NISSAN ALMERA TINO 2001 Service Repair Manual

InstallationNLEM0102S0202+When a stud bolt is pulled out, tighten it to the following torque:
: 18 - 21 N´m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
+Tighten the exhaust manifold mounting nuts in the following
procedure:
a) Tighten the nuts in the order specified in the figure.
b) Re-tighten the nuts 1 to 4.
EXHAUST MANIFOLD GASKETNLEM0102S03InstallationNLEM0102S0301Install the gasket so that the alignment protrusion faces the No. 4
port.
Disassembly and AssemblyNLEM0103
SEM268G
TURBOCHARGERNLEM0103S01DisassemblyNLEM0103S0101After applying penetration lubricant (Lucen, etc.) to the mounting
nuts, check for the penetration of the lubricant, and then loosen the
nuts to remove.
EXHAUST MANIFOLD, TURBOCHARGERYD
Removal and Installation (Cont'd)
EM-194

CAUTION:
Do not disassemble or adjust the turbocharger body.
AssemblyNLEM0103S0102When a stud bolt is pulled out, tighten it to the following torque:
: 24 - 27 N´m (2.4 - 2.8 kg-m, 18 - 20 ft-lb)
JEM267G
InspectionNLEM0104EXHAUST MANIFOLDNLEM0104S01Check the distortion on the mounting surface in the six directions
using a straightedge and a feeler gauge.
Limit: 0.3 mm (0.012 in)
TURBOCHARGERNLEM0104S02
SEM269G
CAUTION:
When the compressor wheel, turbine wheel, or rotor shaft is
damaged, remove all the fragments and foreign matter left in
the following passages in order to prevent a secondary failure:
Suction side: Between turbocharger and air cleaner
Exhaust side: Between turbocharger and catalytic con-
verter
EXHAUST MANIFOLD, TURBOCHARGERYD
Disassembly and Assembly (Cont'd)
EM-195

SEM270G
Rotor ShaftNLEM0104S0201+Check that the rotor shaft rotates smoothly without any resis-
tance when it is rotated by your fingertips.
+Check that the rotor shaft is not loose when it is moved verti-
cally or horizontally.
Standard value for rotor shaft oil clearance:
0.086 - 0.117 mm (0.0034 - 0.0046 in)
SEM271G
Rotor Shaft End PlayNLEM0104S0202Place a dial gauge at the rotor shaft end in the axial direction to
measure the end play.
Standard: 0.036 - 0.090 mm (0.0014 - 0.0035 in)
SEM272G
Turbine WheelNLEM0104S0203+Check that there is no oil adhesion.
+Check that there is no carbon accumulation.
+Check that blades of the turbine wheel are not bent or broken.
+Check that the turbine wheel does not interfere with the turbine
housing.
SEM273G
Compressor WheelNLEM0104S0204+Check that there is no oil adhesion inside the air inlet.
+Check that the compressor wheel does not interfere with the
compressor housing.
+Check that the wheel is not bent or broken.
SEM274G
Waste Gate ActuatorNLEM0104S0205+Connect the handy pump to the actuator, and check that the
rod strokes smoothly in compliance with the following pres-
sure.
+Pressure to be applied at actuator part to move rod end as
follows:
Standard (Pressure/rod stroke amount):
115.44 - 120.76 kPa (1,154 - 1,208 mbar, 866.0 - 906.0
mmHg, 34.1 - 35.7 inHg)/0.38 mm (0.0150 in)
140.54 - 149.86 kPa (1,405 - 1,498 mbar, 1,054.3 -
1,124.2 mmHg, 41.5 - 44.3 inHg)/4.0 mm (0.157 in)
EXHAUST MANIFOLD, TURBOCHARGERYD
Inspection (Cont'd)
EM-196

Trouble Diagnosis of Turbocharger=NLEM0104S0206Preliminary check:
+Check that the engine oil level is between MIN and MAX of the
dipstick. (When the engine oil amount is more than MAX, the
oil flows into the inlet duct through the blow-by gas passage,
and the turbocharger is misjudged failure.)
+Ask the customer if he/she always runs the vehicle in idle
engine speed to cool the oil down after driving.
+Replace the turbocharger assembly when any malfunction is
found after unit inspections specified in the table below.
+If no malfunction is found after the unit inspections, judge that
the turbocharger body has no failure. Check the other parts
again.
Inspection item Inspection resultSymptom (when each inspection item meets
each inspection result)
Oil leak-
ageSmoke NoiseInsuffi-
cient
power/
accelera-
tion failure
Turbine wheelOil leaks.n
nn
Carbon is accumulated.n
jj
Friction with housing.nj
j
Blades are bent or broken.
Compressor wheelInside the air inlet is seriously con-
taminated by oil.jj
Friction with housing.njj
Blades are bent or broken.
After checking both turbine and compressor,
inspect rotor shaft end play.There is resistance when the rotor
shaft is rotated by your fingertips.nnj
The rotor shaft sometimes does
not rotate by your fingertips.
There is too much play in the
bearing.nnjn
Oil return portCarbon or sludge is accumulated
in the waste oil hole.n
nn
Operation of Waste gate actuator+The actuator does not operate
smoothly when vacuum pres-
sure is gradually applied.
+Stroke amount is not in compli-
ance with the vacuum pressure.j
: Large possibility
j: Medium possibility
n: Small possibility
EXHAUST MANIFOLD, TURBOCHARGERYD
Inspection (Cont'd)
EM-197

Removal and InstallationNLEM0099
SEM503G
PREPARATIVE WORKNLEM0099S01Remove engine cover.
JEM247G
ROCKER COVERNLEM0099S02RemovalNLEM0099S0201Loosen holding bolts in the reverse order of that shown in the fig-
ure and remove.
CAUTION:
Do not remove mass damper on top. If damper must be
removed, remove all traces of old locking sealant from threads
of bolts and holes, and apply new locking sealant on the bolts
before tightening.
InstallationNLEM0099S0202+Tighten holding bolts in the numerical order shown in the fig-
ure.
+Re-tighten to the same torque in the same order as above.
ROCKER COVERYD
Removal and Installation
EM-198

JEM248G
+Apply 3.0 mm (0.118 in) dia. of specified liquid gasket (Refer
to EM-158, ªLiquid Gasket Application Procedureº.) on locac-
tions shown in the figure.
ROCKER COVERYD
Removal and Installation (Cont'd)
EM-199

ComponentsNLEM0062
SEM504G
CYLINDER HEADYD
Components
EM-200

CAUTION:
+When installing camshafts, chain tensioners, oil seals, or
other sliding parts, lubricate contacting surfaces with new
engine oil.
+Apply new engine oil to threads and seat surfaces when
installing cylinder head, camshaft sprocket, crankshaft
pulley, and camshaft bracket.
+Attach tags to valve lifters so as not to mix them up.
RemovalNLEM0063PREPARATIVE WORKNLEM0063S011. Drain engine coolant. Refer to LC-59, ªChanging Engine Cool-
antº.
2. Remove exhaust manifold. Refer to EM-193, ªRemovalº.
3. Remove intake manifold. Refer to EM-189, ªRemovalº.
+Apply paint to camshaft sprockets for alignment during
installation.
JEM152G
CAMSHAFTNLEM0063S021. Remove the following parts:
+Rocker cover
+Vacuum pump and cylinder head rear cover assembly
+Spill tube
+High pressure injection nozzle assembly
+Secondary timing chain and associated parts
JEM159G
2. Remove camshaft sprockets.
+Holding the hexagonal part of the camshaft with a wrench
having 21 mm (0.83 in) width between facing flats, loosen the
bolt holding the camshaft sprocket.
JEM160G
3. Remove camshafts.
+Loosen bolts holding the camshaft bracket in several stages in
the reverse order of that shown in the figure, and remove them.
4. Remove adjusting shims and valve lifters.
+Confirm the correct location of each part removed. Store them
so they do not get mixed up.
+For re-installation, be sure to put mark on camshaft
bracket before removal.
CYLINDER HEADYD
Components (Cont'd)
EM-201

JEM149G
CYLINDER HEADNLEM0063S03+Loosen bolts in the reverse order of that shown in the figure
and remove them.
+Be careful not to damage the tips of glow plugs project-
ing out of the bottom surface of the cylinder head. To
avoid damage to glow plugs, either remove them
beforehand, or support cylinder head with wooden blocks
to create a space below the bottom surface.
DisassemblyNLEM0100
JEM150G
1. Remove adjusting shims and valve lifters. Confirm the correct
location of each part removed. Store them in order to avoid
mixing them up.
JEM151G
2. Remove valve collets.
+Compress valve spring with a valve spring compressor, and
remove valve collet with a magnet hand.
3. Remove valve spring retainers, and valve springs.
4. Push valve stem toward combustion chamber and remove
valve.
+Before removing valves, check valve guide clearance. Refer to
EM-205, ªVALVE GUIDE CLEARANCEº.
+Confirm the correct location of each valve. Store them so they
do not get mixed up.
CYLINDER HEADYD
Removal (Cont'd)
EM-202

JEM152G
+For the locations and arrangement of intake and exhaust
valves, refer to the figure.
JEM153G
5. Remove valve oil seals.
+Use a valve oil seal puller (SST) for removal.
6. Remove valve spring seats.
7. When removing valve seats, check valve seat contact. Refer
to EM-207.
8. Before removing valve guides, check valve guide clearance.
Refer to EM-205, ªVALVE GUIDE CLEARANCEº.
9. Remove glow plugs.
+To 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.)
SEM496G
InspectionNLEM0065CYLINDER HEAD DISTORTIONNLEM0065S01Clean surface of cylinder head.
Use a reliable straightedge and feeler gauge to check the flatness
of cylinder head surface.
Check along six positions shown in the figure.
Head surface flatness: Limit 0.04 mm (0.0016 in)
If beyond the specified limit, resurface or replace it.
The limit for cylinder head resurfacing is determined by the
cylinder block resurfacing.
Resurfacing limit:
Amount of cylinder head resurfacing is ªAº.
Amount of cylinder block resurfacing is ªBº.
The maximum limit: A+ B = 0.07 mm (0.0028 in)
After resurfacing cylinder head, check that camshaft rotates freely
by hand. If resistance is felt, cylinder head must be replaced.
Nominal cylinder head height:
153.9 - 154.1 mm (6.059 - 6.067 in)
CYLINDER HEADYD
Disassembly (Cont'd)
EM-203