1995 NISSAN ALMERA N15 Service Manual

Measuringpoints
Warpage ofsurface:
Less than0.1mm (0.004 in)

SEM655ACYLINDER
BLOCK

Inspection (Cont'd)

CYLINDER BLOCKDISTORTION

Clean upperfaceofcylinder blockandmeasure thedistortion.
Limit:
0.10
mm
(0.0039
in)
If out ofspecification, resurfaceit.
The resurfacing limitofcylinder blockisdetermined bycylin-
der head resurfacing inan engine.

SEM008D
Amount
ofcylinder headresurfacing is"A".
Amount ofcylinder blockresurfacing is"B".
The maximum limitisas follows:

A + B=0.1
mm
(0.004
in)
If necessary, replacecylinder block.

~ Moving thebore gauge
as shown, takethe

//p'
minimum reading.
CYLINDER
BORE

1. Check forscratches orseizure. Ifseizure isfound, hone
bore.
2. Using abore gauge, measure cylinderboreforwear, out-
of-round ortaper.
Standard borediameter:

84.500 -84.550
mm
(3.3268 -3.3287
in)

Unit:mm(in)

If itexceeds thelimit, rebore allfour cylinders. Replacecylin-
der block ifnecessary.
If cylinder blockorpiston isreplaced, matchpiston gradewith
grade number oncylinder blockupper surface.

y

Unit mm(in)

SEM704DA
Bore
wear limit
Out-aI-round (X-Y) standard
Taper (A-B) standard
0.2
(0.008)
0.015 (0.0006)
0.010 (0.0004)
EM-150

CYLINDERBLOCK

Inspection (Cont'd)

Front
0000

•

SEM1768

Reboring1. The size towhich cylinders mustbehoned, isdetermined
by adding piston-to-cylinder clearancetothe piston skirt
diameter" A".
Dimension "a":
Approximately 62mm (2.44 in)
Rebored sizecalculation

o
=
A
+
B-C
=
A
+
[0.03 to0.05 mm
(0.0012 to0.0020 in)]
where,

o

A B

C
Honed
diameter
Skirt diameter asmeasured
Piston-to-wall clearance
Machining allowance
0.02 mm(0.0008 in)
2. Install mainbearing capsandtighten boltstothe specified
torque. Thiswillprevent distortion ofcylinder bores.
3. Cut cylinder boresinthe order of2-4-1-3.
Do not cuttoo much outofthe cylinder boreatatime. Cutonly
0.05 mm(0.0020 in)orso indiameter atatime.
4. Hone thecylinders tothe required sizereferring toSOS

(EM-173).

5. Measure thefinished cylinder boreforout-of-round and
taper.
Measurement ofajust machined cylinderborerequires utmost
care since itis expanded bycutting heat.

62

mm

(2.44
in)

SEM904-A
PISTON-TO-BORE CLEARANCE

Using micrometer
1. Measure pistonandcylinder borediameter.
Piston diameter "A":
Refer toSDS (EM-174).
Measuring point"a"(Distance fromthebottom):
Approximately 62mm (2.44 in)
Bore diameter
"0":

Refer toSDS (EM-173).
Measuring point(Distance fromthetop):
Approximately 70mm (2.76 in)
2. Check thatpiston clearance iswithin thespecification.
Piston clearance
(0-
A):
0.025 -0.045 mm(0.0010 -0.0018 in)

EM-151

SEM550
SEM703D CYLINDER
BLOCK
@[]

Inspection (Cont'd)

Using feeler gauge
1. Set piston andfeeler gauge withspring scale.
2. Measure extracting forcewhile pulling upscale slowly.
Feeler gaugeused:
0.05 -0.07 mm(0.0020 -0.0028 in)
Extracting force:
7.8 -14.7 N(0.8 -1.5 kg, 1.8-3.3 Ib)

Assembly
PISTON

• Numbers stampedonconnecting rodand capcorrespond to
each cylinder. Careshould betaken toavoid awrong com-
bination including bearingandconnecting roddirection.

KV101070S0
EM156
•
Install newsnap ringonone side ofpiston pinhole.
• When assembling pistonandconnecting rodwith piston pin,
heat piston tobetween 60and 80°C (140and176°F) and
install piston pinwith asuitable tool.
• Install newsnap ring.
• After assembling, ascertainthatpiston swings smoothly.
• Install
piston
ringswithasuitable tool.
Selective topring; When installing newtopring orreplacing
cylinder block,selecttopring toadjust ringgap.
Punch
marksideup

~r~~

~ Tetl~ntubesetposition

~ ,0

Ql
0

SEM251D
Top
ring grade No. Cylinder
boregrade
1,2,3

No mark 4,
5

S

SEM617
CRANKSHAFT

1. Set main bearings inthe proper position oncylinder block
and main bearing caps.
• Ifeither crankshaft, cylinderblockormain bearing isreused
again, itis necessary tomeasure mainbearing clearance.
• Upper bearings (cylinderblockside)haveoilgroove.
• Apply newengine oiltobearing surfaces.

EM-152

Enginefront1
t;J
SEM230F
~~~:::~"
IJ

~ 2ndring
SEM909 CYLINDER
BLOCK
[ill

Assembly (Cont'd)

2. Apply engine oiltomain bearing surfaces oncrankshaft
journal side.
3. Install crankshaft andmain bearing caps.

Main bearing capbolt:
~: 44-54 N'm (4.5-5.5 kg-m, 33-40 ft-Ib)

4. Tighten mainbearing capbolts.

• Arrange theparts sothat theindicated numbersonbearing •
caps areinarow from thefront ofengine.
• Tighten bearing capbolts gradually intwo orthree stages
and outwardly fromcenter bearing insequence.
• After securing bearingcapbolts, ascertain thatcrankshaft
turns smoothly.
• Apply newengine oiltothreads ofbearing capbolts.

5. Measure crankshaft freeendplay atcenter bearing.

Crankshaft freeendplay:
Standard 0.05 -0.18 mm(0.0020 -0.0071 in)
Limit 0.30 mm(0.0118 in)
PISTON WITHCONNECTING ROD

1. Install connecting rodbearings inthe connecting rodsand
connecting rodcaps.
• Confirm thatcorrect sizeofbearings isused.

Refer to"Inspection" (EM-147).

• Install thebearings sothat theoilhole inthe connecting rod
aligns withtheoilhole ofthe bearing.

• Apply engine oiltoconnecting rodbearing surfaces onthe
crankshaft journalside.

• Set piston ringsasshown.

EM-153

EM03470000orsuitable tool CYLINDER
BLOCK
lliJ

Assembly
(Conl'd)

2. Install pistons withconnecting rods.
• Install themintocorresponding cylinderusingTool.
• Becareful nottoscratch cylinder wallwithconnecting rod.
• Apply engine oiltocylinder wall,piston andbearing.
• Arrange sothat thefront mark onpiston headfaces tothe
front ofengine.
3. Install connecting rodbearing caps.
• Apply engine oiltothe thread ofconnecting rodbearing nut.
(1) Tighten connecting rodbearing nutto15:1:1 N'm(1.5:1:0.1
kg-m, 10.8:1:0.7ft-Ib).
(2) Then tighten anadditional 60
+_~'.
turns withanangular tight-
ening wrench.
~: 15:1:1 N'm(1.5:1:0.1 kg-m,10.8:1:0.7 ft-Ib)plus

60+'::;.
or

~: 37-45 N'm (3.8-4.6 kg-m, 27-33 ft-Ib)
4. Measure connecting rodside clearance.
Connecting rodside clearance (Bigendplay):
Limit
0.3
mm (0.012 in)

FLYWHEEL RUNOUT

Runout (Totalindicator reading):
Less than0.15mm(0.0059 in)

EM-154

SERVICEDATAANDSPECIFICATIONS (SOS)
General Specifications
GENERAL SPECIFICATIONS

Engine GA14DE
GA15DE
GA16DE
Classification Gasoline
Cylinder arrangement 4,
in-line
Displacement cm
3

(cuin) 1,392(84.94) 1,498
(91.41)
1.597(97.45)
Bore xstroke mm(in) 73.6x81.8 (2.898 x3.220) 73.6
x88.0 (2.898 x3.465) 76.0x88.0 (2.992 x3.465)
Valve arrangement DOHC
Firing order 1-3-4-2
Number ofpiston rings
Compression 1'2,2

.

Oil 1
Number ofmain bearings 5
Compression ratio 959.9
9.8'1,9.9'2

Valve timing
~-r-y'
~U&l'

f
0,0

~J}&

BOC
EM120

Unit: degree
a b
cde
GA14DE 214"214° 0°
34° _4°
38°
GA15DE 222°
222° 0"
42°
-40

46°
GA16DE without
222° 214° 0°
34° 0°
VTC 42°
GA16DE withVTC
222" 236°_12°
68°0°42"
for Australia
GA16DE withVTC
except forAustra- 222°
248° 2"
66°
-4"

46"
lia
'1: For Europe andIsrael
'2: Except forEurope andIsrael

EM-155
•

SERVICEDATAANDSPECIFICATIONS (50S)
Inspection andAdjustment
ENGINE COMPRESSION PRESSURE CYLINDERHEAD
Unit: kPa(bar, kg/cm
2,
psi)/rpm Unit:
mm(in)
Compression Difference
ratio Standard Minimumlimitbetween
Refer toSDS
cylinders
(EM-155).
9.5 1,324
(13.24, 1,128
(11.28,
13.5, 192)/350 11.5,
164)/350
9.8 1,353
(13.53, 1,157
(11.57,
98(0.98, 1.0,
13.8, 196)/350 11.8,
168)/350
14)/350
9.9 1,373
(13.7,14, 1,177
(11.8,12,
199)/350 171)/350

VALVE
Standard
Limit
Head surface Lessthan
0.1(0.004)
flatness 0.03
(0.0012)
Height 117.8
-118.0
(4.638 -4.646)
-

Unit: mm(in)

---L
SEM188-b
GA14DE andGA15DE GA16DE
Intake 28.9
-29.2 29.9-30.2
(1.138 -1.150) (1.177
-1.189)
Valve headdiameter "0"
23.9-24.2 (0.941 -0.949): without VTC
Exhaust 23.9
-24.2
24.9-25.2 (0.980 -0.992):
(0.941 -0.953)
withVTC
Intake 92.00
-92.5 (3.6220 -3.6417)
Valve length "L"
Exhaust 92.37-92.87 (3.6366 -3.6563)
Intake 5.465-5.480 (0.2152 -0.2157)
Valve stemdiameter "d"
Exhaust 5.445
-5.460 (0.2144 -0.2150)
Valve faceangle "u" 45°15'
-45°45'

.

Valve margin
'T'
limit 0.9-1.1 (0.035 -0.043)
Valve stemendsurface grinding limit Less
than0.2(0.008)
Valve clearance
Unit:mm(in)
For adjusting Forchecking
Hot Cold*
Hot
Intake 0.32
-0.40 0.25
-0.33
0.21-0.49
(0.013 -0.016) (0.010-0.013) (0.008-0.019)
Exhaust 0.37
-0.45 0.32-0.40
0.30-0.58
(0.015 -0.018) (0.013-0.016) (0.012-0.023)
*: At atemperature ofapproximately 20°C(68°F)
Whenever valveclearances areadjusted tocold specifications,
check thattheclearances satisfyhotspecifications andadjust again
if necessary.
EM-156

SERVICEOATAAND SPECIFICATIONS (SOS)
Inspection andAdjustment (Cont'd)

Indicate

T
=
2.68
mm
(0.1055 In)
Available
shims

Thickness mm(in)
Identificationmark

2.00 (0.0787)
200
2.02 (0.0795)
202
2.04 (0.0803)
204
2.06 (0.0811)
206
2.08 (0.0819)
208
210 (0.0827)
210
2.12 (00835)
212
2.14 (0.0843)
214
216 (0.0850)
216
2.18 (0.0858) 218
2.20 (0.0866) 220
2.22 (00874) 222
224 (00882)
224
2.26 (0.0890)
226
2.28 (0.0898) 228
2.30 (0.0906)
230
2.32 (0.0913) 2.32
2.34 (0.0921)
234
2.36 (0.0929)
236
2.38 (0.0937)
238
240 (0.0945)
240
2.42 (0.0953) 242
2.44 (0.0961) 244
2.46 (0.0969)
246
2.48 (0.0976) 248
2.50 (00984)
250
2.52 (0.0992) 252
2.54 (0.1000)
254
2.56 (01008) 256
2.58 (0.1016) 258
2.60 (0.1024)
260
262 (0.1031) 262
2.64 (0.1039) 264
2.66 (0.1047)
266
2.68 (0.1055) 268
2.70 (0.1063) 270
2.72 (0.1071) 272
2.74 (0.1079) 274
2.76 (0.1087) 276
278 (0.1094)
278
2.80 (01102) 280
282 (01110) 282
284 (0.1118)
284
286 (0.1126) 286
2.88 (01134)
288
290 (0.1142) 290
2.92 (0.1150) 292
294 (0.1157)
294
296 (0.1165) 296
2.98 (0.1173) 298Shim
Type A
Type B
SEM104F
•

EM-157