1995 NISSAN ALMERA N15 Service Manual

ENGINEREMOVAL
mJ

Removal (Cont'd)

• Disconnect controlrodand support rodfrom transaxle.
(M/T

models)
Control rod:

to:J:
14-18 N.m (1.4-1.8 kg-m, 10-13 ft-Ib)
Support rod:

to:J:
35-47 N.m (3.6-4.8 kg-m, 26-35 ft-Ib)

• Disconnect controlcablefromtransaxle.
(A/Tmodels)

• Center member
• Front exhaust tube
• Stabilizer
• Cooling fan
• Radiator
• Cylinder headfrontmounting bracket
• Remove airduct anddisconnect wires,harness, pipes,
hoses andsoon.
8. Lift upengine slightly anddisconnect orremove allengine
mountings.

When liftingengine, becareful nottohit itagainst adjacent
parts, especially againstbraketubesandbrake master cylin-
der.

9. Remove enginewithtransaxle asshown.

Installation
When installing theengine, adjusttheheight ofbuffer rodas
shown. (ForM/T)

• Installation isthe reverse orderofremoval.

EM-46

CYLINDERBLOCK

SEC. 110.120

ij]
6.3•8.3
(0.641 •0.851, 55.6-73.9)

I]
to;J
83.5 •93.3
(8.51 -9.51,
61.6 •68.8)

f]
to.J
93.3 •103.1 (9.51-10.51, 68.8-76.0)

to;J :
N.
m
(kg-m, ft-Ib)
~ :N.m (kg-m, in-Ib)
~ :Apply liquidgasket.

f] :
Lubricate withnew engine oil.

SEM238F
•

CD
Oillevel gauge guide

@
Cylinder block

@
Rear oilseal retainer

@
Rear oilseal

@
Rear plate

@
Flywheel

(J)
Rear lower plate

@
Drive plate
*: Applies toGA 16DE without VTC,14DE.
@

Drain plug

@)
Buffer plate

@
Topring

@
2ndring (Only Europe models*)

@
Oilring

@
Piston

@
Snap ring

@
Piston pin

EM-47
@

Connecting rod

@
Connecting rodbearing

@)
Connecting rodcap

@l
Key

@
Main bearing

@
Thrust bearing

@
Crankshaft

@
Main bearing cap

CYLINDERBLOCK
CAUTION:
• When installing slidingparts(bearings, pistons,etc.),lubri-
cate contacting surfaceswithnewengine oil.
• Place removed partssuchasbearings andbearing capsin
their proper orderanddirection.
• When installing connecting rodnuts, andmain bearing cap
bolts, apply newengine oiltothreads andseating surfaces.
Disassembly
PISTON ANDCRANKSHAFT

1. Place engine onawork stand.
2. Drain coolant andoil.
3. Remove timingchain.
Refer to"Removal" in"TIMING CHAIN"(EM-20).
4 Remove pistonswithconnecting rods.
• When disassembling pistonandconnecting rod,remove
snap ringfirst, thenheat piston to60 to70°C (140to158°F)
or use piston pinpress stand atroom temperature.
5. Loosen mainbearing capinnumerical orderasshown in
the figure.
6. Remove bearingcaps,mainbearings andcrankshaft.

• Before removing bearingcaps,measure crankshaft end
play.
• Bolts should beloosened intwo orthree steps.
AEM023 Inspection
PISTON ANDPISTON PINCLEARANCE

1. Measure innerdiameter ofpiston pinhole "dp".

Standard diameter
"dp":

18.987 -18.999
mm
(0.7475 -0.7480
in)

EM-48

I

Micrometer
AEM024CYLINDER
BLOCK ~

Inspection (Conl'd)

2. Measure outerdiameter ofpiston pin"Op".
Standard diameter "Op":
18.989 -19.001 mm(0.7476 -0.7481 in)
3. Calculate pistonpinclearance.
dp -Op
=
-0.004 to0mm (-0.0002 to0in)
If itexceeds theabove value, replace pistonassembly with

pin.

•

NG
Ring
Measuring point Feeler
gauge
SEM8228 PISTON
RINGSIDECLEARANCE

Side clearance:
Top ring
0.040 -0.080 mm(0.0016 -0.0031 in)
2nd ring (Only Europe models)
0.030 -0.070 mm(0.0012 -0.0028 in)
Max. limitofside clearance:
0.2 mm (0.008 in)
If out ofspecification, replacepistonand/or pistonringassem-
bly.

PISTON RINGENDGAP

End gap:
Top ring
0.20 -0.35 mm(0.0079 -0.0138 in)
2nd ring (Only Europe models)
0.37 -0.52 mm(0.0146 -0.0205 in)
Oil ring
0.20 -0.60 mm(0.0079 -0.0236 in)
Max. limitofring gap:
1.0 mm (0.039 in)
If out ofspecification, replacepistonring.Ifgap exceeds max-
imum limitwithnewring, rebore cylinder anduseoversize
piston andpiston rings.
Refer toSOS (EM-161).
• When replacing thepiston, checkthecylinder blocksurface
for scratches orseizure. Ifscratches orseizure isfound,
hone orreplace thecylinder block.

CONNECTING RODBEND ANDTORSION

Bend: Limit 0.15mm(0.0059 in)
per 100 mm (3.94 in)length
Torsion: Limit 0.3mm (0.012 in)
per 100 mm (3.94 in)length
If itexceeds thelimit, replace connecting rodassembly.

EM-49

SEM003FCYLINDER
BLOCK
Inspection (Cont'd)
Feeler gauge Straightedge
SEM102F

I
I

,

,

!

,

A

X-V
B
Unit:
mm
(In)

SEM166DA CYLINDER
BLOCKDISTORTION ANDWEAR

1. Clean upperfaceofcylinder blockandmeasure thedistor-
tion.
Limit: 0.10 mm(0.0039 in)

2. Ifout ofspecification, resurface
it.

The resurfacing limitisdetermined bycylinder headresur-
facing inengine.

Amount ofcylinder headresurfacing is
"A".

Amount ofcylinder blockresurfacing is
"B".

The maximum limitisas follows:

A
+
B
= 0.2 mm (0.008 in)
Nominal cylinderblockheight
from crankshaft center:
213.95 -214.05 mm(8.4232 .8.4271 in)

3. Ifnecessary, replacecylinder block.

PISTON- TO-BORE CLEARANCE

1. Using abore gauge, measure cylinderboreforwear, out-
of-round andtaper.

Standard innerdiameter:
GA16DE 76.000-76.030 mm(2.9921 -2.9933 in)
GA14, 15DE73.600 -73.630 mm(2.8976 -2.8988 in)
Wear limit:
0.2 mm (0.008 in)

If itexceeds thelimit, rebore allcylinders. Replacecylinder
block ifnecessary.

Out-of-round (X-Y) standard:
0.015 mm(0.0006 in)
Taper (A-B) standard:
0.01 mm(0.0004 in)
EM-50

Cylinderbore
grade number
No. 4
Cylinder block
SEM426C CYLINDER
BLOCK
[]K]

Inspection (Cont'd)

2. Check forscratches andseizure. Ifseizure isfound, hone
it.
• Ifcylinder blockorpiston isreplaced, matchpiston grade
with grade number oncylinder blocklower surface.
3. Measure pistonskirtdiameter.
Piston diameter "A":
Refer toSDS (EM-161).
Measuring point"a"(Distance fromthebottom):
Refer toSDS (EM-161).
4. Check thatpiston-to-bore clearanceiswithin specification.
Piston-to-bore clearance"B":
0.015 -0.035 mm(0.0006 -0.0014 in)
5. Determine pistonoversize according toamount ofcylinder
wear.
Oversize pistonsareavailable forservice. RefertoSDS (EM-
161).
6. Cylinder boresizeisdetermined byadding piston-to-bore
clearance topiston diameter "A".
Rebored sizecalculation:
D=A+B-C
where,

0:
Bored diameter
A: Piston diameter asmeasured
B: Piston-to-bore clearance
C: Honing allowance 0.02mm(0.0008 in)
7. Install mainbearing capsandtighten boltstothe specified
torque. Thiswillprevent distortion ofcylinder bores.
8. Cut cylinder bores.
• When anycylinder needsboring, allother cylinders must
also bebored.
• Donot cuttoo much outofcylinder boreatatime. Cutonly
0.05 mm(0.0020 in)orso indiameter atatime.
9. Hone cylinders toobtain specified piston-to-bore clearance.
10. Measure finishedcylinder boreforout-of-round andtaper.
• Measurement shouldbedone aftercylinder borecools
down.

EM-51
•

AB

Taper:A-B
Out-at-round: X-
y

Oil groove
y

SEM316A
SEM366E CYLINDER
BLOCK ~
Inspection (Cont'd)
CRANKSHAFT
1. Check crankshaft mainandpinjournals forscore, wearor
cracks.
2. With amicrometer, measurejournalsfortaper andout-of-
round.
Out-of-round (X-V):
Less than0.005 mm(O.0002 in)
Taper (A-B):
Less than0.002 mm(O.0001 in)

3. Measure crankshaft runout.

Runout (Totalindicator reading):
Less than0.05mm(O.0020 in)
BEARING CLEARANCE

• Use Method Aor Method B.Method Ais preferred because
it is more accurate.

Method A(Using boregauge µmeter)
Main bearing

1. Set main bearings intheir proper positions oncylinder
block andmain bearing cap.
2. Install mainbearing captocylinder block.

Tighten allbolts incorrect orderintwo orthree stages.

3. Measure innerdiameter "A"ofeach main bearing.
4. Measure outerdiameter "Om"ofeach mainjournal in
crankshaft.
5. Calculate mainbearing clearance.

Main bearing clearance
=
A-
Om
Standard:
0.018 .0.042 mm(O.0007 .0.0017 in)
Limit: 0.1mm (O.004 in)

6. Ifitexceeds thelimit, replace bearing.
7. Ifclearance cannotbeadjusted withinthestandard ofany
bearing, grindcrankshaft journalanduseundersized bear-
ing.

EM-52

Mainjournal andpinjournal

R

SEM588ACYLINDER
BLOCK
[ill

Inspection (Conl'd)
When grinding crankpinand crank journal:
a. Grind untilclearance iswithin specified standardbearing
clearance.
b. Fillets should befinished asshown inthe figure.
R: 2.3 -2.5 mm (0.091 -0.098 in)

•

~ Front

No.5

Main journal
grade number
Cylinder
block
SEM427C
8.
Ifcrankshaft, cylinderblockormain bearing isreused
again, measure mainbearing clearance. Ifthe above parts
are allreplaced, selectthickness ofmain bearings asfol-
lows:

a. Grade number ofeach cylinder blockmainjournal is
punched onthe respective cylinderblock.These numbers
are punched ineither Arabic orRoman numerals.
b. Grade number ofeach crankshaft mainjournal ispunched
on the respective crankshaft. Thesenumbers arepunched
in either Arabic orRoman numerals.
c. Select mainbearing withsuitable thickness according tothe
following table.
Main bearing gradecolor:

Main journal
grade number

0
1

2

Crankshaft
journal gradenumber

0
Black
Brown Green

1
BrownGreenYellow

2
GreenYellow Blue

Crank
journal
grade number
SEM436C

\i1hOle
o,.",,!f0

Front ~~

Q
I\}:J

Identification color~
SEM194C
For
example:
Main journal gradenumber: 1
Crankshaft journalgradenumber: 2
Main bearing gradenumber
=
1
+
2 Yellow

)=====
.-:::::::======_ ..

;::..----

AEM027Connecting
rodbearing (Bigend)

1. Install connecting rodbearing toconnecting rodand cap.
2. Install connecting rodcap toconnecting rod.

Tighten boltstothe specified torque.

3. Measure innerdiameter "C"ofeach bearing.

EM-53