Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Almera 2000-2003.2006 Approved Nissan Almera 2003 Tino em
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ENGINE MECHANICAL
B ENGINE
A
SECTION
ENGINE MECHANICAL
EM EM
C
D
E
CONTENTS
QG EXHAUST MANIFOLD AND CATALYTIC CON- F
VERTER ................................................................... 21
.
PRECAUTIONS ......................................................... 5 . Removal and Installation ....................................... 21 .
Precautions for Drain Coolant ................................. 5 . REMOVAL .......................................................... 22
. G
Precautions for Disconnecting Fuel Piping ............. 5 . INSPECTION AFTER REMOVAL ...................... 23 .
Precautions for Removal and Disassembly ............ 5 . INSTALLATION .................................................. 23 .
Precautions for Inspection, Repair and Replace- Disassembly and Assembly ................................... 24 .
ment ........................................................................ 5
. H
M/T MODELS ..................................................... 24.
Precautions for Assembly and Installation .............. 5 . A/T MODELS ...................................................... 24
.
Parts Requiring Angular Tightening ........................ 5 . DISASSEMBLY .................................................. 24 .
Precautions for Liquid Gasket ................................. 6 . ASSEMBLY ........................................................ 24
. I
REMOVAL OF LIQUID GASKET SEALING ......... 6 . OIL PAN AND OIL STRAINER ................................ 25 .
LIQUID GASKET APPLICATION PROCEDURE 6 ..... Removal and Installation ....................................... 25 .
PREPARATION .......................................................... 7 . REMOVAL .......................................................... 25
. J
Special Service Tools .............................................. 7 . INSTALLATION .................................................. 26 .
Commercial Service Tools ....................................... 9 . INSPECTION AFTER INSTALLATION ............... 26 .
NOISE, VIBRATION AND HARSHNESS (NVH) IGNITION COIL ........................................................ 27
.
TROUBLESHOOTING ..............................................11 . K
Removal and Installation ....................................... 27 .
NVH Troubleshooting --Engine Noise ...................11 . REMOVAL .......................................................... 27
.
Use the Chart Below to Help You Find the Cause INSTALLATION .................................................. 27 .
of the Symptom. .................................................... 12 . SPARK PLUG (CONVENTIONAL) .......................... 28 . L
DRIVE BELTS .......................................................... 13 . Removal and Installation ....................................... 28 .
Checking Drive Belts ............................................. 13 . REMOVAL .......................................................... 28
.
Tension Adjustment ............................................... 14 . INSPECTION AFTER REMOVAL ...................... 28 . M
POWER STEERING PUMP AND WATER PUMP INSTALLATION .................................................. 28 .
BELT .................................................................. 14
. FUEL INJECTOR AND FUEL TUBE ....................... 29 .
ALTERNATOR AND AIR CONDITIONER COM- Removal and Installation ....................................... 29 .
PRESSOR BELT ................................................ 14 . REMOVAL .......................................................... 29
.
Removal and Installation ....................................... 15 . INSTALLATION .................................................. 30 .
REMOVAL .......................................................... 15 . INSPECTION AFTER INSTALLATION ............... 31 .
INSTALLATION .................................................. 15 . ROCKER COVER .................................................... 32 .
AIR CLEANER AND AIR DUCT .............................. 16 . Removal and Installation ....................................... 32 .
Removal and Installation ....................................... 16 . REMOVAL .......................................................... 32
.
REMOVAL .......................................................... 16 . INSTALLATION .................................................. 33 .
INSTALLATION .................................................. 16 . CAMSHAFT ............................................................. 35
.
Changing Air Cleaner Element .............................. 17 . Removal and Installation ....................................... 35 .
INTAKE MANIFOLD ................................................ 18 . REMOVAL .......................................................... 35
.
Removal and Installation ....................................... 18 . INSTALLATION .................................................. 38 .
REMOVAL .......................................................... 18 .
INSPECTION AFTER REMOVAL ...................... 20 .
INSTALLATION .................................................. 20 .
EM-1
INSPECTION AFTER REMOVAL ....................... 42 . HOW TO SELECT MAIN BEARING ...................86 .
Valve Clearance ..................................................... 45. Inspection After Disassembly .................................87 .
INSPECTION ...................................................... 45 . CRANKSHAFT SIDE CLEARANCE ...................87 .
ADJUSTMENT (SHIMLESS TYPE) ................... 46 . CONNECTING ROD SIDE CLEARANCE ..........88 .
ADJUSTMENT (SHIM TYPE) ............................. 47 . PISTON AND PISTON PIN CLEARANCE ..........88 .
TIMING CHAIN ......................................................... 50 . PISTON RING SIDE CLEARANCE ....................89 .
Removal and Installation ....................................... 50 . PISTON RING END GAP ...................................89 .
REMOVAL .......................................................... 50 . CONNECTING ROD BEND AND TORSION ......90 .
INSPECTION AFTER REMOVAL ....................... 54 . CONNECTING ROD BEARING (BIG END) .......90 .
INSTALLATION ................................................... 54 . CONNECTING ROD BUSHING OIL CLEAR-
INSPECTION AFTER INSTALLATION ............... 56 . ANCE (SMALL END) ..........................................90 .
OIL SEAL ................................................................. 57
. CYLINDER BLOCK DISTORTION .....................91 .
Removal and Installation of Valve Oil Seal ............ 57 . INNER DIAMETER OF MAIN BEARING HOUS-
REMOVAL .......................................................... 57 . ING ......................................................................92
.
INSTALLATION ................................................... 57 . PISTON TO CYLINDER BORE CLEARANCE ...92
Removal and Installation of Front Oil Seal ............ 58 . OUTER DIAMETER OF CRANKSHAFT JOUR-
REMOVAL .......................................................... 58 . NAL .....................................................................93
.
INSTALLATION ................................................... 58 . OUTER DIAMETER OF CRANKSHAFT PIN .....93 .
Removal and Installation of Rear Oil Seal ............. 58 . OUT-OF-ROUND AND TAPER OF CRANK-
REMOVAL .......................................................... 58 . SHAFT ................................................................93
.
INSTALLATION ................................................... 58 . CRANKSHAFT RUNOUT ...................................94 .
CYLINDER HEAD .................................................... 60 . OIL CLEARANCE OF CONNECTING ROD
On-Vehicle Service ................................................ 60 . BEARING ............................................................94 .
CHECKING COMPRESSION PRESSURE ........ 60 . OIL CLEARANCE OF MAIN BEARING ..............94 .
Removal and Installation ....................................... 61 . CRUSH HEIGHT OF MAIN BEARING ...............95 .
REMOVAL .......................................................... 61 . FLYWHEEL RUNOUT ........................................95 .
INSTALLATION ................................................... 62 . SERVICE DATA AND SPECIFICATIONS (SDS) .....96 .
Disassembly and Assembly ................................... 63 . Standard and Limit .................................................96 .
DISASSEMBLY .................................................. 63 . GENERAL SPECIFICATIONS ............................96 .
ASSEMBLY ........................................................ 64 . INTAKE MANIFOLD AND EXHAUST MANI-
Inspection After Disassembly ................................ 65 . FOLD ..................................................................96
.
CYLINDER HEAD DISTORTION ....................... 65 . DRIVE BELTS .....................................................96 .
VALVE DIMENSIONS ......................................... 65 . SPARK PLUG .....................................................97 .
VALVE GUIDE CLEARANCE ............................. 66 . CYLINDER HEAD ...............................................97 .
VALVE GUIDE REPLACEMENT ........................ 66 . VALVE .................................................................97
.
VALVE SEAT CONTACT .................................... 67 . CAMSHAFT AND CAMSHAFT BEARING ........ 103 .
VALVE SEAT REPLACEMENT .......................... 68 . CYLINDER BLOCK ........................................... 104 .
VALVE SPRING SQUARENESS ........................ 69 . PISTON, PISTON RING AND PISTON PIN ..... 104 .
VALVE SPRING DIMENSIONS AND VALVE CONNECTING ROD ......................................... 105 .
SPRING PRESSURE LOAD .............................. 69 . CRANKSHAFT .................................................. 105 .
ENGINE ASSEMBLY ............................................... 70 . MAIN BEARING ................................................ 106 .
Removal and Installation ....................................... 70 . CONNECTING ROD BEARING ........................ 106 .
REMOVAL .......................................................... 71 . MISCELLANEOUS COMPONENTS ................. 107 .
INSTALLATION ................................................... 72 . Tightening Torque ................................................ 107 .
INSPECTION AFTER INSTALLATION ............... 72 .
CYLINDER BLOCK .................................................. 74 . YD
Disassembly and Assembly ................................... 74 .
DISASSEMBLY .................................................. 75 . PRECAUTIONS ...................................................... 109 .
ASSEMBLY ........................................................ 79 . Precautions for Drain Coolant .............................. 109 .
How to Select Piston and Bearing ......................... 84 . Precautions for Disconnecting Fuel Piping .......... 109 .
DESCRIPTION ................................................... 84 . Precautions for Removal and Disassembly ......... 109 .
HOW TO SELECT PISTON ................................ 84 . Precautions for Inspection, Repair and Replace-
HOW TO SELECT CONNECTING ROD BEAR- ment ..................................................................... 109
.
ING ..................................................................... 85
. Precautions for Assembly and Installation ........... 109 .
Parts Requiring Angular Tightening ..................... 109 .
Precautions for Liquid Gasket .............................. 110 .
REMOVAL OF LIQUID GASKET SEALING ..... 110 .
LIQUID GASKET APPLICATION PROCEDURE. 110
EM-2
PREPARATION ....................................................... 111. GLOW PLUG ......................................................... 142
.
Special Service Tools ........................................... 111. Removal and Installation ..................................... 142. A
Commercial Service Tools ....................................114 . REMOVAL ........................................................ 142
.
NOISE, VIBRATION AND HARSHNESS (NVH) INSTALLATION ................................................ 142
.
TROUBLESHOOTING ............................................115 . VACUUM PUMP ..................................................... 143
. EM
NVH Troubleshooting --Engine Noise .................115 . Removal and Installation ..................................... 143.
Use the Chart Below to Help You Find the Cause INSPECTION BEFORE REMOVAL ................. 143 .
of the Symptom. ...................................................116
. REMOVAL ........................................................ 143
.
DRIVE BELTS .........................................................117
. INSTALLATION ................................................ 144
. C
Checking Drive Belts ............................................117 . INSPECTION AFTER INSTALLATION ............. 144 .
Tension Adjustment ..............................................117 . Disassembly and Assembly ................................. 145 .
AIR CONDITIONER COMPRESSOR BELT .....118 . DISASSEMBLY ................................................ 145. D
ALTERNATOR AND WATER PUMP BELT .......118 . ASSEMBLY ...................................................... 145
.
Removal and Installation ......................................118 . INJECTION TUBE AND FUEL INJECTOR ........... 147 .
REMOVAL .........................................................118
. Removal and Installation ..................................... 147. E
INSTALLATION .................................................118 . REMOVAL ........................................................ 147
.
AIR CLEANER AND AIR DUCT .............................119 . INSTALLATION ................................................ 148
.
Removal and Installation ......................................119 . INSPECTION AFTER INSTALLATION ............. 149 .
REMOVAL .........................................................119
. FUEL PUMP ........................................................... 150
. F
INSTALLATION .................................................119 . Removal and Installation ..................................... 150.
CHANGING AIR CLEANER ELEMENT ............119 . REMOVAL ........................................................ 150
.
CHARGE AIR COOLER ........................................ 121 . INSPECTION AFTER REMOVAL .................... 155 . G
Removal and Installation ..................................... 121 . INSTALLATION ................................................ 155
.
REMOVAL ........................................................ 121
. ROCKER COVER .................................................. 160 .
INSPECTION AFTER REMOVAL .................... 122 . Removal and Installation ..................................... 160. H
INSTALLATION ................................................ 122 . REMOVAL ........................................................ 160
.
INTAKE MANIFOLD .............................................. 123 . INSTALLATION ................................................ 161
.
Removal and Installation ..................................... 123 . INSPECTION AFTER INSTALLATION ............. 161 .
I
REMOVAL ........................................................ 123
. CAMSHAFT ........................................................... 162
.
INSPECTION AFTER REMOVAL .................... 124 . Removal and Installation ..................................... 162.
INSTALLATION ................................................ 124 . REMOVAL ........................................................ 162
.
INSPECTION AFTER INSTALLATION ............ 125 . INSPECTION AFTER REMOVAL .................... 163 . J
CATALYST ............................................................. 126
. INSTALLATION ................................................ 166
.
Removal and Installation ..................................... 126 . Valve Clearance .................................................. 167
.
REMOVAL ........................................................ 127
. INSPECTION ................................................... 167
. K
INSTALLATION ................................................ 127 . ADJUSTMENTS ............................................... 168 .
EXHAUST MANIFOLD AND TURBOCHARGER . 128 SECONDARY TIMING CHAIN ............................... 171 .
Removal and Installation ..................................... 128 . Removal and Installation ..................................... 171. L
REMOVAL ........................................................ 129
. REMOVAL ........................................................ 171
.
INSTALLATION ................................................ 130 . INSPECTION AFTER REMOVAL .................... 173 .
INSPECTION AFTER INSTALLATION ............ 130 . INSTALLATION ................................................ 174
.
Disassembly and Assembly ................................ 131 . PRIMARY TIMING CHAIN ..................................... 176 . M
REMOVAL ........................................................ 132
. Removal and Installation ..................................... 176.
INSPECTION AFTER REMOVAL .................... 132 . REMOVAL ........................................................ 178
.
Turbocharger ....................................................... 133
. INSPECTION AFTER REMOVAL .................... 180 .
ROTOR SHAFT CLEARANCE ........................ 134 . INSTALLATION ................................................ 181
.
ROTOR SHAFT END PLAY ............................. 134 . CYLINDER HEAD .................................................. 186.
TURBINE WHEEL ............................................ 134 . On-Vehicle Service .............................................. 186
.
COMPRESSOR WHEEL ................................. 134 . CHECKING COMPRESSION PRESSURE ...... 186 .
TURBOCHARGER BOOST CONTROL ACTU- Removal and Installation ..................................... 187.
ATOR ............................................................... 135
. REMOVAL ........................................................ 187
.
TROUBLE DIAGNOSIS OF TURBOCHARGER 136 . INSPECTION AFTER REMOVAL .................... 188 .
OIL PAN AND OIL STRAINER .............................. 137 . INSTALLATION ................................................ 188
.
Removal and Installation ..................................... 137 . Disassembly and Assembly ................................. 191 .
REMOVAL ........................................................ 137
. DISASSEMBLY ................................................ 191.
INSPECTION AFTER REMOVAL .................... 139 . ASSEMBLY ...................................................... 192
.
INSTALLATION ................................................ 139 . INSPECTION AFTER DISASSEMBLY ............. 192 .
INSPECTION AFTER INSTALLATION ............ 141 .
EM-3
ENGINE ASSEMBLY ............................................. 197 . TION ................................................................. 217
.
Removal and Installation ..................................... 197 . MAIN BEARING HOUSING INNER DIAMETER.217
REMOVAL ........................................................ 198 . PISTON TO CYLINDER BORE CLEARANCE . 217
INSTALLATION ................................................. 200 . CRANKSHAFT JOURNAL OUTER DIAMETER.218
INSPECTION AFTER INSTALLATION ............. 200 . CRANKSHAFT PIN OUTER DIAMETER .........218 .
CYLINDER BLOCK ................................................ 201 . CRANKSHAFT OUT-OF-ROUND AND TAPER.219
Disassembly and Assembly ................................. 201 . CRANKSHAFT RUNOUT ................................. 219 .
DISASSEMBLY ................................................ 202 . CONNECTING ROD BEARING OIL CLEAR-
ASSEMBLY ...................................................... 206 . ANCE ................................................................ 219
.
How to Select Piston and Bearing ....................... 210 . MAIN BEARING OIL CLEARANCE .................. 220 .
DESCRIPTION ................................................. 210 . MAIN BEARING CRUSH HEIGHT ................... 220 .
HOW TO SELECT PISTON .............................. 210 . MAIN BEARING CAP BOLT DEFORMATION .. 220 .
HOW TO SELECT CONNECTING ROD BEAR- CONNECTING ROD BOLT DEFORMATION ... 221 .
ING ................................................................... 211
. OIL JET ............................................................. 221
.
HOW TO SELECT MAIN BEARING ................. 212 . OIL JET RELIEF VALVE ................................... 221 .
Inspection After Disassembly .............................. 213 . MOVEMENT AMOUNT OF FLYWHEEL .......... 221 .
CRANKSHAFT SIDE CLEARANCE ................. 213 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 223 .
CONNECTING ROD SIDE CLEARANCE ........ 214 . Standard and Limit ............................................... 223 .
PISTON TO PISTON PIN CLEARANCE .......... 214 . GENERAL SPECIFICATIONS .......................... 223 .
PISTON RING SIDE CLEARANCE .................. 214 . INTAKE MANIFOLD AND EXHAUST MANI-
PISTON RING END GAP ................................. 215 . FOLD ................................................................ 223
.
CONNECTING ROD BEND AND TORSION .... 215 . DRIVE BELTS ................................................... 223 .
CONNECTING ROD BIG END INNER DIAME- CYLINDER HEAD ............................................. 224 .
TER .................................................................. 216
. VALVE ............................................................... 224
.
CONNECTING ROD BUSHING OIL CLEAR- CAMSHAFT AND CAMSHAFT BEARING ........ 228 .
ANCE (SMALL END) ........................................ 216 . CYLINDER BLOCK ........................................... 228 .
CYLINDER BLOCK TOP SURFACE DISTOR- PISTON, PISTON RING AND PISTON PIN ..... 229 .
CONNECTNG ROD .......................................... 230 .
CRANKSHAFT .................................................. 230 .
AVAILABLE MAIN BEARING ............................ 231 .
AVAILABLE CONNECTING ROD BEARING .... 231 .
MISCELLANEOUS COMPONENTS ................. 231 .
Tightening Torque ................................................ 232 .
EM-4
PRECAUTIONS
[QG]
PRECAUTIONS
[QG] PFP:00001
A
Precautions for Drain Coolant EBS00QDT
q Drain coolant when engine is cooled.
EM
Precautions for Disconnecting Fuel Piping EBS00QDU
q Before starting work, make sure no fire or spark producing items are in the work area.
q Release fuel pressure before disassembly. C
q After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly EBS00QDV
D
q When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
q Exercise maximum care to avoid damage to mating or sliding surfaces. E
q Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
q Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
q When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally F
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precautions for Inspection, Repair and Replacement EBS00QDW
G
q Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way,
and replace if necessary.
Precautions for Assembly and Installation EBS00QDX H
q Use torque wrench to tighten bolts or nuts.
q When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci- I
fied, do exactly as specified.
q Replace with new gasket, packing, oil seal or O-ring.
q Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction J
and blockage.
q Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well. K
q Release air within route after draining coolant.
q After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems
for leakage. L
Parts Requiring Angular Tightening EBS00QDY
q Use an angle wrench for the final tightening of the following engine parts. M
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