Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Almera 2000-2003.2006 Approved Nissan Almera 2001 N16 2001 Nissan Almera UK em
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ENGINE MECHANICAL
SECTION EM
CONTENTS
QG Inspection...................................................................36
CYLINDER HEAD DISTORTION ...............................36
PRECAUTIONS ...............................................................4 CAMSHAFT VISUAL CHECK ....................................36
Parts Requiring Angular Tightening.............................4 CAMSHAFT RUNOUT ..............................................37
Liquid Gasket Application Procedure ..........................4 CAMSHAFT CAM HEIGHT .......................................37
PREPARATION ...............................................................5 CAMSHAFT JOURNAL CLEARANCE ........................37
Special Service Tools ..................................................5 CAMSHAFT END PLAY............................................38
Commercial Service Tools ...........................................7 CAMSHAFT SPROCKET RUNOUT ...........................38
NOISE, VIBRATION AND HARSHNESS (NVH) VALVE GUIDE CLEARANCE ....................................38
TROUBLESHOOTING .....................................................9 VALVE GUIDE REPLACEMENT ................................39
NVH Troubleshooting - Engine Noise .........................9 VALVE SEATS .........................................................40
REPLACING VALVE SEAT FOR SERVICE PARTS ....40
OUTER COMPONENT PARTS .....................................11
VALVE DIMENSIONS ...............................................41
Removal and Installation ...........................................11
VALVE SPRING .......................................................41
MEASUREMENT OF COMPRESSION PRESSURE ....14
VALVE LIFTER AND VALVE SHIM ............................41
DRIVE BELTS................................................................15 Valve Clearance.........................................................42
Checking ....................................................................15 CHECKING .............................................................42
AIR CLEANER...............................................................17 ADJUSTING ............................................................43
Cleaning and Changing .............................................17 Assembly ...................................................................45
VISCOUS PAPER TYPE ...........................................17 Installation..................................................................45
SPARK PLUG................................................................18 ENGINE ASSEMBLY.....................................................49
Checking and Changing ............................................18 Removal and Installation ...........................................49
OIL PAN.........................................................................19 REMOVAL ...............................................................50
Components...............................................................19 INSTALLATION........................................................51
Removal.....................................................................19 CYLINDER BLOCK .......................................................52
Installation..................................................................20 Components...............................................................52
TIMING CHAIN ..............................................................22 Removal and Installation ...........................................53
Components...............................................................22 Disassembly...............................................................53
Removal.....................................................................23 PISTON AND CRANKSHAFT ....................................53
Inspection...................................................................26 Inspection...................................................................54
Installation..................................................................27 PISTON AND PISTON PIN CLEARANCE ..................54
OIL SEAL.......................................................................31 PISTON RING SIDE CLEARANCE ............................54
Replacement..............................................................31 PISTON RING END GAP..........................................54
VALVE OIL SEAL .....................................................31 CONNECTING ROD BEND AND TORSION ...............55
FRONT OIL SEAL ....................................................31 CYLINDER BLOCK DISTORTION AND WEAR ...........55
REAR OIL SEAL ......................................................32 PISTON-TO-BORE CLEARANCE ..............................56
CYLINDER HEAD..........................................................33 CRANKSHAFT.........................................................57
Components...............................................................33 BEARING CLEARANCE ...........................................57
CONNECTING ROD BUSHING CLEARANCE
Removal.....................................................................34
(SMALL END) ..........................................................59
Disassembly...............................................................36
CONTENTS (Cont'd)
REPLACEMENT OF CONNECTING ROD ALTERNATOR & WATER PUMP BELT .....................85
BUSHING (SMALL END) ..........................................60 Removal.....................................................................85
FLYWHEEL/DRIVE PLATE RUNOUT ........................60 Installation..................................................................86
Assembly ...................................................................60 AIR CLEANER...............................................................87
PISTON ..................................................................60 Changing Air Cleaner Filter .......................................87
CRANKSHAFT.........................................................61 VISCOUS PAPER TYPE ...........................................87
SERVICE DATA AND SPECIFICATIONS (SDS) .........64 OIL PAN.........................................................................88
General Specifications...............................................64 Components...............................................................88
Compression Pressure ..............................................64 Removal.....................................................................88
Belt Deflection............................................................64 Installation..................................................................90
Spark Plug .................................................................65 TIMING CHAIN ..............................................................93
Cylinder Head ............................................................65 Secondary Timing Chain ...........................................93
Valve ..........................................................................66 REMOVAL ...............................................................93
VALVE ....................................................................66 INSPECTION ...........................................................95
VALVE SPRING .......................................................66 INSTALLATION........................................................95
VALVE LIFTER ........................................................66 Primary Timing Chain ................................................98
VALVE CLEARANCE................................................67 REMOVAL ...............................................................99
VALVE GUIDE .........................................................67 INSPECTION .........................................................101
AVAILABLE SHIMS ..................................................67 INSTALLATION......................................................101
VALVE SEAT ...........................................................70 INTAKE MANIFOLD ....................................................106
VALVE SEAT RESURFACE LIMIT.............................71
Removal and Installation .........................................106
Camshaft and Camshaft Bearing ..............................71 PREPARATIVE WORK ...........................................106
Cylinder Block............................................................72 FUEL PIPING ........................................................107
Piston, Piston Ring and Piston Pin ...........................73 INTAKE MANIFOLD ...............................................107
PISTON ..................................................................73 EGR VOLUME CONTROL VALVE ...........................107
PISTON RING .........................................................73 WATER HOSE .......................................................107
PISTON PIN ............................................................73 Inspection.................................................................108
Connecting Rod .........................................................74 INTAKE MANIFOLD ...............................................108
Crankshaft..................................................................74 CATALYST ..................................................................109
Main Bearing..............................................................74 Removal and Installation .........................................109
STANDARD .............................................................74 PREPARATIVE WORK ...........................................109
UNDERSIZE ............................................................74 CATALYST ............................................................109
Connecting Rod Bearing ...........................................75 GUSSET ...............................................................110
STANDARD SIZE ....................................................75 EXHAUST MANIFOLD, TURBOCHARGER ............... 111
UNDERSIZE ............................................................75 Removal and Installation ......................................... 111
Bearing Clearance .....................................................75 PREPARATIVE WORK ........................................... 111
Miscellaneous Components.......................................75 EXHAUST MANIFOLD AND TURBOCHARGER ....... 111
EXHAUST MANIFOLD GASKET .............................112
YD Disassembly and Assembly.....................................112
TURBOCHARGER .................................................112
PRECAUTIONS .............................................................76 Inspection.................................................................113
Parts Requiring Angular Tightening...........................76 EXHAUST MANIFOLD ...........................................113
Liquid Gasket Application Procedure ........................76 TURBOCHARGER .................................................113
PREPARATION .............................................................77 ROCKER COVER ........................................................116
Special Service Tools ................................................77 Removal and Installation .........................................116
Commercial Service Tools .........................................79 PREPARATIVE WORK ...........................................116
NOISE, VIBRATION AND HARSHNESS (NVH) ROCKER COVER ..................................................116
TROUBLESHOOTING ...................................................81 CYLINDER HEAD........................................................118
NVH Troubleshooting - Engine Noise .......................81 Components.............................................................118
MEASUREMENT OF COMPRESSION PRESSURE ....82 Removal...................................................................119
DRIVE BELTS................................................................84 PREPARATIVE WORK ...........................................119
Inspection...................................................................84 CAMSHAFT ...........................................................119
Adjustment .................................................................84 CYLINDER HEAD ..................................................120
AIR CONDITIONER COMPRESSOR BELT ................85 Disassembly.............................................................120
Inspection.................................................................121
EM-2
CONTENTS (Cont'd)
CYLINDER HEAD DISTORTION .............................121 PISTON-TO-BORE CLEARANCE ............................146
CAMSHAFT VISUAL CHECK ..................................122 CRANKSHAFT.......................................................148
CAMSHAFT RUNOUT ............................................122 MAIN BEARING HOUSING INNER DIAMETER ........148
CAMSHAFT CAM HEIGHT .....................................122 BEARING CLEARANCE .........................................148
CAMSHAFT JOURNAL CLEARANCE ......................122 MAIN BEARING CRUSH HEIGHT ...........................152
CAMSHAFT END PLAY..........................................123 MAIN BEARING CAP BOLT DEFORMATION ...........152
CAMSHAFT SPROCKET RUNOUT .........................123 CONNECTING ROD BUSHING CLEARANCE
VALVE GUIDE CLEARANCE ..................................123 (SMALL END) ........................................................152
VALVE GUIDE REPLACEMENT ..............................124 CONNECTING ROD BOLT DEFORMATION ............153
VALVE SEATS .......................................................125 FLYWHEEL RUNOUT ............................................153
REPLACING VALVE SEAT FOR SERVICE PARTS ..125 OIL JET ................................................................153
VALVE DIMENSIONS .............................................127 OIL JET RELIEF VALVE .........................................154
VALVE SPRING .....................................................127 Assembly .................................................................154
VALVE LIFTER ......................................................127 PISTON ................................................................154
Assembly .................................................................128 CRANKSHAFT.......................................................154
Installation................................................................129 REPLACEMENT OF PILOT BUSHING.....................157
CYLINDER HEAD GASKET SELECTION .................129 SERVICE DATA AND SPECIFICATIONS (SDS) .......159
CYLINDER HEAD BOLT DEFORMATION CHECK ...130 General Specifications.............................................159
CYLINDER HEAD-TO-BLOCK DIFFERENCE Compression Pressure ............................................159
CHECK .................................................................130 Belt Deflection..........................................................159
LIQUID GASKET APPLICATION ON REAR CHAIN Cylinder Head ..........................................................159
CASE ....................................................................130
Valve ........................................................................160
CYLINDER HEAD INSTALLATION ..........................131
VALVE ..................................................................160
GLOW PLUG INSTALLATION .................................131
VALVE CLEARANCE..............................................160
CAMSHAFT INSTALLATION ...................................131
AVAILABLE SHIMS ................................................160
Valve Clearance.......................................................132 VALVE SPRING .....................................................161
CHECKING ...........................................................132 VALVE LIFTER ......................................................162
ADJUSTING ..........................................................133 VALVE GUIDE .......................................................162
ENGINE ASSEMBLY...................................................136 Valve Seat................................................................163
Removal and Installation .........................................136 Camshaft and Camshaft Bearing ............................165
REMOVAL .............................................................137
Cylinder Block..........................................................166
INSTALLATION......................................................138
Piston, Piston Ring and Piston Pin .........................167
CYLINDER BLOCK .....................................................139
AVAILABLE PISTON ..............................................167
Components.............................................................139 PISTON RING .......................................................167
Removal and Installation .........................................140 PISTON PIN ..........................................................167
Disassembly.............................................................140 Connecting Rod .......................................................168
PISTON AND CRANKSHAFT ..................................140 Crankshaft................................................................168
Inspection.................................................................143 Available Main Bearing............................................169
CRANKSHAFT END PLAY .....................................143 UNDERSIZE ..........................................................169
CONNECTING ROD SIDE CLEARANCE .................143
Available Connecting Rod Bearing..........................169
PISTON AND PISTON PIN CLEARANCE ................144
CONNECTING ROD BEARING ...............................169
PISTON RING SIDE CLEARANCE ..........................144
UNDERSIZE ..........................................................169
PISTON RING END GAP........................................145
Miscellaneous Components.....................................169
CONNECTING ROD BEND AND TORSION .............145
BEARING CLEARANCE .........................................170
CYLINDER BLOCK DISTORTION AND WEAR .........145
EM-3
PRECAUTIONS QG
Parts Requiring Angular Tightening
Parts Requiring Angular Tightening NJEM0001
+ Use an angle wrench for the final tightening of the following
engine parts:
a) Cylinder head bolts
b) Main bearing cap bolts
c) Connecting rod cap nuts
+ Do not use a torque value for final tightening.
+ The torque value for these parts are for a preliminary step.
+ Ensure thread and seat surfaces are clean and coated with
engine oil.
Liquid Gasket Application Procedure NJEM0002
1. Use a scraper to remove old liquid gasket from mating
surfaces and grooves. Also, completely clean any oil from
these areas.
2. Apply a continuous bead of liquid gasket to mating sur-
faces. (Use Genuine Liquid Gasket or equivalent.)
+ For oil pan, be sure liquid gasket diameter is 3.5 to 4.5 mm
(0.138 to 0.177 in).
+ For areas except oil pan, be sure liquid gasket diameter is
2.0 to 3.0 mm (0.079 to 0.118 in).
SEM164F 3. Apply liquid gasket around the inner side of bolt holes
(unless otherwise specified).
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and
engine coolant.
AEM080
EM-4
PREPARATION QG
Special Service Tools
Special Service Tools NJEM0003
Tool number
Description
Tool name
ST0501S000 Disassembling and assembling
Engine stand assembly
(1) ST05011000
Engine stand
(2) ST05012000
Base
NT042
Engine attachment Overhauling engine
assembly
(1) KV10106500
Engine attachment
(2) KV10113300
Sub-attachment
NT029
ST10120000 Loosening and tightening cylinder head bolt
Cylinder head bolt a: 13 mm (0.51 in) dia.
wrench b: 12 mm (0.47 in)
c: 10 mm (0.39 in)
NT583
KV10116200 Disassembling valve mechanism
Valve spring compressor
(1) KV10115900
Attachment
NT022
KV10115600 Installing valve oil seal
Valve oil seal drift
NT024
KV10107902 Displacement valve lip seal
Valve oil seal puller
NT011
EM-5
PREPARATION QG
Special Service Tools (Cont'd)
Tool number
Description
Tool name
KV101151S0 Changing shims
Lifter stopper set
(1) KV10115110
Camshaft pliers
(2) KV10115120
Lifter stopper
NT041
EM03470000 Installing piston assembly into cylinder bore
Piston ring compressor
NT044
KV10107400 Disassembling and assembling piston pin
Piston pin press stand
(1) KV10107310
Center shaft
(2) ST13040020
Stand
(3) ST13040030
Spring
(4) KV10107320
Cap
(5) ST13040050
Drift
NT013
KV10111100 Removing oil pan
Seal cutter
NT046
WS39930000 Pressing the tube of liquid gasket
Tube presser
NT052
KV10112100 Tightening bolts for bearing cap, cylinder head,
Angle wrench etc.
NT014
ST16610001 Removing pilot bushing
Pilot bushing puller
NT045
EM-6
PREPARATION QG
Special Service Tools (Cont'd)
Tool number
Description
Tool name
Front (heated) oxygen Loosening or tightening heated oxygen sensor
sensor wrench with 22 mm (0.87 in) hexagon nut
NT379
KV101056S0* Preventing crankshaft from rotating
Rear gear stopper
(1) KV10105620
Adapter
(2) KV10105610
Plate assembly
NT773
Commercial Service Tools NJEM0004
Tool name Description
Spark plug wrench Removing and installing spark plug
NT047
Valve seat cutter set Finishing valve seat dimensions
NT048
Piston ring expander Removing and installing piston ring
NT030
Valve guide drift Removing and installing valve guide
Intake & Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.
NT015
EM-7
PREPARATION QG
Commercial Service Tools (Cont'd)
Tool name Description
Valve guide reamer Reaming valve guide 1 or hole for oversize valve
guide 2
Intake & Exhaust:
d1: 5.5 mm (0.217 in) dia.
d2: 9.685 mm (0.3813 in) dia.
NT016
Front oil seal drift Installing front oil seal
a: 52 mm (2.05 in) dia.
b: 40 mm (1.57 in) dia.
NT049
Rear oil seal drift Installing rear oil seal
a: 103 mm (4.06 in) dia.
b: 84 mm (3.31 in) dia.
NT049
Oxygen sensor thread Reconditioning the exhaust system threads before
cleaner installing a new oxygen sensor. Use with anti-
seize lubricant shown below.
a: 18 mm dia. with a pitch of 1.5 mm for Zirco-
nia Oxygen Sensor
b: 12 mm dia. with a pitch of 1.25 mm for Tita-
nia Oxygen Sensor
NT778
Anti-seize lubricant (Per- Lubricating oxygen sensor thread cleaning tool
matexTM 133AR or when reconditioning exhaust system threads
equivalent meeting MIL
specification MIL-A-907)
NT779
EM-8
NJEM0005
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING QG
NVH Troubleshooting -- Engine Noise
NVH Troubleshooting -- Engine Noise NJEM0005S01
Use the chart below to help you find the cause of the symptom.
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
Operating condition of engine
Location of Type of Before After When Source of Reference
When When While Check item
noise noise warm- warm- start- noise page
idling racing driving
up up ing
Top of Ticking or C A -- A B -- Tappet + Valve clearance EM-42
Engine click noise
Rocket
Cover Cyl- Rattle C A -- A B C Camshaft + Camshaft journal EM-37
inder Head bearing clearance
noise + Camshaft runout
Crankshaft Slap or -- A -- B B -- Piston pin + Piston and piston pin EM-54, 59
Pulley knock noise clearance
Cylinder + Connecting rod bush-
block (Side ing clearance
of Engine)
Oil pan Slap or A -- -- B B A Piston slap + Piston-to-bore clear- EM-54, 55,
rap noise ance 56
+ Piston ring side clear-
ance
+ Piston ring end gap
+ Connecting rod bend
and torsion
Knock A B C B B B Connecting + Connecting rod bear- EM-58, 59
rod-bearing ing clearance (Big
noise end)
+ Connecting rod bush-
ing clearance (Small
end)
Knock A B -- A B C Main bear- + Main bearing oil clear- EM-57
ing noise ance
+ Crankshaft runout
Front of Tapping or A A -- B B B Timing + Timing chain cracks EM-26
Engine Tim- ticking chain and and wear
ing Chain chain ten- + Timing chain tensioner
Cover sioner noise operation
Front of Squeak or A B -- B -- C Other drive + Drive belts deflection EM-15
Engine fizzing belts (stick-
ing or slip-
ping)
Creaking A B A B A B Other drive + Idler pulley bearing
belts (slip- operation
ping)
Squall or A B -- B A B Water pump + Water pump operation LC-14
creak noise
A: Closely related B: Related C: Sometimes related --: Not related
EM-9
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING QG
NVH Troubleshooting -- Engine Noise (Cont'd)
SEM937F
EM-10
OUTER COMPONENT PARTS QG
Removal and Installation
Removal and Installation NJEM0006
YEM008
1. Oil pressure switch 6. Intake manifold upper support 11. Water pump pulley
2. EGR valve 7. Intake manifold rear supports 12. EGR solenoid valve
3. EGR tube 8. Oil filter 13. EGR guide tube
4. Air relief plug 9. Thermostat 14. EGR gas temperature sensor
5. Intake manifold 10. Water pump
EM-11
OUTER COMPONENT PARTS QG
Removal and Installation (Cont'd)
YEM020
1. Throttle position sensor 4. Injector 7. Intake manifold
2. IACV-AAC valve 5. Injector tube 8. Canister purge control valve
3. Throttle body 6. Pressure regulator 9. Throttle opener
EM-12
OUTER COMPONENT PARTS QG
Removal and Installation (Cont'd)
YEM021
1. Crankshaft pulley 5. Exhaust manifold cover 10. Converter cap
2. Engine coolant temperature sen- 6. Thermal transmitter 11. Converter cover
sor 7. Water drain plug 12. Ignition coil
3. Gasket 8. Heated oxygen sensor 1 (front) 13. Spark plug
4. Exhaust manifold 9. Three way catalyst
EM-13
NJEM0007
MEASUREMENT OF COMPRESSION PRESSURE QG
1. Warm up engine.
2. Turn ignition switch OFF.
3. Release fuel pressure.
Refer to EC-38, "Releasing Fuel Pressure".
4. Remove ignition coils.
5. Remove spark plugs.
+ Clean area around plug with compressed air before removing
the spark plug.
6. Attach a compression tester to No. 1 cylinder.
7. Depress accelerator pedal fully to keep throttle valve wide
open.
8. Crank engine and record highest gauge indication.
9. Repeat the measurement on each cylinder as shown above.
+ Always use a fully-charged battery to obtain specified
engine speed.
Compression pressure: kPa (bar, kg/cm2, psi)/rpm
QG18DE
Standard
SEM973E
1,324 (13.24, 13.5, 192)/350
Minimum
1,128 (11.28, 11.5, 164)/350
Maximum allowable difference between cylinders
98 (0.98, 1.0, 14)/350
QG15DE
Standard
1,372 (13.720, 13.99, 198.9)/350
Minimum
1,176 (11.759, 11.99, 170.5)/350
AEM308 Maximum allowable difference between cylinders
98 (0.98, 1.0, 14)/350
10. If cylinder compression in one or more cylinders is low, pour a
small amount of engine oil into the cylinder through the spark
plug hole and retest compression.
+ If adding oil improves cylinder compression, piston rings
may be worn or damaged. If so, replace piston rings after
checking piston.
+ If pressure stays low, a valve may be sticking or seating
improperly. Inspect and repair valve and valve seat. Refer
to SDS, EM-70. If valve or valve seat is damaged
excessively, replace them.
+ If compression in any two adjacent cylinders is low and if add-
ing oil does not improve compression, there is leakage past the
gasket surface. If so, replace cylinder head gasket.
11. Reinstall spark plugs, ignition coils and fuel pump fuse.
12. Perform "Self-diagnosis Procedure" referring to EC-68, "How
to Erase DTC" if any DTC appears.
EM-14
DRIVE BELTS QG
Checking
Checking NJEM0042
SEM100G
1. Inspect for cracks, fraying, wear or oil adhesion. If necessary,
replace with a new one.
+ When replacing belt, make sure the new belt has the same
number of ribs as the old one.
2. Inspect drive belt deflections by pushing on the belt midway
between pulleys.
3. Turn crankshaft two revolutions and recheck drive belt deflec-
tion.
+ Inspect drive belt deflection when engine is cold.
+ Adjust if belt deflections exceed the limit.
EM-15
DRIVE BELTS QG
Checking (Cont'd)
Belt deflection:
Unit: mm (in)
Used belt deflection
Applied engine Deflection Deflection
Limit after of new belt
adjustment
With air 5.3 - 5.7 4.5 - 5.0
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