 0.026 - 0.044 (0.0010 - 0.0017)
Limit 0.057 (0.0022)
*: Values measured at ambient temperature of 20°C (68°F)
SERVICE DATA AND SPECIFICATIONS (SDS)YD
Piston, Piston Ring and Piston Pin
EM-94

Connecting RodNJEM0083Unit: mm (in)
Center distance157.5 (6.201)
Bend [per 100 (3.94)] Limit 0.12 (0.0047)
Torsion [per 100 (3.94)] Limit 0.12 (0.0047)
Connecting rod small end inner diameter 30.080 - 31.000 (1.1842 - 1.2205)
Piston pin bushing inner diameter* 28.026 - 28.038 (1.1034 - 1.1039)
Connecting rod big end inner diameter 55.000 - 55.013 (2.1654 - 2.1659)
Side clearanceStandard 0.200 - 0.350 (0.0079 - 0.0138)
Limit 0.4 (0.016)
*: After installing in connecting rod
CrankshaftNJEM0084Unit: mm (in)
Main journal dia. “Dm” gradeGrade No. 0
Grade No. 1
Grade No. 262.967 - 62.975 (2.4790 - 2.4793)
62.959 - 62.967 (2.4787 - 2.4790)
62.951 - 62.959 (2.4784 - 2.4787)
Pin journal dia. “Dp”Grade No. 0 51.968 - 51.974 (2.0460 - 2.0462)
Grade No. 1 51.961 - 51.968 (2.0457 - 2.0460)
Grade No. 2 51.954 - 51.961 (2.0454 - 2.0457)
Center distance “r”46.97 - 47.03 (1.8492 - 1.8516)
Out-of-round (X − Y) Standard/Limit Less than 0.003 (0.0001)/Less than 0.005 (0.0002)
Taper (A − B) Standard/Limit Less than 0.003 (0.0001)/Less than 0.005 (0.0002)
Runout [TIR*]Standard Less than 0.05 (0.0020)
Limit Less than 0.10 (0.0039)
Free end playStandard 0.10 - 0.25 (0.0039 - 0.0098)
Limit 0.30 (0.0118)
SEM645EM715
*: Total indicator reading
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SERVICE DATA AND SPECIFICATIONS (SDS)YD
Connecting Rod
EM-95

Available Main BearingNJEM0085
SEM255G
Grade number Thickness “T” mm (in) Width “W” mm (in) Identification color
0 1.816 - 1.820 (0.0715 - 0.0717)
19.9 - 20.1 (0.783 - 0.791)Black
1 1.820 - 1.824 (0.0717 - 0.0718) Red or Brown
2 1.824 - 1.828 (0.0718 - 0.0720) Green
3 1.828 - 1.832 (0.0720 - 0.0721) Yellow
4 1.832 - 1.836 (0.0721 - 0.0723) Blue
UNDERSIZENJEM0085S01Unit: mm (in)
Thickness Main journal diameter “Dm”
0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769)Grind so that bearing clearance is the specified
value.
Available Connecting Rod BearingNJEM0086CONNECTING ROD BEARINGNJEM0086S01
Grade number Thickness “T” mm (in) Width “W” mm (in) Identification color (mark)
0 1.492 - 1.496 (0.0587 - 0.0589)
22.9 - 23.1
(0.902 - 0.909)Black
1 1.496 - 1.500 (0.0589 - 0.0591) Brown
2 1.500 - 1.504 (0.0591 - 0.0592) Green
UNDERSIZENJEM0086S02Unit: mm (in)
Thickness Crank pin journal diameter “Dp”
0.08 (0.0031) 1.536 - 1.540 (0.0605 - 0.0606)
Grind so that bearing clearance is the specified
value. 0.12 (0.0047) 1.556 - 1.560 (0.0613 - 0.0614)
0.25 (0.0098) 1.621 - 1.625 (0.0638 - 0.0640)
Miscellaneous ComponentsNJEM0087Unit: mm (in)
Flywheel runout [TIR]*Less than 0.15 (0.0059)
*: Total indicator reading
SERVICE DATA AND SPECIFICATIONS (SDS)YD
Available Main Bearing
EM-96