NISSAN ALMERA TINO 2001 Service Repair Manual

Removal and InstallationNLEM0139CAUTION:
+When installing sliding parts (bearings, pistons, etc.),
lubricate contacting surfaces with new engine oil.
+Place removed parts, such as bearings and bearing caps
in their proper order and direction.
+When installing connecting rod nuts and main bearing cap
bolts, apply new engine oil to threads and seating sur-
faces.
+Do not allow any magnetic materials to contact the ring
gear teeth of drive plate.
SEM141FA
DisassemblyNLEM0140PISTON AND CRANKSHAFTNLEM0140S011. Place engine on engine stand (ST0501S000).
2. Remove cylinder head and timing chain.
Refer to EM-97, EM-109.
3. Remove oil pan.
Refer to EM-91.
SEM877B
4. Remove pistons with connecting rods.
+To disassemble piston and connecting rod, first remove snap
rings. Heat piston to 60 to 70ÉC (140 to 158ÉF) then use pis-
ton pin press to remove pin.
+When piston rings are not replaced, make sure that piston
rings are mounted in their original positions.
+When replacing piston rings, if there is no punch mark,
install with either side up.
5. Remove rear oil seal retainer.
SEM068G
6. Remove main bearing cap and crankshaft as shown.
+Bolts should be loosened in two or three steps.
AEM023
InspectionNLEM0141PISTON AND PISTON PIN CLEARANCENLEM0141S011. Measure inner diameter of piston pin hole ªdpº.
Standard diameter ªdpº:
21.993 - 22.005 mm (0.8659 - 0.8663 in)
CYLINDER BLOCKSR
Removal and Installation
EM-134

AEM024
2. Measure outer diameter of piston pin ªDpº.
Standard diameter ªDpº:
21.989 - 22.001 mm (0.8657 - 0.8622 in)
3. Calculate interference fit of piston pin to piston.
dp - Dp: 0.002 - 0.006 mm (0.0001 - 0.0002 in)
If it exceeds the above value, replace piston assembly with pin.
SEM024AA
PISTON RING SIDE CLEARANCENLEM0141S02Side clearance:
Top ring
0.040 - 0.080 mm (0.0016 - 0.0031 in)
2nd ring
0.030 - 0.070 mm (0.0012 - 0.0028 in)
Max. limit of side clearance:
0.1 mm (0.004 in)
If out of specification, replace piston ring. If clearance exceeds
maximum limit with new ring, replace piston.
SEM822B
PISTON RING END GAPNLEM0141S03End gap:
Top ring 0.20 - 0.39 mm (0.0079 - 0.0154 in)
2nd ring 0.35 - 0.59 mm (0.0138 - 0.0232 in)
Oil ring 0.20 - 0.69 mm (0.0079 - 0.0272 in)
Max. limit of ring gap:
1.00 mm (0.0209 in)
If out of specification, replace piston ring. If gap exceeds maximum
limit with a new ring, rebore cylinder and use oversized piston and
piston rings. Refer to SDS, EM-153.
+When replacing the piston, check cylinder block surface for
scratches or seizure. If scratches or seizure are found, hone
or replace the cylinder block.
CYLINDER BLOCKSR
Inspection (Cont'd)
EM-135

SEM038F
SEM003F
CONNECTING ROD BEND AND TORSIONNLEM0141S04Bend:
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
If it exceeds the limit, replace connecting rod assembly.
AEM156
CYLINDER BLOCK DISTORTION AND WEARNLEM0141S05Clean upper surface of cylinder block.
Use a reliable straightedge and feeler gauge to check the flatness
of cylinder block surface. Check along six positions shown in fig-
ure.
Block surface flatness:
Standard Less than 0.03 mm (0.0012 in)
Limit 0.10 mm (0.0039 in)
If out of specification, resurface it.
The limit for cylinder block resurfacing is determined by the amount
of cylinder head resurfacing.
SEM008D
Amount of cylinder head resurfacing is ªAº.
Amount of cylinder block resurfacing is ªBº.
The maximum limit is as follows:
A + B = 0.2 mm (0.008 in)
Nominal cylinder block height
from crankshaft center:
211.25 - 211.35 mm (8.3169 - 8.3208 in)
If necessary, replace cylinder block.
CYLINDER BLOCKSR
Inspection (Cont'd)
EM-136

SEM363EA
SEM011D
PISTON-TO-BORE CLEARANCENLEM0141S061. Using a bore gauge, measure cylinder bore for wear, out-of-
round and taper.
Standard inner diameter:
86.000 - 86.030 mm (3.3858 - 3.3870 in)
Wear limit:
0.20 mm (0.0079 in)
Out-of-round (X þ Y) standard:
0.015 mm (0.0006 in)
Taper (A þ B and A þ C) standard:
0.010 mm (0.0004 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder
block if necessary.
2. Check for score and seizure. If seizure is found, hone it.
+If cylinder block and piston are replaced, match piston
grade with grade number on cylinder block upper surface.
SEM085G
3. Measure piston skirt diameter.
Piston diameter ªAº: Refer to SDS, EM-153.
Measuring point ªaº (Distance from the top):
45.0 mm (1.772 in)
4. Check that piston-to-bore clearance is within specification.
Piston-to-bore clearance = bore measurement ªCº þ
Piston diameter ªAº:
0.010 - 0.030 mm (0.0004 - 0.0012 in)
5. Determine piston oversize according to amount of cylinder
wear.
Oversize pistons are available for service. Refer to SDS,
EM-153.
6. Cylinder bore size is determined by adding piston-to-bore
clearance to piston diameter ªAº.
Rebored size calculation:
D=A+BþC
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
SEM069G
7. Install main bearing caps and tighten bolts to the specified
torque. This will prevent distortion of cylinder bores, otherwise
cylinder bores may be distorted in final assembly.
8. 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 at a time.
9. Hone cylinders to obtain specified piston-to-bore clearance.
10. Measure finished cylinder bore for out-of-round and taper.
CYLINDER BLOCKSR
Inspection (Cont'd)
EM-137

+Measurement should be done after cylinder bore cools
down.
SEM316A
CRANKSHAFTNLEM0141S071. Check crankshaft main and pin journals for score, wear or
cracks.
2. With a micrometer, measure journals for taper and out-of-
round.
Out-of-round (X þ Y):
Taper (A þ B):
Main journal: Less than 0.005 mm (0.0002 in)
Pin journal: Less than 0.003 mm (0.0001 in)
SEM434
3. Measure crankshaft runout.
Runout (Total indicator reading):
Less than 0.05 mm (0.0020 in)
SEM685D
SEM070G
BEARING CLEARANCENLEM0141S08+Use Method A or Method B. Method A is preferred because it
is more accurate.
Method A (Using bore gauge and micrometer)
Main bearingNLEM0141S08011. Set main bearings in their proper positions on cylinder block
and main bearing cap.
2. Install main bearing cap and main bearing beam to cylinder
block.
Tighten all bolts in correct order in two or three stages. Refer
to EM-143.
3. Measure inner diameter ªAº of each main bearing.
CYLINDER BLOCKSR
Inspection (Cont'd)
EM-138

AEM026
4. Measure outer diameter ªDmº of each crankshaft main journal.
5. Calculate main bearing clearance.
Main bearing clearance = A þ Dm
Standard: 0.004 - 0.022 mm (0.0002 - 0.0009 in)
Limit: 0.050 mm (0.0020 in)
If it exceeds the limit, replace bearing.
+If clearance cannot be adjusted within the standard of any
bearing, grind crankshaft main journal and use undersized
bearing.
SEM964
+When grinding crankshaft journal, confirm that ªLº dimen-
sion in fillet roll is more than the specified limit.
ªLº: 0.1 mm (0.004 in)
+Refer to SDS, EM-155 for grinding crankshaft and avail-
able service parts.
SEM313D
+If crankshaft is replaced, select thickness of main bearings as
follows:
a. Grade number of each cylinder block main journal is punched
on the respective cylinder block. These numbers are punched
in either Arabic or Roman numerals.
SEM013D
SEM203D
b. Grade number of each crankshaft main journal is punched on
the respective crankshaft. These numbers are punched in
either Arabic or Roman numerals.
c. Select main bearing with suitable thickness according to the
following table.
How to Select Main Bearings (Identification Mark and
Color)
NLEM0141S0804
Crankshaft main
journal grade
numberCylinder block main journal grade number
0123
00
(A, Black)1
(B, Red)2
(C, Green)3
(D, Yellow)
11
(B, Red)2
(C, Green)3
(D, Yellow)4
(E, Blue)
22
(C, Green)3
(D, Yellow)4
(E, Blue)5
(F, Pink)
33
(D, Yellow)4
(E, Blue)5
(F, Pink)6
(G, White)
For example:
Cylinder block main journal grade number: 1
CYLINDER BLOCKSR
Inspection (Cont'd)
EM-139

Crankshaft main journal grade number: 2
Main bearing grade number=1+2=3(D,Yellow)
AEM027
Connecting Rod Bearing (Big end)NLEM0141S08021. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
Tighten bolts to the specified torque. Refer to EM-143.
3. Measure inner diameter ªCº of each bearing.
AEM028
SEM013D
SEM204D
4. Measure outer diameter ªDpº of corresponding crankshaft pin
journal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance=CþDp
Standard: 0.020 - 0.045 mm (0.0008 - 0.0018 in)
Limit: 0.065 mm (0.0026 in)
If it exceeds the limit, replace bearing.
+If clearance cannot be adjusted within the standard of any
bearing, grind crankshaft journal and use undersized bearing.
Refer to EM-155 for fillet roll remarks, grinding crankshaft and
available service parts.
+If crankshaft is replaced with a new one, select connecting rod
bearing according to the following table.
Connecting rod bearing grade number:
These numbers are punched in either Arabic or Roman numer-
als.
Crank pin grade number Connecting rod bearing grade number
00
11
22
Identification color:
Grade 0; Black or Yellow
Grade 1; Brown or Red
Grade 2; Green or Blue
CYLINDER BLOCKSR
Inspection (Cont'd)
EM-140

EM142
Method B (Using Plastigage)
CAUTION:
+Do not turn crankshaft or connecting rod while Plastigage
is being inserted.
+If incorrect bearing clearance exists, use a thicker or
undersized main bearing to ensure specified clearance.
AEM029
CONNECTING ROD BUSHING CLEARANCE (SMALL
END)
NLEM0141S091. Measure inner diameter ªCº of bushing.
AEM030
2. Measure outer diameter ªDpº of piston pin.
3. Calculate connecting rod bushing clearance.
Connecting rod bushing clearance=CþDp
Standard:
0.005 - 0.017 mm (0.0002 - 0.0007 in)
Limit:
0.023 mm (0.0009 in)
If it exceeds the limit, replace connecting rod assembly or
connecting rod bushing and/or piston set with pin.
SEM062A
REPLACEMENT OF CONNECTING ROD BUSHING
(SMALL END)
NLEM0141S101. Drive in small end bushing until it is flush with end surface of
rod.
Be sure to align the oil holes.
2. Ream the bushing so that clearance with piston pin is within
specification.
Clearance between connecting rod bushing and piston
pin:
0.005 - 0.017 mm (0.0002 - 0.0007 in)
SEM916AB
REPLACEMENT OF PILOT CONVERTER (CVT)NLEM0141S131. Remove pilot converter using Tool or suitable tool.
CYLINDER BLOCKSR
Inspection (Cont'd)
EM-141

SEM163B
2. Install pilot converter as shown.
AEM100
DRIVE PLATE RUNOUTNLEM0141S11Runout (Total indicator reading):
Drive plate (CVT models)
Less than 0.20 mm (0.0079 in)
CAUTION:
+Be careful not to damage the ring gear teeth.
+Check the drive plate for deformation or cracks.
+Do not allow any magnetic materials to contact the ring
gear teeth.
SEM166B
AssemblyNLEM0142PISTONNLEM0142S011. Install new snap ring on one side of piston pin hole.
SEM946C
2. Heat piston to 60 to 70ÉC (140 to 158ÉF) and assemble piston,
piston pin, connecting rod and new snap ring.
+Align the direction of piston and connecting rod.
+Numbers stamped on connecting rod and cap correspond
to each cylinder.
+After assembly, make sure connecting rod swings
smoothly.
SEM601D
3. Set piston rings as shown.
CAUTION:
+When piston rings are not replaced, make sure that piston
rings are mounted in their original positions.
+Install new piston rings either side up if there is no punch
mark.
CYLINDER BLOCKSR
Inspection (Cont'd)
EM-142

SEM160B
+Align piston rings so that end gaps are positioned as
shown.
SEM685D
CRANKSHAFTNLEM0142S021. Set main bearings in their proper positions on cylinder block
and main bearing cap.
+Confirm that correct main bearings are selected by using
Method A or Method B. Refer to EM-138.
+Apply new engine oil to bearing surfaces.
SEM069G
2. Install crankshaft and main bearing caps, then tighten bolts to
the specified torque.
+Prior to tightening bearing cap bolts, shift crankshaft back
and forth to properly seat the bearing cap.
+Apply new engine oil to threads and seating surfaces of
bearing cap bolts before installing them.
+Tightening procedure:
SEM071G
SEM072G
a.Tighten all bolts to 32 to 38 N´m (3.3 to 3.8 kg-m, 24 to 28
ft-lb).
b.Turn all bolts 30 to 35 degrees clockwise with Tool or
suitable angle wrench.
+If an angle wrench is not available, mark all bearing cap
bolts on the side facing engine rear. Then, turn each bolt
specified degrees clockwise. Confirm angle of degrees
with a graduator, not by eye measurement.
+After securing bearing cap bolts, make sure crankshaft
turns smoothly by hand.
CYLINDER BLOCKSR
Assembly (Cont'd)
EM-143