2001 NISSAN ALMERA N16 service

ENGINE MECHANICAL
SECTION
EM
CONTENTS
QG
PRECAUTIONS...............................................................4
Parts Requiring Angular Tightening .............................4
Liquid Gasket Application Procedure ..........................4
PREPARATION...............................................................5
Special Service Tools ..................................................5
Commercial Service Tools ...........................................7
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING.....................................................9
NVH Troubleshooting - Engine Noise .........................9
OUTER COMPONENT PARTS..................................... 11
Removal and Installation ........................................... 11
MEASUREMENT OF COMPRESSION PRESSURE....14
DRIVE BELTS................................................................15
Checking ....................................................................15
AIR CLEANER...............................................................17
Cleaning and Changing .............................................17
VISCOUS PAPER TYPE...........................................17
SPARK PLUG................................................................18
Checking and Changing ............................................18
OIL PAN.........................................................................19
Components...............................................................19
Removal .....................................................................19
Installation ..................................................................20
TIMING CHAIN..............................................................22
Components...............................................................22
Removal .....................................................................23
Inspection...................................................................26
Installation ..................................................................27
OIL SEAL.......................................................................31
Replacement ..............................................................31
VALVE OIL SEAL.....................................................31
FRONT OIL SEAL....................................................31
REAR OIL SEAL......................................................32
CYLINDER HEAD..........................................................33
Components...............................................................33
Removal .....................................................................34
Disassembly...............................................................36Inspection...................................................................36
CYLINDER HEAD DISTORTION...............................36
CAMSHAFT VISUAL CHECK....................................36
CAMSHAFT RUNOUT..............................................37
CAMSHAFT CAM HEIGHT.......................................37
CAMSHAFT JOURNAL CLEARANCE........................37
CAMSHAFT END PLAY............................................38
CAMSHAFT SPROCKET RUNOUT...........................38
VALVE GUIDE CLEARANCE....................................38
VALVE GUIDE REPLACEMENT................................39
VALVE SEATS.........................................................40
REPLACING VALVE SEAT FOR SERVICE PARTS....40
VALVE DIMENSIONS...............................................41
VALVE SPRING.......................................................41
VALVE LIFTER AND VALVE SHIM............................41
Valve Clearance.........................................................42
CHECKING.............................................................42
ADJUSTING............................................................43
Assembly ...................................................................45
Installation ..................................................................45
ENGINE ASSEMBLY.....................................................49
Removal and Installation ...........................................49
REMOVAL...............................................................50
INSTALLATION........................................................51
CYLINDER BLOCK.......................................................52
Components...............................................................52
Removal and Installation ...........................................53
Disassembly...............................................................53
PISTON AND CRANKSHAFT....................................53
Inspection...................................................................54
PISTON AND PISTON PIN CLEARANCE..................54
PISTON RING SIDE CLEARANCE............................54
PISTON RING END GAP..........................................54
CONNECTING ROD BEND AND TORSION...............55
CYLINDER BLOCK DISTORTION AND WEAR...........55
PISTON-TO-BORE CLEARANCE..............................56
CRANKSHAFT.........................................................57
BEARING CLEARANCE...........................................57
CONNECTING ROD BUSHING CLEARANCE
(SMALL END)
..........................................................59

REPLACEMENT OF CONNECTING ROD
BUSHING (SMALL END)
..........................................60
FLYWHEEL/DRIVE PLATE RUNOUT........................60
Assembly ...................................................................60
PISTON..................................................................60
CRANKSHAFT.........................................................61
SERVICE DATA AND SPECIFICATIONS (SDS).........64
General Specifications ...............................................64
Compression Pressure ..............................................64
Belt Deflection............................................................64
Spark Plug .................................................................65
Cylinder Head ............................................................65
Valve ..........................................................................66
VALVE....................................................................66
VALVE SPRING.......................................................66
VALVE LIFTER........................................................66
VALVE CLEARANCE................................................67
VALVE GUIDE.........................................................67
AVAILABLE SHIMS..................................................67
VALVE SEAT...........................................................70
VALVE SEAT RESURFACE LIMIT.............................71
Camshaft and Camshaft Bearing ..............................71
Cylinder Block ............................................................72
Piston, Piston Ring and Piston Pin ...........................73
PISTON..................................................................73
PISTON RING.........................................................73
PISTON PIN............................................................73
Connecting Rod .........................................................74
Crankshaft..................................................................74
Main Bearing..............................................................74
STANDARD.............................................................74
UNDERSIZE............................................................74
Connecting Rod Bearing ...........................................75
STANDARD SIZE....................................................75
UNDERSIZE............................................................75
Bearing Clearance .....................................................75
Miscellaneous Components.......................................75
YD
PRECAUTIONS.............................................................76
Parts Requiring Angular Tightening ...........................76
Liquid Gasket Application Procedure ........................76
PREPARATION.............................................................77
Special Service Tools ................................................77
Commercial Service Tools .........................................79
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING...................................................81
NVH Troubleshooting - Engine Noise .......................81
MEASUREMENT OF COMPRESSION PRESSURE....82
DRIVE BELTS................................................................84
Inspection...................................................................84
Adjustment .................................................................84
AIR CONDITIONER COMPRESSOR BELT................85
ALTERNATOR & WATER PUMP BELT.....................85
Removal .....................................................................85
Installation ..................................................................86
AIR CLEANER...............................................................87
Changing Air Cleaner Filter .......................................87
VISCOUS PAPER TYPE...........................................87
OIL PAN.........................................................................88
Components...............................................................88
Removal .....................................................................88
Installation ..................................................................90
TIMING CHAIN..............................................................93
Secondary Timing Chain ...........................................93
REMOVAL...............................................................93
INSPECTION...........................................................95
INSTALLATION........................................................95
Primary Timing Chain ................................................98
REMOVAL...............................................................99
INSPECTION.........................................................101
INSTALLATION......................................................101
INTAKE MANIFOLD....................................................106
Removal and Installation .........................................106
PREPARATIVE WORK...........................................106
FUEL PIPING........................................................107
INTAKE MANIFOLD...............................................107
EGR VOLUME CONTROL VALVE...........................107
WATER HOSE.......................................................107
Inspection.................................................................108
INTAKE MANIFOLD...............................................108
CATALYST..................................................................109
Removal and Installation .........................................109
PREPARATIVE WORK...........................................109
CATALYST............................................................109
GUSSET............................................................... 110
EXHAUST MANIFOLD, TURBOCHARGER............... 111
Removal and Installation ......................................... 111
PREPARATIVE WORK........................................... 111
EXHAUST MANIFOLD AND TURBOCHARGER....... 111
EXHAUST MANIFOLD GASKET............................. 112
Disassembly and Assembly ..................................... 112
TURBOCHARGER................................................. 112
Inspection................................................................. 113
EXHAUST MANIFOLD........................................... 113
TURBOCHARGER................................................. 113
ROCKER COVER........................................................ 116
Removal and Installation ......................................... 116
PREPARATIVE WORK........................................... 116
ROCKER COVER.................................................. 116
CYLINDER HEAD........................................................ 118
Components............................................................. 118
Removal ................................................................... 119
PREPARATIVE WORK........................................... 119
CAMSHAFT........................................................... 119
CYLINDER HEAD..................................................120
Disassembly.............................................................120
Inspection.................................................................121
CONTENTS(Cont'd)
EM-2

CYLINDER HEAD DISTORTION.............................121
CAMSHAFT VISUAL CHECK..................................122
CAMSHAFT RUNOUT............................................122
CAMSHAFT CAM HEIGHT.....................................122
CAMSHAFT JOURNAL CLEARANCE......................122
CAMSHAFT END PLAY..........................................123
CAMSHAFT SPROCKET RUNOUT.........................123
VALVE GUIDE CLEARANCE..................................123
VALVE GUIDE REPLACEMENT..............................124
VALVE SEATS.......................................................125
REPLACING VALVE SEAT FOR SERVICE PARTS..125
VALVE DIMENSIONS.............................................127
VALVE SPRING.....................................................127
VALVE LIFTER......................................................127
Assembly .................................................................128
Installation ................................................................129
CYLINDER HEAD GASKET SELECTION.................129
CYLINDER HEAD BOLT DEFORMATION CHECK...130
CYLINDER HEAD-TO-BLOCK DIFFERENCE
CHECK
.................................................................130
LIQUID GASKET APPLICATION ON REAR CHAIN
CASE
....................................................................130
CYLINDER HEAD INSTALLATION..........................131
GLOW PLUG INSTALLATION.................................131
CAMSHAFT INSTALLATION...................................131
Valve Clearance.......................................................132
CHECKING...........................................................132
ADJUSTING..........................................................133
ENGINE ASSEMBLY...................................................136
Removal and Installation .........................................136
REMOVAL.............................................................137
INSTALLATION......................................................138
CYLINDER BLOCK.....................................................139
Components.............................................................139
Removal and Installation .........................................140
Disassembly.............................................................140
PISTON AND CRANKSHAFT..................................140
Inspection.................................................................143
CRANKSHAFT END PLAY.....................................143
CONNECTING ROD SIDE CLEARANCE.................143
PISTON AND PISTON PIN CLEARANCE................144
PISTON RING SIDE CLEARANCE..........................144
PISTON RING END GAP........................................145
CONNECTING ROD BEND AND TORSION.............145
CYLINDER BLOCK DISTORTION AND WEAR.........145
PISTON-TO-BORE CLEARANCE............................146
CRANKSHAFT.......................................................148
MAIN BEARING HOUSING INNER DIAMETER........148
BEARING CLEARANCE.........................................148
MAIN BEARING CRUSH HEIGHT...........................152
MAIN BEARING CAP BOLT DEFORMATION...........152
CONNECTING ROD BUSHING CLEARANCE
(SMALL END)
........................................................152
CONNECTING ROD BOLT DEFORMATION............153
FLYWHEEL RUNOUT............................................153
OIL JET................................................................153
OIL JET RELIEF VALVE.........................................154
Assembly .................................................................154
PISTON................................................................154
CRANKSHAFT.......................................................154
REPLACEMENT OF PILOT BUSHING.....................157
SERVICE DATA AND SPECIFICATIONS (SDS).......159
General Specifications .............................................159
Compression Pressure ............................................159
Belt Deflection..........................................................159
Cylinder Head ..........................................................159
Valve ........................................................................160
VALVE..................................................................160
VALVE CLEARANCE..............................................160
AVAILABLE SHIMS................................................160
VALVE SPRING.....................................................161
VALVE LIFTER......................................................162
VALVE GUIDE.......................................................162
Valve Seat................................................................163
Camshaft and Camshaft Bearing ............................165
Cylinder Block ..........................................................166
Piston, Piston Ring and Piston Pin .........................167
AVAILABLE PISTON..............................................167
PISTON RING.......................................................167
PISTON PIN..........................................................167
Connecting Rod .......................................................168
Crankshaft................................................................168
Available Main Bearing ............................................169
UNDERSIZE..........................................................169
Available Connecting Rod Bearing..........................169
CONNECTING ROD BEARING...............................169
UNDERSIZE..........................................................169
Miscellaneous Components.....................................169
BEARING CLEARANCE.........................................170
CONTENTS(Cont'd)
EM-3

Special Service ToolsNJEM0003
Tool number
Tool nameDescription
ST0501S000
Engine stand assembly
(1) ST05011000
Engine stand
(2) ST05012000
Base
NT042
Disassembling and assembling
Engine attachment
assembly
(1) KV10106500
Engine attachment
(2) KV10113300
Sub-attachment
NT029
Overhauling engine
ST10120000
Cylinder head bolt
wrench
NT583
Loosening and tightening cylinder head bolt
a: 13 mm (0.51 in) dia.
b: 12 mm (0.47 in)
c: 10 mm (0.39 in)
KV10116200
Valve spring compressor
(1) KV10115900
Attachment
NT022
Disassembling valve mechanism
KV10115600
Valve oil seal drift
NT024
Installing valve oil seal
KV10107902
Valve oil seal puller
NT011
Displacement valve lip seal
PREPARATIONQG
Special Service Tools
EM-5

Tool number
Tool nameDescription
KV101151S0
Lifter stopper set
(1) KV10115110
Camshaft pliers
(2) KV10115120
Lifter stopper
NT041
Changing shims
EM03470000
Piston ring compressor
NT044
Installing piston assembly into cylinder bore
KV10107400
Piston pin press stand
(1) KV10107310
Center shaft
(2) ST13040020
Stand
(3) ST13040030
Spring
(4) KV10107320
Cap
(5) ST13040050
Drift
NT013
Disassembling and assembling piston pin
KV101111 0 0
Seal cutter
NT046
Removing oil pan
WS39930000
Tube presser
NT052
Pressing the tube of liquid gasket
KV10112100
Angle wrench
NT014
Tightening bolts for bearing cap, cylinder head,
etc.
ST16610001
Pilot bushing puller
NT045
Removing pilot bushing
PREPARATIONQG
Special Service Tools (Cont'd)
EM-6

Tool number
Tool nameDescription
Front (heated) oxygen
sensor wrench
NT379
Loosening or tightening heated oxygen sensor
with 22 mm (0.87 in) hexagon nut
KV101056S0*
Rear gear stopper
(1) KV10105620
Adapter
(2) KV10105610
Plate assembly
NT773
Preventing crankshaft from rotating
Commercial Service ToolsNJEM0004
Tool name Description
Spark plug wrench
NT047
Removing and installing spark plug
Valve seat cutter set
NT048
Finishing valve seat dimensions
Piston ring expander
NT030
Removing and installing piston ring
Valve guide drift
NT015
Removing and installing valve guide
Intake & Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.
PREPARATIONQG
Special Service Tools (Cont'd)
EM-7

Tool name Description
Valve guide reamer
NT016
Reaming valve guide1or hole for oversize valve
guide2
Intake & Exhaust:
d
1: 5.5 mm (0.217 in) dia.
d
2: 9.685 mm (0.3813 in) dia.
Front oil seal drift
NT049
Installing front oil seal
a: 52 mm (2.05 in) dia.
b: 40 mm (1.57 in) dia.
Rear oil seal drift
NT049
Installing rear oil seal
a: 103 mm (4.06 in) dia.
b: 84 mm (3.31 in) dia.
Oxygen sensor thread
cleaner
NT778
Reconditioning the exhaust system threads before
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
Anti-seize lubricant (Per-
matex
TM133AR or
equivalent meeting MIL
specification MIL-A-907)
NT779
Lubricating oxygen sensor thread cleaning tool
when reconditioning exhaust system threads
PREPARATIONQG
Commercial Service Tools (Cont'd)
EM-8

Unit: mm (in)
Standard Limit
Intake0.020 - 0.050
(0.0008 - 0.0020)0.1 (0.004)
Exhaust0.040 - 0.070
(0.0016 - 0.0028)0.1 (0.004)
+If it exceeds the limit, replace valve and remeasure clearance.
+If limit is still exceeded after replacing valve, replace valve
guide.
SEM008A
VALVE GUIDE REPLACEMENTNJEM0019S091. To remove valve guide, heat cylinder head to 110 to 130ÉC
(230 to 266ÉF).
SEM931C
2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2
US ton, 2.0 Imp ton) pressure] or hammer and suitable tool.
SEM932C
3. Ream cylinder head valve guide hole.
Valve guide hole diameter
(for service parts):
Intake & Exhaust
9.685 - 9.696 mm (0.3813 - 0.3817 in)
MEM096A
4. Heat cylinder head to 110 to 130ÉC (230 to 266ÉF) and press
service valve guide into cylinder head.
Projection ªLº:
11.5 - 11.7 mm (0.453 - 0.461 in)
CYLINDER HEADQG
Inspection (Cont'd)
EM-39