2001 NISSAN ALMERA engine

Removal and InstallationNJEM0102
JEM265G
PREPARATIVE WORKNJEM0102S01Remove the following parts.
+Engine coolant (drain)
Refer to LC-44, ªChanging Engine Coolantº.
+Air duct, air inlet pipe
+Water inlet pipe
+Catalytic converter
+Exhaust manifold cover
+Insulator
+A/T fluid charging pipe mounting bolt
+Each wiring and piping (disconnect/move)
JEM266G
EXHAUST MANIFOLD AND TURBOCHARGERNJEM0102S02RemovalNJEM0102S0201+Loosen exhaust manifold mounting nuts in the reverse order
specified in the figure.
+Rotate the exhaust manifold and turbocharger assembly so
that the rear side (EGR tube mounting side) faces upward. And
then pull out the assembly from between the engine and the
air conditioning piping.
CAUTION:
Be careful not to deform each turbocharger piping when pull-
ing out the assembly.
EXHAUST MANIFOLD, TURBOCHARGERYD
Removal and Installation
EM-112

Trouble Diagnosis of Turbocharger=NJEM0104S0206Preliminary check:
+Check that the engine oil level is between MIN and MAX of the
dipstick. (When the engine oil amount is more than MAX, the
oil flows into the inlet duct through the blow-by gas passage,
and the turbocharger is misjudged failure.)
+Ask the customer if he/she always runs the vehicle in idle
engine speed to cool the oil down after driving.
+Replace the turbocharger assembly when any malfunction is
found after unit inspections specified in the table below.
+If no malfunction is found after the unit inspections, judge that
the turbocharger body has no failure. Check the other parts
again.
Inspection item Inspection resultSymptom (when each inspection
item meets each inspection result)
Oil
leakageSmoke NoiseInsuffi-
cient
power/
accel-
eration
failure
Turbine wheelOil leaks.n
nn
Carbon is accumulated.n
jj
Friction with housing.nj
j
Blades are bent or broken.
Compressor wheelInside the air inlet is seriously contami-
nated by oil.jj
Friction with housing.njj
Blades are bent or broken.
After checking both turbine and compressor,
inspect rotor shaft end play.There is resistance when the rotor shaft
is rotated by your fingertips.nnj
The rotor shaft sometimes does not
rotate by your fingertips.
There is too much play in the bearing.nnjn
Oil return portCarbon or sludge is accumulated in the
waste oil hole.n
nn
: Large possibility
j: Medium possibility
n: Small possibility
EXHAUST MANIFOLD, TURBOCHARGERYD
Inspection (Cont'd)
EM-116

Removal and InstallationNJEM0099
SEM655G
PREPARATIVE WORKNJEM0099S01Remove engine cover.
JEM664G
ROCKER COVERNJEM0099S02RemovalNJEM0099S0201Loosen holding bolts in the reverse order of that shown in the fig-
ure and remove.
CAUTION:
Do not remove mass damper on top. If damper must be
removed, remove all traces of old locking sealant from threads
of bolts and holes, and apply new locking sealant on the bolts
before tightening.
InstallationNJEM0099S0202+Tighten holding bolts in the numerical order shown in the fig-
ure.
+Re-tighten to the same torque in the same order as above.
ROCKER COVERYD
Removal and Installation
EM-117

CAUTION:
+When installing camshafts, chain tensioners, oil seals, or
other sliding parts, lubricate contacting surfaces with new
engine oil.
+Apply new engine oil to threads and seat surfaces when
installing cylinder head, camshaft sprocket, crankshaft
pulley, and camshaft bracket.
+Attach tags to valve lifters so as not to mix them up.
RemovalNJEM0063PREPARATIVE WORKNJEM0063S011. Drain engine coolant. Refer to LC-44, ªChanging Engine Cool-
antº.
2. Remove exhaust manifold. Refer to EM-112, ªRemovalº.
3. Remove intake manifold. Refer to EM-108, ªRemovalº.
+Apply paint to camshaft sprockets for alignment during
installation.
JEM152G
CAMSHAFTNJEM0063S021. Remove the following parts:
+Rocker cover
+Vacuum pump and cylinder head rear cover assembly
+Spill tube
+High pressure injection nozzle assembly
+Secondary timing chain and associated parts
JEM159G
2. Remove camshaft sprockets.
+Holding the hexagonal part of the camshaft with a wrench
having 21 mm (0.83 in) width between facing flats, loosen the
bolt holding the camshaft sprocket.
JEM160G
3. Remove camshafts.
+Loosen bolts holding the camshaft bracket in several stages in
the reverse order of that shown in the figure, and remove them.
4. Remove adjusting shims and valve lifters.
+Confirm the correct location of each part removed. Store them
so they do not get mixed up.
+For re-installation, be sure to put mark on camshaft
bracket before removal.
CYLINDER HEADYD
Components (Cont'd)
EM-120

SEM505G
CYLINDER HEAD GASKET SELECTIONNJEM0067S01+Select and install cylinder head gasket with appropriate thick-
ness according to the following procedure:
When replacing gasket alone:
+Install a gasket with the same thickness as that of the one
removed.
+Identify the thickness of gasket by the number of holes on the
RH side.
Gasket thickness*
mm (in)Number of holes
0.900 (0.0354) 1
0.925 (0.0364) 2
0.950 (0.0374) 3
0.975 (0.0384) 4
1.000 (0.0394) 5
1.025 (0.0404) 6
*: Measured with head bolts tightened
SEM507G
When the following parts have been repaired/replaced:
+With cylinder block upper surface and/or crankshaft pin journal
ground
+With cylinder block, pistons, connecting rods, and/or crank-
shaft replaced
1. Set piston at a point close to TDC.
2. Set a dial gauge at the location as shown in the figure. Turn-
ing crankshaft gradually, set the gauge scale to ª0º where the
piston protrusion is maximized.
3. Move the dial gauge stand so that the tip of dial gauge can
contact the cylinder block. Read the difference.
4. Measure at two locations per cylinder, that is eight locations for
four cylinders. Select gasket based on the maximum protru-
sion of eight measurements.
5. Measure front and rear at two locations for each cylinder and
calculate the mean value.
Among the four measured points for each cylinder, determine
the maximum protrusion value as the engine's piston protru-
sion value, and select and install a head gasket according to
the value.
+This SELECTION has been discontinued since June, 2000.
Piston protrusion mm (in)Gasket thickness*
mm (in)Identification
Number of holes
Less than 0.255 (0.0100) 0.900 (0.0354) 1
Less than 0.255 - 0.280
(0.0100 - 0.0110)0.925 (0.0364) 2
Less than 0.280 - 0.305
(0.0110 - 0.0120)0.950 (0.0374) 3
Less than 0.305 - 0.330
(0.0120 - 0.0130)0.975 (0.0384) 4
CYLINDER HEADYD
Installation (Cont'd)
EM-130

Piston protrusion mm (in)Gasket thickness*
mm (in)Identification
Number of holes
Less than 0.330 - 0.355
(0.0130 - 0.0140)1.000 (0.0394) 5
More than 0.355 (0.0140) 1.025 (0.0404) 6
*: Measured with head bolts tightened
JEM171G
CYLINDER HEAD BOLT DEFORMATION CHECKNJEM0067S02+Measure the outer diameter of threaded area, d1 and d2, at the
points specified in the figure.
+When the necked point is identified at a point other than speci-
fied points, measure at the point as d1.
+Calculate the difference between d1 and d2. If the value
exceeds the limit, replace with new ones.
Limit: 0.15 mm (0.0059 in)
JEM172G
CYLINDER HEAD-TO-BLOCK DIFFERENCE CHECKNJEM0067S03+After installing cylinder head, measure dimension from the
front end surface of cylinder block to that of cylinder head.
Standard: 23.53 - 24.07 mm (0.9264 - 0.9476 in)
+If the difference is out of the range, check fitting of dowel pins
and cylinder head.
JEM167G
LIQUID GASKET APPLICATION ON REAR CHAIN CASENJEM0067S04Apply a continuous bead of specified liquid gasket (Refer to EM-77,
ªLiquid Gasket Application Procedureº.) on the surface shown in
the figure.
A: Apply bead so that it does not protrude into oil passage.
B: Minimize the overlapping area of the bead, with start and end
areas of bead as shown in the figure.
Apply so that the portion marked * comes at an external location
but cannot be viewed externally after engine is assembled.
CYLINDER HEADYD
Installation (Cont'd)
EM-131

JEM149G
JEM166G
CYLINDER HEAD INSTALLATIONNJEM0067S05+Tighten bolts in numerical order as shown in the figure accord-
ing to the following procedure:
1. Apply engine oil to bolt threads and seat surfaces.
2. Tighten bolts to 29 to 38 N´m (2.9 to 3.9 kg-m, 21 to 28 ft-lb).
3. Tighten 180É to 185É [target: 180É] (angular tightening).
4. Loosen completely to 0 N´m (0 kg-m, 0 in-lb) in the reverse
order of that shown in the figure.
5. Tighten bolts to 35 to 44 N´m (3.5 to 4.5 kg-m, 26 to 32 ft-lb).
6. Tighten 90É to 95É [target: 90É] (angular tightening).
7. Tighten another 90É to 95É [target: 90É] (angular tightening).
+When an angle wrench is not used, paint an alignment
mark on the head of cylinder head bolt and cylinder head
surface before tightening. Check the angle with a protrac-
tor.
GLOW PLUG INSTALLATIONNJEM0067S06+To avoid damage, glow plugs should be removed only
when required.
+Handle with care to avoid applying shock. (When dropped
from approx. 100 mm (3.94 in) or higher, always replace
with a new one.)
+Before installing, remove carbon depositing on mounting hole
of glow plug with a reamer.
JEM173G
CAMSHAFT INSTALLATIONNJEM0067S071. Install valve lifters and adjusting shims.
+Install in the correct locations (the same places as before
removal).
2. Install camshafts.
+Identify camshafts by the paint position and screw hole at the
rear end.
Camshaft RH: Paint is at position A without screw hole.
Camshaft LH: Paint is at position B with screw hole.
SEM516G
+Install so that knock pins are positioned in the directions shown
in the figure.
CYLINDER HEADYD
Installation (Cont'd)
EM-132

JEM175G
3. Install camshaft brackets.
+Install correctly, identifying brackets by the journal No. and
front mark on top surface.
JEM160G
4. Tighten bolts in the order shown in the figure according to the
following procedure:
a. Tighten to 2.0 N´m (0.2 kg-m, 17 in-lb).
+Make sure camshaft thrusting parts (on rear side) securely fit
in their mating parts on the cylinder head.
b. Tighten to 6 N´m (0.6 kg-m, 52 in-lb).
c. Tighten to 12 to 13 N´m (1.2 to 1.4 kg-m, 9 to 10 ft-lb).
5. Install camshaft sprockets.
+Camshaft sprockets are commonly used for RH and LH.
+Align camshaft sprocket and dowel pin on camshaft, and
install.
+Holding the hexagonal part of camshaft with a wrench, tighten
bolt securing camshaft sprocket.
6. Before installing spill tube after installing secondary timing
chain, check and adjust valve clearance. Refer to EM-133,
ªValve Clearanceº.
7. Hereafter, install in the reverse order of removal.
JEM176G
Valve ClearanceNJEM0068CHECKINGNJEM0068S01Check valve clearance while engine is cold and not running.
1. Set the No. 1 piston to TDC on its compression stroke.
+Turn crankshaft pulley clockwise so that the knock pin on cam-
shaft LH faces straight above. (No position indicator, etc. is
provided on the crankshaft pulley.)
JEM177G
2. Put an alignment mark with paint, etc. on the crankshaft pul-
ley and on the oil pump as an angle indicator.
CYLINDER HEADYD
Installation (Cont'd)
EM-133