front NISSAN ALMERA N16 2003 Electronic Service Manual

ENGINE ASSEMBLY
EM-69
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●Center member
●Front exhaust tube
●Stabilizer bar
●Cooling fan
●Radiator
●Disconnect wires, harness, pipes, hoses and so on.
10. Lift up engine slightly and disconnect or remove all engine
mountings.
When lifting engine, be sure to clear surrounding parts. Use
special care near brake tubes and brake master cylinder.
11. Remove engine with transaxle as shown.
INSTALLATION
●Install in reverse order of removal.
SEM108G
SEM420D

CYLINDER BLOCK
EM-71
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CAUTION:
Apply new engine oil to parts marked in illustration before installation.
DISASSEMBLY
1. Remove engine and transaxle assembly from vehicle, and separate transaxle from engine. Refer to EM-
67, "ENGINE ASSEMBLY" .
2. Mount engine on an engine stand with the following procedure.
a. Remove exhaust manifold and catalytic converter. Refer to EM-19, "
EXHAUST MANIFOLD AND CATA-
LYTIC CONVERTER" .
b. Remove engine front mounting bracket, alternator and air compressor bracket.
c. Install engine sub-attachment to left side of cylinder block.
d. Lift engine, and mount it onto the engine stand.
1. Rear oil seal 2. Rear oil seal retainer 3. Crankshaft position sensor (POS)
4. O-ring 5. Knock sensor 6. Oil level gauge guide
7. Cylinder block 8. Thrust bearing 9. Main bearing
10. Crankshaft 11. Key 12. Top ring
13. 2nd ring 14. Oil ring 15. Main bearing
16. Piston 17. Snap ring 18. Piston pin
19. Connecting rod 20. Connecting rod bearing 21. Connecting rod cap
22. Connecting rod nut 23. Main bearing cap bolt 24. Baffle plate
25. Main bearing cap 26. Signal plate 27. Rear plate
28. Coolant drain plug 29. Flywheel (M/T models) 30. Drive plate (A/T models)
PBIC0585E
PBIC1017E

EM-72
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CYLINDER BLOCK
●A commercial engine stand can be used.
NOTE:
●This example is an engine stand for holding at transaxle
mounting side with the flywheel or drive plate removed.
3. Drain engine oil and coolant from inside of engine.
4. Remove the following components and associated parts.
●Fuel tube and injector assembly; Refer to EM-26, "Removal and Installation" .
●Intake manifold and intake manifold collector assembly; Refer to EM-16, "Removal and Installation" .
●Ignition coil; Refer to EM-24, "Removal and Installation" .
●Rocker cover; Refer to EM-29, "Removal and Installation" .
●Oil pan and oil strainer; Refer to EM-22, "Removal and Installation" .
●Front cover and timing chain; Refer to EM-47, "Removal and Installation" .
●Camshaft; Refer to EM-32, "Removal and Installation" .
●Cylinder head assembly; Refer to EM-58, "Removal and Installation" .
●Auxiliary brackets and oil filter
5. Remove knock sensor.
CAUTION:
Avoid impacts such as a dropping.
6. Remove crankshaft position sensor (POS).
CAUTION:
●Avoid impacts such as a dropping.
●Do not disassemble.
●Keep it away from metal particles.
●Do not place sensor close to magnetic materials.
7. Remove flywheel (M/T models) or drive plate (A/T models). Fix
crankshaft with a ring gear stopper (special service tool), and
remove mounting bolts.
8. Remove rear plate.
9. Remove rear oil seal retainer.
●Insert a flat-bladed screwdriver between main bearing cap
and rear oil seal retainer to remove retainer.
10. Remove rear oil seal from rear oil seal retainer.
●Punch out with a flat-bladed screwdriver.
CAUTION:
●Be careful not to damage rear oil seal retainer.
PBIC0085E
PBIC0586E
SEM880F

EM-74
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CYLINDER BLOCK
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
EMD0222D

EM-76
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CYLINDER BLOCK
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
SEM420C
SEM933F
PBIC0591E

CYLINDER BLOCK
EM-77
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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
PBIC0482E
PBIC0267E
PBIC0593E

CYLINDER BLOCK
EM-81
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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)
PBIC0606E

CYLINDER BLOCK
EM-83
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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

SERVICE DATA AND SPECIFICATIONS (SDS)
EM-105
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Intake valve timing control solenoid valve
6.3 - 8.3 (0.64 - 0.85, 56 - 73)*2
Camshaft position sensor (PHASE)
7.2 - 10.8 (0.73 - 1.1, 64 - 95) *2
Camshaft sprocket (INT) 78.4 - 88.2 (8.0 - 9.0, 58 - 65)
Camshaft sprocket (EXH) 98.1 - 127.5 (10.0 - 13.0, 73 - 94)
*1 Camshaft bracket 1)
2.0 (0.2, 18) *
2
2)
5.9 (0.6, 52) *2
3)
9.0 - 11.8 (0.92 - 1.20, 80 - 104)*2
Crankshaft pulley132.4 - 152.0 (14.0 - 15.0, 98 - 112)
Front cover
6.92 - 9.51 (0.71 - 0.97, 62 - 84)*
2
Timing chain tension guide 15.7 - 20.6 (1.6 - 2.1, 12 - 15)
*1 Cylinder head 1) 29.4 (3.0, 22)
2) 58.8 (6.0, 43)
3) 0 (0.0, 0)
4) 27.4 - 31.4 (2.8 - 3.2, 21 - 23)
5) 50° - 55° (Angle tightening)
Cylinder head front cover
6.92 - 9.5 (0.71 - 0.96, 62 - 84)*
2
Flywheel (M/T)83.4 - 93.2 (8.5 - 9.5, 62 - 68)
Drive plate (A/T)93.2 - 103 (9.5 - 10.5, 69 - 75)
*1 Connecting rod bearing cap 1) 13.72 - 15.68 (1.4 - 1.5, 10.2 - 11 . 5 )
2) 35° - 40° (Angle tightening)
Knock sensor15.7 - 20.6 (1.6 - 2.1, 12 - 15)
Crankshaft position sensor (POS)
7.2 - 10.8 (0.8 - 1.1, 64 - 95)*
2
Rear oil seal retainer
6.3 - 8.3 (0.65 - 0.84, 56 - 73)*2
Signal plate
7.6 - 9.2 (0.78 - 0.93, 68 - 81)*2

NJEM0051
NVH Troubleshooting — Engine NoiseNJEM0051S01Use the chart below to help you find the cause of the symptom.
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
Location of
noiseTy p e o f
noiseOperating condition of engine
Source of
noiseCheck itemReference
page Before
warm-upAfter
warm-upWhen
startingWhen
idlingWhen
racingWhile
driving
To p o f
engine
Rocker
cover
Cylinder
headTicking or
clickingC A—A B—Tappet
noiseValve clearance EM-60
Rattle C A — A B CCamshaft
bearing
noiseCamshaft journal
clearance
Camshaft runoutEM-49, 49
Crankshaft
pulley
Cylinder
block
(Side of
engine)
Oil panSlap or
knock—A—B B—Piston pin
noisePiston and piston
pin clearance
Connecting rod
bushing clearanceEM-71, 79
Slap or
rapA——B B APiston slap
noisePiston-to-bore
clearance
Piston ring side
clearance
Piston ring end gap
Connecting rod
bend and torsionEM-71, 72,
72, 73
Knock A B C B B BConnect-
ing rod
bearing
noiseConnecting rod
bushing clearance
(Small end)
Connecting rod
bearing clearance
(Big end)EM-79, 77
Knock A B — A B CMain bear-
ing noiseMain bearing oil
clearance
Crankshaft runoutEM-75, 75
Front of
engine
Timing
chain
coverTapping or
tickingAA—BBBTiming
chain and
chain ten-
sioner
noiseTiming chain
cracks and wear
Timing chain ten-
sioner operationEM-22, 20
Front of
engineSqueaking
or fizzingA B—B—COther
drive belts
(Sticking
or slipping)Drive belts deflec-
tion
EM-11
CreakingABABABOther
drive belts
(Slipping)Idler pulley bearing
operation
Squall
CreakAB—BABWater
pump
noiseWater pump opera-
tionLC-39
A: Closely related B: Related C: Sometimes related —: Not related
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGYD
NVH Troubleshooting — Engine Noise
EM-8