NISSAN LATIO 2010 Service Repair Manual

EM-92
< DISASSEMBLY AND ASSEMBLY >[HR16DE]
CYLINDER BLOCK
2. Install water drain plug (1) to cylinder block as shown.
Use Genuine Silicone RTV Sealant or equivalent. Refer to
GI-42, "
Recommended Chemical Product and Sealant".
3. Install main bearings and thrust bearings in their original positions with the following procedure:
a. Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block.
b. Install thrust bearings to the both sides of the No. 3 journal hous- ing (B) on cylinder block.
• Install thrust bearings with the oil groove (A) facing crankshaftarm (outside).
c. Install the main bearings (1) paying attention to the direction. • Install the one with oil holes (A) onto cylinder block and the
one without oil holes onto main bearing cap.
• Before installing main bearings, apply new engine oil to the bearing surface (inside). Do not apply engine oil to the back
surface, but thoroughly clean it.
• Ensure the oil holes on cylinder block and those on the corre- sponding bearing are aligned.
• Install the main bearing in the position shown.
NOTE:
Install the main bearing in the center position with the following
dimension. For service operati on, the center position can be
checked visually.
: Engine front
PBIC3742E
: Engine front
PBIC3258J
PBIC3746E
1 : Cylinder block
2 : Main bearing (upper)
3 : Main bearing (lower)
4 : Main bearing cap
: Engine front
PBIC3747E
Journal position No. 1No. 2 No. 3No. 4 No. 5
L1 [Unit: mm (in)] 1.65–2.05 1.25–1.65
2.30–2.701.25–1.65 1.60–2.00
(0.065-0.081) (0.049-0.065) (0.091-0.106) (0.049-0.065) (0.063-0.079)
L2 [Unit: mm (in)] 1.30–1.70
1.30–1.702.30–2.701.30–1.70 1.30–1.70
(0.051-0.067) (0.051-0.067) (0.091-0.106) (0.051-0.067) (0.051-0.067)
Revision: January 20102010 Versa

CYLINDER BLOCKEM-93
< DISASSEMBLY AND ASSEMBLY > [HR16DE]
C
D
E
F
G H
I
J
K L
M A
EM
NP
O
CAUTION:
Dimension L1 of journal No. 3 is the distance from the housing base end
surface (bulk) (not the
distance from the thrust bearing mounting end surface).
4. Install signal plate to crankshaft if removed.
a. Set the signal plate (1) with the flange facing toward the counter- weight side (engine front side) to the crankshaft rear surface.
b. After positioning crankshaft and signal plate with positioning dowel pin, tighten bolt.
NOTE:
Dowel pin of crankshaft and signal plate is provided as a set for
each.
c. Remove dowel pin. CAUTION:
Be sure to remove dowel pin.
5. Install crankshaft to cylinder block. • Make sure that crankshaft turns smoothly by hand.
CAUTION:
Never install rear oil seal yet.
6. Install main bearing caps in their original positions. • Install the main bearing cap while referring to the front mark(B) and the journal number stamp (A).
NOTE:
Main bearing cap cannot be replaced as a single part,
because it is machined together with cylinder block.
7. Tighten main bearing cap bolts in numerical order shown with the following steps.
a. Apply new engine oil to threads and seat surfaces of the bolts.
b. Tighten main bearing cap bolts in the numerical order shown.
A : Dowel pin hole
: Engine front
PBIC3748E
PBIC3749E
: Engine front
PBIC3744E
: 32.4 N·m (3.3 kg-m, 24 ft-lb)
Revision: January 20102010 Versa

EM-94
< DISASSEMBLY AND ASSEMBLY >[HR16DE]
CYLINDER BLOCK
c. Turn main bearing cap bolts 60 degrees clockwise (angle tight-
ening) in numerical order shown.
CAUTION:
Check and confirm the tightening angle by using Tool (A) or
protractor. Avoid judgment by visual inspection without the
tool.
• After installing the bolts, make sure that crankshaft can be rotated smoothly by hand.
• Check crankshaft end play. Refer to EM-97, "
Inspection".
8. Install piston to connecting rod with the following procedure:
a. Set so that the front mark (A) on the piston head and the cylin- der number (C) are in the position shown.
NOTE:
The symbols without notes are for management.
b. Press-fit the piston pin using Tool.
CAUTION:
Press-fit the piston so as not to damage it.
NOTE:
The joint between the connecting rod and the piston pin is a
press fit.Tool number : KV10112100 (BT-8653-A)
PBIC3750E
B : Oil hole
D : Connecting rod big end grade
JPBIA0537ZZ
Tool number (A) : KV10109730 ( — )
Tool number (B) : KV10110310 ( — )
Tool number (C) : ST13030020 ( — )
Tool number (D) : KV10114120 ( — )
Tool number (E) : ST13030030 ( — )
F: For detail
PBIC5271J
Revision: January 20102010 Versa

CYLINDER BLOCKEM-95
< DISASSEMBLY AND ASSEMBLY > [HR16DE]
C
D
E
F
G H
I
J
K L
M A
EM
NP
O
• Press-fit the piston pin (2) from piston surface “A” to the depth
of 2.35 mm (0.092 in).
• After finishing work, make sure that the piston (3) moves freely.
9. Using a suitable tool, install piston rings. CAUTION:
• Be careful not to damage piston.
• Be careful not to damage piston rings by expanding them excessively.
• Position each ring with the gap as shown referring to the pis-
ton front mark (B).
• Install second ring with the stamped mark (E) facing upward.
10. Install connecting rod bearings to connecting rod and connecting rod cap. • When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Do not
apply engine oil to the back surface, but thoroughly clean it.
• Install the bearing in the center position. NOTE:
There is no stopper tab.
• Make sure that the oil holes on connecting rod and connecting rod bearing are aligned.
• Install the connecting rod in the dimension shown.
NOTE:
Install the connecting rod bearing in the center pos ition with the dimension shown. For service opera-
tion, the center position can be checked visually.
11. Install piston and connecting rod assembly to crankshaft. • Position crankshaft pin corres ponding to connecting rod to be installed onto the bottom dead center.
• Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin.
• Match the cylinder position with the cy linder number on connecting rod to install.
1 : Connecting rod
: Press-fit direction
PBIC3751E
A : Oil ring upper or lower rail gap (either of them)
C : Second ring and oil ring spacer gap
D : Top ring gap
Stamped mark: Second ring : R
PBIC3588J
1 : Connecting rod
2 : Connecting rod bearing (upper)
3 : Connecting rod bearing (lower)
4 : Connecting rod cap
: Engine front
Dimension “A” : 1.7 - 2.1 mm (0.067 - 0.083 in)
PBIC4169E
Revision: January 20102010 Versa

EM-96
< DISASSEMBLY AND ASSEMBLY >[HR16DE]
CYLINDER BLOCK
• Using Tool (A) or suitable tool, install piston with the front mark
on the piston head facing the front of the engine.
CAUTION:
• Be careful not to damage matching surface with con-necting rod cap.
• Be careful not to damage the cylinder wall and crank-
shaft pin, resulting from an interference of the connect-
ing rod big end.
12. Install connecting rod cap. • Match the stamped cylinder number marks (C) on connectingrod with those on connecting rod cap to install.
13. Inspect outer diameter of c onnecting rod cap bolts. Refer to EM-97, "
Inspection".
14. Tighten connecting rod bolt with the following procedure:
a. Apply new engine oil to the threads and seats of connecting rod bolts.
b. Tighten connecting rod bolts in several steps.
c. Then turn all bolts 60 degrees clockwise (angle tightening). CAUTION:
Confirm the tightening angle by using Tool (A) or protractor.
Avoid judgment by visual inspection without the tool.
• After tightening connecting rod bolts, make sure that crankshaft rotates smoothly.
• Check the connecting rod side clearance. Refer to EM-97, "
Inspection".
15. Install oil pan (upper). Refer to EM-42, "
Removal and Installation".
NOTE:
Install the rear oil seal after installing the oil pan (upper).
16. Install rear oil seal. Refer to EM-71, "
REAR OIL SEAL : Removal and Installation".
17. Install flywheel. • Secure crankshaft with Tool, and tighten bolts crosswise over several times.Tool number : EM03470000 (J-8037)
PBIC3765E
A : Front mark
B : Oil hole
D : Connecting rod big end grade
JPBIA0537ZZ
: 19.6 N·m (2.0 kg-m, 14 ft-lb)
Tool number : KV10112100 (BT-8653-A)
PBIC3753E
Tool number : KV11105210 (J-44716)
Revision: January 20102010 Versa

CYLINDER BLOCKEM-97
< DISASSEMBLY AND ASSEMBLY > [HR16DE]
C
D
E
F
G H
I
J
K L
M A
EM
NP
O
18. Install knock sensor (1).
• Install connectors so that they are positioned towards the rearof the engine.
CAUTION:
• Never tighten bolt while holding the connector.
• If any impact by dropping is applied to knock sensor,
replace it with a new one.
NOTE:
• Make sure that there is no foreign material on the cylinder
block mating surface and the back surface of knock sensor.
• Make sure that knock sensor does not interfere with other parts.
19. Install crankshaft position sensor (POS) and cover. • Tighten bolts with it seated completely.
20. For the oil level gauge guide (1), fix the position (B) shown to the water inlet clip (A) after inserting to the cylinder block side.
21. Assembly is in the reverse order of disassembly after this step.
InspectionINFOID:0000000005398083
CRANKSHAFT END PLAY
• Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with a dial
indicator (A).
• If the measured value exceeds the limit, replace thrust bearings, and measure again. If it still exceeds the limit, replace crankshaft
also.
CONNECTING ROD SIDE CLEARANCE
• Measure the side clearance between connecting rod and crank-shaft arm with a feeler gauge (A).
• If the measured value exceeds the limit, replace connecting rod, and measure again. If it still exceeds the standard, replace crank-
shaft also.
PISTON TO PISTON PIN OIL CLEARANCE
Piston Pin Hole Diameter
: Engine front
PBIC3754E
PBIC3755E
Standard and Limit : Refer to EM-116, "Cylinder Block".
PBIC3762E
Standard : Refer to EM-116, "Cylinder Block".
PBIC3763E
Revision: January 20102010 Versa

EM-98
< DISASSEMBLY AND ASSEMBLY >[HR16DE]
CYLINDER BLOCK
Measure the inner diameter of piston pin hole with an inside
micrometer.
Piston Pin Outer Diameter
Measure the outer diameter of piston pin with a micrometer.
Piston to Piston Pin Oil Clearance
(Piston to piston pin oil clearance) = (Piston pi
n hole diameter) – (Piston pin outer diameter)
• If oil clearance is out of the standard, replace piston and piston pin assembly.
PISTON RING SIDE CLEARANCE
• Measure the side clearance of piston ring and piston ring groove with a feeler gauge.
• If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, replace piston also.
PISTON RING END GAP
• Make sure that cylinder bore inner diameter is within the specifica-
tion. Check "Cylinder Bore Inner Diameter".
• Lubricate with new engine oil to piston and piston ring, and then insert piston ring until middle of cylinder with piston, and measure
piston ring end gap with a feeler gauge.
• If the measured value exceeds the limit, replace piston ring.
CONNECTING ROD BEND AND TORSION
Standard : Refer to EM-116, "Cylinder Block".
PBIC0116E
Standard : Refer to EM-116, "Cylinder Block".
PBIC0117E
Standard : Refer to EM-116, "Cylinder Block".
Standard and Limit : Refer to EM-116, "
Cylinder
Block".
SEM024AA
Standard and Limit : Refer to EM-116, "Cylinder
Block".
SEM822B
Revision: January 20102010 Versa

CYLINDER BLOCKEM-99
< DISASSEMBLY AND ASSEMBLY > [HR16DE]
C
D
E
F
G H
I
J
K L
M A
EM
NP
O
• Check with a connecting rod aligner.
• If it exceeds the limit, replace connecting rod assembly.
CONNECTING ROD BIG END DIAMETER
• Install connecting rod cap without connecting rod bearing installed, and tightening connecting rod bolts to
the specified torque. Refer to EM-90, "
Disassembly and Assembly".
• Measure the inner diameter of connecting rod big end with an
inside micrometer.
• If out of the standard, replace connecting rod assembly.
CONNECTING ROD SMALL END CLEARANCE
Connecting Rod Small End Inner Diameter
Measure the inner diameter of connecting rod small end with an
inside micrometer.
Piston Pin Outer Diameter
Limit : Refer to EM-116, "Cylinder Block".
PBIC2077E
Standard : Refer to EM-116, "Cylinder Block".
PBIC1641E
Standard : Refer to EM-116, "Cylinder Block".
PBIC0120E
Revision: January 20102010 Versa

EM-100
< DISASSEMBLY AND ASSEMBLY >[HR16DE]
CYLINDER BLOCK
Measure the outer diameter of piston pin with a micrometer.
Connecting Rod Small End Clearance
(Connecting rod small end clearance) = (Connecting rod sm
all end inner diameter) – (Piston pin outer diame-
ter)
• If the measured value is out of the standard, repl ace connecting rod assembly and/or piston and piston pin
assembly.
• If replacing connecting rod assembly, use "CONNECTING ROD BEARING OIL CLEARANCE" to select con-
necting rod bearing.
CYLINDER BLOCK TOP SURFACE DISTORTION
• Using a scraper, remove gasket on the cylinder block su rface, and also remove engine oil, scale, carbon, or
other contamination.
CAUTION:
Be careful not to allow gasket flakes to en ter engine oil or engine coolant passages.
• Measure the distortion on the cylinder block upper face at some different points in six directions with a straight edge and a feeler
gauge.
• If it exceeds the limit, replace cylinder block.
MAIN BEARING HOUSING INNER DIAMETER
• Install main bearing cap without main bearings install ed, and tighten main bearing cap bolts to the specified
torque. Refer to EM-90, "
Disassembly and Assembly".
• Measure the position shown [5 mm (0.196 in) rearward from main bearing housing front side end surface) in the 2 directions as
shown. The smaller one is the measured value.
• If out of the standard, replace cylinder block and main bearing caps as an assembly.
NOTE:
These components cannot be replaced as a single unit, because they were processed together.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter
Standard : Refer to EM-116, "Cylinder Block".
PBIC0117E
Standard : Refer to EM-116, "Cylinder Block".
Limit : Refer to EM-116, "
Cylinder Block".
PBIC0121E
1 : Cylinder block
2 : Main bearing cap
: Engine front
Standard : Refer to EM-116, "Cylinder Block".
PBIC3879E
Revision: January 20102010 Versa

CYLINDER BLOCKEM-101
< DISASSEMBLY AND ASSEMBLY > [HR16DE]
C
D
E
F
G H
I
J
K L
M A
EM
NP
O
• Using a bore gauge, measure the cylinder bore for wear, out-of-
round and taper at six different points on each cylinder. (“X” and
“Y” directions at “A”, “B” and “C”) (“Y” is in longitudinal direction of
the engine)
NOTE:
When determining cylinder bore grade, measure cylinder bore at
“B” position.
• If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
replace cylinder block.
NOTE:
There is no service setting for oversized piston.
Piston Skirt Diameter
Measure the outer diameter of piston skirt with a micrometer.
Piston to Cylinder Bore Clearance
Calculate by piston skirt diameter and cylinder bor e inner diameter (direction “X”, position “B”).
(Clearance) = (Cylinder bore inner di ameter) – (Piston skirt diameter)
• If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block.
CRANKSHAFT MAIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft main journals with a micrometer (A).
• If out of the standard, measure the main bearing oil clearance. Then use undersize bearing.
CRANKSHAFT PIN JOURNAL DIAMETER
A : Unit: mm (in)
Standard:
Cylinder bore inner diameter : Refer to EM-116, "
Cylinder Block".
Limit: Out-of-round (Difference between“X”and“Y”)
Taper (Difference between“A”and“B” : Refer to EM-116, "
Cylinder Block".
PBIC3767E
Standard : Refer to EM-116, "Cylinder Block".
PBIC0125E
Standard and Limit : Refer to EM-116, "Cylinder Block".
Standard : Refer to EM-116, "
Cylinder Block".
PBIC3457J
Revision: January 20102010 Versa