lock NISSAN NOTE 2016 Service Repair Manual

CYLINDER BLOCKEM-97
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3. Install oil jets.
4. Install main bearings and thrust bearings:
a. Remove dust, dirt, and engine oil on the bear
ing 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 paying attention to the direction. • 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.
• When installing, align main bearing to the center position of cylinder block and main bearing cap.
• Ensure the oil holes on cylinder block and oil holes (A) on the
main bearings (1) are aligned.
NOTE:
For assembly, the center position can be visually identified.
• To install the main bearing, obtain a proper fit. Do not allow the main bearing to lie off the cylinder block chamfer.
• To install the main bearing, obtain a proper fit. Do not allow the
main bearing to lie off bearing cap chamfer.
5. 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.
6. Install crankshaft to cylinder block. • While turning crankshaft by hand, check that it turns smoothly.
CAUTION:
Do not install rear oil seal at this time.
7. Install main bearing caps.
: Engine front
PBIC3258J
PBIC3746E
(A) : Dowel pin hole
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EM-98
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CYLINDER BLOCK
• 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.
8. Tighten main bearing cap bolts in numerical order as 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 numerical order.
c. Turn main bearing cap bolts 60 degrees clockwise (angle tight- ening) in numerical order as shown.
CAUTION:
Check and confirm the tightening angle by using the Tool
(A) or protractor. Do not judge by visual inspection without
the Tool (A).
• After installing the main bearing cap bolts, check that crankshaft can be rotated smoothly by hand.
• Check crankshaft end play. Refer to EM-102, "
Inspection".
9. Install piston to connecting rod with the following procedure:
a. Using a heat gun, heat the piston until the pist on pin can be pushed in by hand without excess force
[approximately 60 to 70 °C (140 to 158 °F)]. From the front to the rear, insert piston pin into piston and con-
necting rod.
b. Set so that the front mark (A) on the piston head and the cylin- der number (C) are in the position as shown.
NOTE:
The symbols without notes are for manufacturing.
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.
: Engine front
JPBIA4204ZZ
: Engine front
Step 1 : 32.4 N·m (3.3 kg-m, 24 ft-lb)
Step 2 : 60° clockwise
JPBIA4203ZZ
Tool number (A) : KV10112100 (BT-8653-A)
PBIC3750E
(B) : Oil hole
(D) : Connecting rod big end grade
PBIC3766E
Revision: August 2015 2016 Versa Note

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CYLINDER BLOCKEM-99
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• Press-fit the piston pin (2) from piston surface (A) to the depth
of 2.35 mm (0.092 in) (b).
• After finishing work, check that the piston (3) moves freely.
10. Using suitable tool (A), install piston rings. CAUTION:
• Do not damage piston.
• Do not damage piston rings by expanding them exces-sively.
• 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.
11. 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 notapply engine oil to the back surface, but thoroughly clean it.
• Install the bearing in the center position. NOTE:
There is no stopper tab.
• Check that the oil holes on connecting rod and connecting rod bearing are aligned.
• Install the connecting rod in the dimension (A) as shown.
NOTE:
Install the connecting rod bearing in the center position with
the dimension as shown. For service operation, the center
position can be checked visually.
(1) : Connecting rod : Press-fit direction
JPBIA2058ZZ
PBIC3233J
(A) : Oil ring upper or lowe r rail gap (either of them)
(C) : Second ring and oil ring spacer gap
(D) : Top ring gap
Stamped mark: Top ring : 1R
Second ring : 2R
(1) : Connecting rod
(2) : Connecting rod bearing (upper)
(3) : Connecting rod bearing (lower)
(4) : Connecting rod cap
(A) : 1.7 - 2.1 mm (0.067 - 0.083 in)
: Engine front
PBIC3752E
PBIC4169E
Revision: August 2015 2016 Versa Note

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EM-100
< UNIT DISASSEMBLY AND ASSEMBLY >[HR16DE]
CYLINDER BLOCK
12. Install piston and connecting rod assembly to crankshaft.
• Position crankshaft pin corresponding 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 cyli nder number on connecting rod to install.
• Using Tool (A) or suitable tool, install piston with the front mark on the piston head facing the front of the engine.
CAUTION:
• Do not damage mating surface with connecting rod cap.
• Do not damage the cylinder wall or crankshaft pin.
13. Install connecting rod cap. • Match the stamped cylinder number marks (C) on connectingrod with those on connecting rod cap to install.
14. Inspect outer diameter of connecting rod bolts. Refer to EM-102, "
Inspection".
15. Tighten connecting rod bolt:
a. Apply new engine oil to the threads and seats of connecting rod bolts.
b. Install connecting rod bolts in several steps.
c. Then turn all connecting rod bolts 60 degrees clockwise (angle tightening). CAUTION:
Check and confirm the tight ening angle by using the Tool (A) or protractor. Avoid judgement by
visual inspection without the Tool (A).
• After tightening connecting rod bolt, che ck that crankshaft rotates smoothly.
• Check the connecting rod side clearance. Refer to EM-102, "
Inspection".
16. Install oil pan (upper). Refer to EM-37, "
Removal and Installation (Upper Oil Pan)".
NOTE: Tool number (A) : EM03470000 (J-8037)
PBIC3765E
(A) : Front mark
(B) : Oil hole
(D) : Connecting rod big end grade
PBIC3766E
Step 1 Tighten to
: 27.4 N·m (2.8 kg-m, 20 ft-lb)
Step 2 Completely loosen : 0 N·m (0 kg-m, 0 ft-lb)
Step 3 Tighten to : 19.6 N·m (2.0 kg-m, 14 ft-lb)
Tool number (A) : KV10112100 (BT-8653-A)
PBIC3753E
Revision: August 2015 2016 Versa Note

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CYLINDER BLOCKEM-101
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Install the rear oil seal after installing the oil pan (upper).
17. Install rear oil seal. Refer to EM-74, "
REAR OIL SEAL : Removal and Installation".
18. Install flywheel (M/T models) or drive plate (CVT models).
M/T models
• Secure crankshaft with a stopper plate and tighten bolts crosswise over several times.
CVT models
• Secure crankshaft with a stopper plate and tighten bolts crosswise over several times.
CAUTION:
Do not damage or scratch and contact surface for clutch disc of flywheel.
19. Install knock sensor (1).
• Install connectors so that they are positioned toward the rearof the engine.
CAUTION:
• Do not tighten bolt while holding the connector.
• If any impact by dropping is applied to knock sensor,
replace it with a new one.
NOTE:
• Check that there is no foreign material on the cylinder block
mating surface and the back surface of knock sensor.
• Check that knock sensor does not interfere with other parts.
20. Install crankshaft position sensor (POS) (2) and O-ring (1) and then install the crankshaft position sensor cover (3) on the cylin-
der block (4).
• Tighten bolts with sensor inserted completely.
CAUTION:
• Avoid impacts such as a dropping.
• Do not disassemble.
• Keep sensor away from metal particles.
• Do not place the sensor in a location where it is exposedto magnetism.
• Do not reuse O-ring.
21. For the oil level gauge guide (1), secure in position (B) shown to the water inlet clip (A) after inserting to the cylinder block side.
22. Assembly of the remaining components is in the reverse order of disassembly.
Tool number : KV11105210 (J-44716)
Tool number : KV11105210 (J-44716)
: Engine front
: Engine front
PBIC3754E
JPBIA4202ZZ
PBIC3755E
Revision: August 2015
2016 Versa Note

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EM-102
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CYLINDER BLOCK
Inspection
INFOID:0000000012431738
CRANKSHAFT END PLAY
• Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward using
suitable tool (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 using suitable tool (A).
• If the measured value exceeds the limit, replace connecting rod, and measure again. If it still exceeds the limit, replace crankshaft
also.
PISTON TO PISTON PIN OIL CLEARANCE
Piston Pin Hole Diameter
Measure the inner diameter of pist on pin hole using suitable tool (A).
Piston Pin Outer Diameter
Measure the outer diameter of piston pin using suitable tool (A).
Piston to Piston Pin Oil Clearance
(Piston to piston pin oil clearance) = (Piston pi n hole diameter) – (Piston pin outer diameter)
Standard and Limit : Refer to
EM-121, "
Cylinder
Block".
PBIC3762E
Standard and Limit : Refer to EM-121, "Cylinder
Block".
PBIC3763E
Standard : Refer to EM-121, "Cylinder Block".
PBIC3265J
Standard : Refer to EM-121, "Cylinder Block".
PBIC3266J
Standard : Refer to EM-121, "Cylinder Block".
Revision: August 2015 2016 Versa Note

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CYLINDER BLOCKEM-103
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• If oil clearance is out of the standard, replace piston and piston pin assembly.
• When replacing piston and piston pin assembly. Refer to
EM-94, "
Disassembly and Assembly".
NOTE:
• Piston is available together with piston pin as assembly.
• Piston pin (piston pin hole) grade is provided only for the parts installed at the factory. For service parts, no
grades can be selected. Only grade “0” is available.
PISTON RING SIDE CLEARANCE
• Measure the side clearance of piston ring and piston ring groove with a suitable tool (A).
• If the measured value exceeds t he limit, replace piston ring, and
measure again. If it still exceeds the limit, replace piston also.
PISTON RING END GAP
• Check that cylinder bore inner diameter is within specification. Refer to “PISTON TO CYLINDER BORE CLEARANCE”.
• Lubricate piston (1) and piston ring (2) with new engine oil and then insert (A) piston ring until mi ddle of cylinder (B) with piston,
and measure piston ring end gap using feeler gauge (C).
• If the measured value exceeds t he limit, replace piston ring, and
measure again. If it still exceeds the limit, replace cylinder block.
CONNECTING ROD BEND AND TORSION
• Check using connecting rod aligner.
• If it exceeds the limit, replace connecting rod assembly.
CONNECTING ROD BIG END DIAMETER
Standard and Limit : Refer to EM-121, "Cylinder
Block".
PBIC3280J
Standard and Limit : Refer to EM-121, "Cylinder
Block".
PBIC3267J
(A) : Bend
(B) : Torsion
(C) : Feeler gauge
Limit : Refer to EM-121, "Cylinder Block".
PBIC3268J
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EM-104
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CYLINDER BLOCK
• Install connecting rod cap (1) without connecting rod bearing
installed, and tightening connecting rod cap bolts to the specified
torque. Refer to EM-93, "
Exploded View".
• Measure the inner diameter (B) of connecting rod big end using suitable tool.
• If out of the standard, replace connecting rod assembly.
CONNECTING ROD BUSHING OIL CLEARANCE
Connecting Rod Bushing Inner Diameter
Measure the inner diameter of connecting rod bushing using suitable
tool (A).
Piston Pin Outer Diameter
Measure the outer diameter of piston pin using micrometer (A).
Connecting Rod Bushing Oil Clearance
(Connecting rod bushing oil clearance) = (Connecting rod bus hing inner diameter) – (Piston pin outer diame-
ter)
• If the measured value is out of the standard range, replace connecting rod assembly and/or piston and pis- ton pin assembly.
• If replacing piston and piston pin assembly. Refer to EM-121, "
Cylinder Block".
• If replacing connecting rod assembly. Refer to EM-125, "
Connecting 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 particles to enter engine oil or engine coolant passages.
(2) : Connecting rod
(A) : Example
(B) : Measuring direction of inner diameter
Standard : Refer to EM-121, "Cylinder Block".PBIC3269J
Inner diameter
(Standard) : Refer to
EM-121, "Cylinder
Block".
JPBIA0223ZZ
Outer diameter
(Standard) : Refer to
EM-121, "Cylinder
Block".
JPBIA0218ZZ
Oil clearance
(Standard and Limit) : Refer to
EM-121, "Cylinder Block".
Revision: August 2015 2016 Versa Note

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CYLINDER BLOCKEM-105
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• Measure the distortion on the cylinder block upper face at different
points in six directions using suitable tool (A / B).
• If it exceeds the limit, replace cylinder block.
MAIN BEARING HOUSING INNER DIAMETER
• Install main bearing cap without main bearings insta lled, and tighten main bearing cap bolts to the specified
torque. Refer to EM-94, "
Disassembly and Assembly".
• Measure the inner diameter of main bearing housing using suitable tool.
• Measure the position shown [5 mm (0.20 in)] backward from main
bearing housing front side 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 assembly.
NOTE:
Main bearing caps cannot be replaced individually, bec ause they are machined together with cylinder block.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter
• Using a suitable tool, measure the cylinder bore for wear, out-of-
round and taper at six different points on each cylinder. [(A) and (B)
directions at (C), (D), and (E)] [(A) is in longitudinal direction of
engine]
NOTE:
When determining cylinder bore grade, measure the cylinder bore
(B) direction at (D) 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:
Oversize piston is not available. Limit : Refer to
EM-121, "
Cylinder Block".
JPBIA0224ZZ
(1) : Cylinder block
(2) : Main bearing cap
: Engine front
Standard : Refer to EM-121, "Cylinder Block".
PBIC4005E
(f) : 10 mm (0.39 in)
(g) : 60 mm (2.36 in)
(h) : 124 mm (4.88 in)
Standard:
Cylinder bore inner diameter : Refer to EM-121, "
Cylinder Block".
Limit: Out-of-round [Difference between (A) and (B)]
Taper [Difference between (C) and (E)] : Refer to EM-121, "
Cylinder Block".
JPBIA2059ZZ
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EM-106
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CYLINDER BLOCK
Piston Skirt Diameter
Measure the outer diameter of piston skirt using suitable tool (A).
Piston to Cylinde
r Bore Clearance
Calculate by piston skirt diameter and cylinder bore inner diameter
[direction (B), position (D)].
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diame-
ter)
• If it exceeds the limit, replace piston and pist on pin assembly and/or cylinder block. Refer to EM-121, "
Cylin-
der Block".
CRANKSHAFT MAIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft main journals using suit-
able tool (A).
• If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to EM-124, "
Main Bearing".
CRANKSHAFT PIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft pin journal using suitable tool.
• If out of the standard, measure the connecting rod bear ing oil clearance. Then use undersize bearing. Refer
to EM-125, "
Connecting Rod Bearing".
OUT-OF-ROUND AND TAPER OF CRANKSHAFT
Standard : Refer to EM-121, "Cylinder Block".
PBIC3272J
(A) : Direction A
(C) : Position C
(E) : Position E
(f) : 10 mm (0.39 in)
(g) : 60 mm (2.36 in)
(h) : 124 mm (4.88 in)
Standard and Limit : Refer to EM-121, "Cylinder Block".
JPBIA2059ZZ
Standard : Refer to EM-121, "Cylinder Block".
PBIC3457J
Standard : Refer to EM-121, "Cylinder Block".
Revision: August 2015 2016 Versa Note

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