engine disassembly NISSAN TIIDA 2008 Service User Guide

CYLINDER BLOCK
EM-77
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Disassembly and AssemblyINFOID:0000000001702510
DISASSEMBLY
1. Remove engine and transaxle assembly from vehicle, separate transaxle from engine. Refer to EM-72.
2. Install engine to engine stand as follows;
a. Remove flywheel (M/T models) or drive plate (1) (A/T or CVT
models).
• Secure flywheel (M/T models) or drive plate (A/T or CVT mod-
els) using Tool (A), and remove bolts.
CAUTION:
Be careful not to damage or scratch drive plate (A/T or CVT
models) and contact surface for clutch disc of flywheel (M/T
models).
NOTE:
Figure shows drive plate (A/T or CVT models)
b. Lift the engine with a hoist to install it onto widely use engine stand.
CAUTION:
• Use the engine stand that has a load capacity [approximately 135 kg (298 lb) or more] large
enough for supporting the engine weight.
• If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the poten-
tial risk of overturning stand.
- Exhaust manifold; Refer to EM-21
.
- Rocker cover; Refer to EM-30
.
NOTE:
The figure shows an example of widely used engine stand (A)
that can support mating surface of transaxle with flywheel (M/T
models) or drive plate (A/T or CVT models) removed.
CAUTION:
Before removing the hanging chains, make sure the engine
stand is stable and there is no risk of overturning.
3. Remove oil pan (upper and lower). Refer to EM-24
.
4. Remove cylinder head. Refer to EM-62
.
5. Remove thermostat housing. Refer to CO-17
.
6. Remove knock sensor.
CAUTION:
Carefully handle knock sensor avoiding shocks.
7. Remove crankshaft position sensor (POS) cover and crankshaft position sensor (POS).
7. Oil pressure switch 8. Top ring 9. Second ring
10. Oil ring 11. Snap ring 12. Piston
13. Piston pin 14. Connecting rod 15. Thrust bearing
16. Connecting rod bearing upper 17. Main bearing upper 18. Crankshaft key
19. Main bearing lower 20. Connecting rod bearing lower 21. Connecting rod bearing cap
22. Connecting rod bolt 23. Main bearing cap 24. Main bearing cap bolt
25. Crankshaft 26. Pilot converter (A/T or CVT models) 27. Signal plate
28. Rear oil seal 29. Drive plate (A/T or CVT models) 30. Reinforcement plate (A/T or CVT
models)
31. Flywheel (M/T models) 32. Block heater (Canada only) A. Refer to EM-77
Tool number : KV 11105210 (J-44716)
PBIC3226J
PBIC3227J

CYLINDER BLOCK
EM-79
< SERVICE INFORMATION >
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16. Using snap ring pliers (A), remove snap rings.
17. Heat piston to 60° to 70°C (140° to 158°F) using a suitable tool
(A).
18. Push out piston pin using a suitable tool of an outer diameter
approximately 18 mm (0.71 in).
19. Loosen main bearing cap bolts in reverse order as shown, and
remove them.
NOTE:
Before loosening main bearing cap bolts, measure crankshaft
end play. Refer to EM-93, "
Inspection After Disassembly".
20. Remove main bearing caps.
• Tap main bearing caps lightly using a suitable tool for removal.
CAUTION:
Be careful not to damage the mounting surface.
21. Remove crankshaft.
CAUTION:
PBIC3230J
PBIC3231J
PBIC0262E
: Engine front
PBIC3235J

EM-82
< SERVICE INFORMATION >
CYLINDER BLOCK
15. Tighten main bearing cap bolts in two steps.
NOTE:
Tighten main bearing cap bolts in numerical order as shown:
• After installing bolts, make sure that crankshaft can be rotated smoothly by hand.
• Check crankshaft end play. Refer to EM-93, "
Inspection After Disassembly".
16. Using snap ring pliers, install new snap ring to the groove of the piston rear side.
• Insert it fully into groove to install.
17. Assemble piston to connecting rod.
• Using a suitable tool, heat the piston until the piston 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
connecting rod.
• Assemble so that the front mark (A) on the piston head and
the oil hole (B) and the cylinder number (C) on connecting rod
are positioned as shown.
18. Install new snap ring to the groove of the piston front side.
• Insert it fully into groove to install.
• After installing, make sure that connecting rod moves
smoothly.
19. 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.
: Engine front
Step 1 : 34.3 N·m (3.5 kg-m, 25 ft-lb)
Step2 60° clockwise
PBIC3235J
Tool number : KV10112100 (BT-8653-A)
PBIC3240J
D : Big end diameter grade
E : Small end diameter grade
F : Front mark (connecting rod bearing cap)
PBIC3587J

EM-84
< SERVICE INFORMATION >
CYLINDER BLOCK
• Using a piston ring compressor [SST: EM03470000 (J-8037)]
(A) or suitable tool, install piston with the front mark on the pis-
ton head facing the front of the engine.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod
big end.
22. Install connecting rod cap.
• Match the stamped cylinder number marks (C) on connecting
rod with those on connecting rod cap to install.
23. Tighten connecting rod bolt with the following procedure:
CAUTION:
• Make sure that there is no gap in the thrust surface (A) of
the joint between connecting rod (1) and connecting rod
bearing cap (2) and that these parts are in the correct
position. And then, tighten the connecting rod bolts.
• If the connecting rod bolts are reused, measure the outer
diameter. Refer to EM-93, "
Inspection After Disassembly".
24. Apply new engine oil to the threads and seats of connecting rod
bolts.
25. Tighten bolts in three steps
• After tightening connecting rod bolt, make sure that crankshaft rotates smoothly.
• Check the connecting rod side clearance. Refer to EM-93, "
Inspection After Disassembly".
26. Install oil pan (upper). Refer to EM-24
.
NOTE:
Install the rear oil seal after installing the oil pan (upper).
27. Install rear oil seal. Refer to EM-24
.
28. Install flywheel (M/T models) or drive plate (1) (A/T or CVT mod-
els).
• Secure crankshaft using Tool. (A), and tighten bolts crosswise
over several times.
NOTE:
A/T model shown CVT and M/T similar.
PBIC3244J
A : Front mark (piston)
B : Oil hole
D : Big end diameter grade
E : Small end diameter grade
F : Front mark (connecting rod bearing cap)
PBIC3587J
Step 1 : 27.4 N·m (2.8 kg-m, 20 ft-lb)
Step 2 : 0 N·m (0 kg-m, 0 ft-lb)
Step 3 : 19.6 N·m (2.0 kg-m, 14 ft-lb)
Tool number : KV11105210 (J-44716)PBIC3510J
PBIC3998E

CYLINDER BLOCK
EM-85
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• Install pilot converter (1), drive plate (2) and reinforcement
plate (3) as shown (A/T or CVT models).
• Using a suitable tool of 33 mm. (1.30 in) in diameter, press-fit
pilot converter into the end of crankshaft until it stops (A/T or
CVT models).
NOTE:
M/T models have no pilot converter and reinforcement plate.
29. Install knock sensor (1) with connector facing toward the rear of
engine.
CAUTION:
• Never tighten bolts 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.
30. Install crankshaft position sensor (POS) and crankshaft position sensor (POS) cover.
CAUTION:
• Avoid impacts such as a dropping.
• Keep it away from metal particles.
• Never place sensor in a location where it is exposed to magnetism.
31. Install oil filter (for intake valve timing control) (1) in the direction
shown.
• Make sure that the oil filter does not protrude from the upper
surface of cylinder block (2) after installation.
32. Assemble in the reverse order of disassembly.
How to Select Piston and BearingINFOID:0000000001702511
DESCRIPTION
A : Crankshaft rear end
B: R
PBIC4075E
A : Cylinder block left side
: Engine front
PBIC3246J
PBIC3260J

EM-86
< SERVICE INFORMATION >
CYLINDER BLOCK
• The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
• For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, follow the applicable procedures.
HOW TO SELECT PISTON
When New Cylinder Block is Used
• Check the cylinder bore grade on rear left side of cylinder block (L),
and select piston of the same grade.
• If there is a correction stamp mark on the cylinder block, use it as a
correct reference.
When Cylinder Block is Reused
1. Measure the cylinder bore inner diameter. Refer to EM-93, "Inspection After Disassembly".
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner
diameter of the “Piston Selection Table”.
Selection points Selection parts Selection items Selection methods
Between cylinder block and
crankshaftMain bearingMain bearing grade (bearing
thickness)Determined by match of cylin-
der block bearing housing
grade (inner diameter of hous-
ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Between crankshaft and con-
necting rodConnecting rod bearingConnecting rod bearing grade
(bearing thickness)Combining service grades for
connecting rod big end diame-
ter and crankshaft pin outer di-
ameter determine connecting
rod bearing selection.
Between cylinder block and pis-
tonPiston and piston pin assembly
(piston is available together with
piston pin as an assembly.)Piston grade (piston outer diam-
eter)Piston grade = cylinder bore
grade (inner diameter of bore)
A : Correction stamp
B : Standard stamp
C : Cylinder No. 1 bore grade
D : Cylinder No. 2 bore grade
E : Cylinder No. 3 bore grade
F : Cylinder No. 4 bore grade
G : No. 1 main bearing housing grade
H : No. 2 main bearing housing grade
I : No. 3 main bearing housing grade
J : No. 4 main bearing housing grade
K : No. 5 main bearing housing grade
: Engine front
PBIC3264J

EM-90
< SERVICE INFORMATION >
CYLINDER BLOCK
1. “Main Bearing Selection Table” rows correspond to main bearing
housing grade on rear left side of cylinder block (L).
• If there is a correction stamp mark on cylinder block, use it as
a correct reference.
2. Apply main journal diameter grade stamped on crankshaft front
side to column in the “Main Bearing Selection Table”.
3. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”.
CAUTION:
There are two main bearing selection tables. One is for No. 1, 4 and 5 journals and the other is for
No. 2 and 3 journals. Make certain to use the appropriate table. This is due to differences in the
specified clearances.
4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.
NOTE:
Service part is available as a set of both upper and lower.
When Cylinder Block and Crankshaft are Reused
1. Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main
journal diameter individually. Refer to EM-93, "
Inspection After Disassembly" and EM-93, "Inspection After
Disassembly".
2. Apply the measured dimension to the “Main Bearing Selection Table”.
3. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”.
CAUTION:
There are two main bearing selection tables. One is for No. 1, 4 and 5 journals and the other is for
No. 2 and 3 journals. Make certain to use the appropriate table. This is due to differences in the
specified clearances.
4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.
NOTE:
A : Correction stamp
B : Standard stamp
C : Cylinder No. 1 bore grade
D : Cylinder No. 2 bore grade
E : Cylinder No. 3 bore grade
F : Cylinder No. 4 bore grade
G : No. 1 main bearing housing grade
H : No. 2 main bearing housing grade
I : No. 3 main bearing housing grade
J : No. 4 main bearing housing grade
K : No. 5 main bearing housing grade
: Engine front
PBIC3264J
A : No. 1 pin journal diameter grade
B : No. 2 pin journal diameter grade
C : No. 3 pin journal diameter grade
D : No. 4 pin journal diameter grade
E : No. 1 main journal diameter grade
F : No. 2 main journal diameter grade
G : No. 3 main journal diameter grade
H : No. 4 main journal diameter grade
I : No. 5 main journal diameter grade
PBIC3261J

CYLINDER BLOCK
EM-97
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Measure the outer diameter of piston pin with a micrometer (A).
Connecting Rod Bushing Oil Clearance
(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)
• If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin
assembly.
• If replacing piston and piston pin assembly, follow the "PISTON TO PISTON PIN OIL CLEARANCE" proce-
dure.
• If replacing connecting rod assembly, follow the "Connecting Rod Bushing Oil Clearance" procedure to
select connecting rod bearing.
CYLINDER BLOCK TOP SURFACE DISTORTION
• Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or
other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter 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 (A) and feeler
gauge (B).
• If it exceeds the limit, replace cylinder block.
MAIN BEARING HOUSING INNER DIAMETER
• Install main bearing cap without main bearings installed, and tighten main bearing cap bolts to the specified
torque. Refer to EM-77, "
Disassembly and Assembly" for the tightening procedure.
• Measure the inner diameter of main bearing housing with a bore gauge.
• 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:Standard: 19.989 - 19.995 mm (0.7870 - 0.7872 in)
PBIC3266J
Standard : 0.005 - 0.023 mm (0.0002 - 0.0009 in)
Limit : 0.03 mm (0.0012 in)
Limit: 0.1 mm (0.004 in)
PBIC3250J
1 : Cylinder block
2 : Main bearing cap
: Engine front
Standard: 55.997 - 56.017 mm (2.2046 - 2.2054 in)
PBIC4005E

EM-100
< SERVICE INFORMATION >
CYLINDER BLOCK
• Install connecting rod bearings (2) to connecting rod (3) and con-
necting rod bearing cap (1), and tighten connecting rod bolts to the
specified torque. Refer to EM-77, "
Disassembly and Assembly"
for tightening procedure.
• Measure the inner diameter of connecting rod bearing with an
inside micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter)
– (Crankshaft pin journal diameter)
• If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end
diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to EM-85, "
How
to Select Piston and Bearing".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified
torque. Refer to EM-77, "
Disassembly and Assembly" for the tightening procedure.
CAUTION:
Never rotate crankshaft.
• Remove connecting rod cap and bearing, and using the scale (A)
on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
MAIN BEARING OIL CLEARANCE
Method by Calculation
• Install main bearings (3) to cylinder block (1) and main bearing cap
(2), and tighten main bearing cap bolts to the specified torque.
Refer to EM-77, "
Disassembly and Assembly" for the tightening
procedure.
• Measure the inner diameter of main bearing with a bore gauge.
(Bearing oil clearance) = (Main bearing inner diameter) – (Crank-
shaft main journal diameter)
A : Example
B : Inner diameter measuring direction
Standard : 0.037 - 0.047 mm (0.0015 - 0.0019 in)
Limit : 0.07 mm (0.0028 in)
PBIC3275J
PBIC3276J
A : Example
B : Inner diameter measuring direction
Standard:
No. 1, 4 and 5 journals
: 0.024 - 0.034 mm (0.0009 - 0.0013 in)
No. 2 and 3 journals
: 0.012 - 0.022 mm (0.0005 - 0.0009 in)
Limit : 0.065 mm (0.0026 in)
PBIC3277J

CYLINDER BLOCK
EM-101
< SERVICE INFORMATION >
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• If clearance exceeds the limit, select proper main bearing according to main bearing inner diameter and
crankshaft main journal diameter to obtain specified bearing oil clearance. Refer to EM-85, "
How to Select
Piston and Bearing".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap bolts to the spec-
ified torque. Refer to EM-77, "
Disassembly and Assembly" for the tightening procedure.
CAUTION:
Never rotate crankshaft.
• Remove main bearing cap and bearings, and using the scale (A)
on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
MAIN BEARING CRUSH HEIGHT
• When main bearing cap is removed after being tightened to the
specified torque with main bearings (1) installed, the tip end of
bearing must protrude (B). Refer to EM-77, "
Disassembly and
Assembly" for the tightening procedure.
• If the standard is not met, replace main bearings.
CONNECTING ROD BEARING CRUSH HEIGHT
• When connecting rod bearing cap is removed after being tightened
to the specified torque with connecting rod bearings (1) installed,
the tip end of bearing must protrude. Refer to EM-77, "
Disassem-
bly and Assembly" for the tightening procedure (B).
• If the standard is not met, replace connecting rod bearings.
MAIN BEARING CAP BOLT OUTER DIAMETER
PBIC3278J
A : Example
Standard : There must be crush height.
PBIC3279J
A : Example
Standard : There must be crush height.
PBIC3279J