2003 NISSAN ALMERA N16 torque

CYLINDER BLOCK
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●If it exceeds the limit, replace connecting rod assembly.
CONNECTING ROD BEARING (BIG END)
●Install the connecting rod cap without the connecting rod bearing
installed. After tightening the connecting rod bolt to the specified
torque, measure the connecting rod big end inner diameter
using an inside micrometer.
CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)
Inner Diameter of Connecting Rod (Small End)
●Measure inner diameter of bushing.
Outer Diameter of Piston Pin
●Measure outer diameter of piston pin.
Connecting Rod Bushing Oil Clearance (Small End)
(Connecting rod small end oil clearance) = (Inner diameter of connecting rod small end) – (Outer diameter of
piston pin)
●If the measured value exceeds the standard, replace the connecting rod assembly and/or piston and pis-
ton pin assembly.
SEM003F
Standard : 43.000 - 43.013 mm (1.6929 - 1.6934 in) dia.
PBIC0119E
Standard : 19.000 - 19.012 mm (0.7480 - 0.7485 in) dia.
PBIC0120E
Standard : 18.989 - 19.001 mm (0.7476 - 0.7481 in)
PBIC0117E
Standard : 0.005 - 0.017 mm (0.0002 - 0.0007 in)

EM-88
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CYLINDER BLOCK
●If replacing the piston and piston pin assembly, refer to the “Piston Selection Table” to select the piston
corresponding to the applicable bore grade of the cylinder block to be used. Refer to EM-80, "
HOW TO
SELECT PISTON" .
Factory installed parts grading:
●Service parts apply only to grade 0.
Unit: mm (in)
CYLINDER BLOCK DISTORTION
●Using a scraper, remove gasket on the cylinder block surface,
and also remove oil, scale, carbon, or other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter the oil or cool-
ant passages.
●Measure the distortion on the block upper face at some different
points in 6 directions.
●If out of the distortion limit, replace the cylinder block.
INNER DIAMETER OF MAIN BEARING HOUSING
●Install the main bearing caps with the main bearings removed,
and tighten the mounting bolts to the specified torque.
●Using a bore gauge, measure the inner diameter of the main
bearing housing.
●If out of the standard, replace the cylinder block and lower cylin-
der block assembly.
NOTE:
These components cannot be replaced as a single unit because
they were processed together.
PISTON TO CYLINDER BORE CLEARANCE
Inner Diameter of Cylinder Bore
●Using a bore gauge, measure cylinder bore for wear, out-of-
round and taper at 6 different points on each cylinder. (X and Y
directions at A, B and C) (Y is in longitudinal direction of engine)
Grade 0 1
Connecting rod small end inner diam-
eter19.000 - 19.006
(0.7480 - 0.7483)19.006 - 19.012
(0.7483 - 0.7485)
Piston pin outer diameter18.989 - 18.995
(0.7476 - 0.7478)18.995 - 19.001
(0.7478 - 0.7481)
Piston pin hole diameterQG15DE18.987 - 18.993
(0.7475 - 0.7478)18.993 - 18.999
(0.7478 - 0.7480)
QG18DE18.993 - 18.996
(0.7478- 0.7479)18.996 - 18.999
(0.7479 - 0.7480)
PBIC0591E
Limit : 0.1 mm (0.004 in)
PBIC0121E
Standard : 53.644 - 53.668 mm (2.1120 - 2.1129 in) dia.
PBIC0611E
PBIC0612E

CYLINDER BLOCK
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●If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
hone or rebore the inner wall.
●An oversize piston is provided. When using an oversize piston, rebore the cylinder so that the clearance
of the piston cylinder satisfies the standard.
Outer Diameter of Piston
●Measure piston skirt diameter.
Piston to Cylinder Bore Clearance
●Calculate by outer diameter of piston skirt and inner diameter of cylinder (direction X, position B).
(Clearance) = (Inner diameter of cylinder) – (Outer diameter of piston skirt).
●If it exceeds the standard, replace piston/piston pin assembly.
Reboring Cylinder Bore
1. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter “A”.
2. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted
in final assembly.Standard inner diameter:
QG15DE : 73.600 - 73.630 mm (2.8976 - 2.8988 in) dia.
QG18DE : 80.000 - 80.030 mm (3.1496 - 3.1508 in) dia.
Wear limit:
0.2 mm (0.008 in)
Out-of-round (Difference between X and Y):
0.015 mm (0.0006 in)
Taper limit (Difference between A and C):
0.01 mm (0.0004 in)
Oversize (OS) : 0.25 mm (0.0098 in)
: 0.5 mm (0.0197 in)
PBIC0613E
QG15DE
Measuring
point: 43.6 mm (1.717 in) below piston head
upper edge
Standard : 73.575 - 73.605 mm (2.8966 - 2.8978 in)
dia.
QG18DE
Measuring
point: 42.3 mm (1.665 in) below piston head
upper edge
Standard : 79.965 - 79.995 mm (3.1482 - 3.1494 in)
dia.
PBIC0125E
QG15DE
Standard : 0.015 - 0.035 mm (0.0006 - 0.0014 in)
QG18DE
Standard : 0.025 - 0.045 mm (0.010 - 0.018 in)
Rebored size calculation: D = A + B - C
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston - to - bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 in)

CYLINDER BLOCK
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OIL CLEARANCE OF CONNECTING ROD BEARING
Method of Measurement
●Install the connecting rod bearings to the connecting rod and the
cap, and tighten the connecting rod bolts to the specified torque.
Using a inside micrometer measure the inner diameter of con-
necting rod bearing.
(Oil clearance) = (Inner diameter of connecting rod bearing) – (Outer
diameter of crankshaft pin)
●If clearance cannot be adjusted within the standard, grind crank-
shaft pin and use undersized bearing. Refer to EM-81, "
HOW
TO SELECT CONNECTING ROD BEARING" .
Method of Using Plastigage
●Remove oil and dust on the crankshaft pin and the surfaces of
each bearing completely.
●Cut a plastigage slightly shorter than the bearing width, and
place it in crankshaft axial direction, avoiding oil holes.
●Install the connecting rod bearings to the connecting rod cap,
and tighten the connecting rod bolts to the specified torque.
CAUTION:
Never rotate the crankshaft.
●Remove the connecting rod cap and bearings, and using the
scale on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is same as that described in the method by
calculation.
OIL CLEARANCE OF MAIN BEARING
Method of Measurement
●Install the main bearings to the cylinder block and bearing cap. Measure the main bearing inner diameter
with the bearing cap bolt tightened to the specified torque.
(Oil clearance) = (Inner diameter of main bearing) – (Outer diameter of crankshaft journal)
●If the measured value exceeds the limit, select main bearings referring to the main bearing inner diameter
and crankshaft journal outer diameter, so that the oil clearance satisfies the standard. Refer to EM-82,
"HOW TO SELECT MAIN BEARING" .
Method of Using Plastigage
●Remove oil and dust on the crankshaft journal and the surfaces
of each bearing completely.
●Cut a plastigage slightly shorter than the bearing width, and
place it in crankshaft axial direction, avoiding oil holes.
●Tighten the main bearing bolts to the specified torque.
CAUTION:
Never rotate the crankshaft.
●Remove the bearing cap and bearings, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in “the method by calculation.”Standard : 0.014 - 0.039 mm (0.0006 - 0.0015 in)
Limit : 0.10 mm (0.0039 in)
PBIC0119E
EM142
Standard : 0.020 - 0.044 mm (0.0008 - 0.0017 in)
Limit : 0.1 mm (0.004 in)
EM142

EM-92
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CYLINDER BLOCK
CRUSH HEIGHT OF MAIN BEARING
●When the bearing cap is removed after being tightened to the
specified torque with main bearings installed, the tip end of bear-
ing must protrude.
●If the standard is not met, replace main bearings.
FLYWHEEL RUNOUT
●Measure deflection of contact surface with dial gauge.Standard : There must be crush height
SEM502G
Flywheel (M/T models)
Limit : 0.1 mm (0.004 in)
SEM931F

EM-104
[QG]
SERVICE DATA AND SPECIFICATIONS (SDS)
CONNECTING ROD BEARING
Standard Size
Unit: mm (in)
Undersize
Unit: mm (in)
Bearing Clearance
Unit: mm (in)
MISCELLANEOUS COMPONENTS
Unit: mm (in)
*: Total indicator reading
Tightening TorqueEBS00LQQ
*1: Parts to be tightened in particular orders.
1)-: Order of tightening when tightening two or more times separately.
Unit: N·m (kg-m, ft-lb) / Unit: N·m (kg-m, in-lb)*2
Grade No. Thickness Identification color or number
0 1.503 - 1.506 (0.0592 - 0.0593) Block
1 1.506 - 1.509 (0.0593 - 0.0594) Red
2 1.509 - 1.512 (0.0594 - 0.0595) Green
Grade No. Thickness Identification color or number
0.08 (0.0031) 1.542 - 1.546 (0.0607 - 0.0609) —
0.12 (0.0047) 1.562 - 1.566 (0.0615 - 0.0617) —
0.25 (0.0098) 1.627 - 1.631 (0.0641 - 0.0642) —
Connecting rod bearing clear-
anceStandard 0.014 - 0.039 (0.0006 - 0.0015)
Limit 0.1 (0.004)
Flywheel runout [TIR*] Less than 0.1 (0.004)
Camshaft sprocket runout [TIR*] Less than 0.15 (0.0059)
Mass air flow sensor
8.4 - 10.8 (0.9 - 1.1, 75 - 95)*2
Resonator
3.8 - 4.5 (0.39 - 0.45, 34 - 39)*2
Air cleaner case lower
3.8 - 4.5 (0.39 - 0.46, 34 - 39)*2
Intake manifold16.7 - 23.5 (1.7 - 2.4, 13 - 17)
Intake manifold collector
7.0 - 9.5 (0.71 - 0.97, 62 - 84)*
2
Intake manifold support 16.7 - 23.5 (1.7 - 2.4, 13 - 17)
Electric throttle control actuator 17.7 - 21.6 (1.8 - 2.2, 13 - 15)
Exhaust manifold25.5 - 29.4 (2.6 - 2.9, 19 - 21)
Exhaust manifold cover
6.3 - 8.3 (0.64 - 0.85, 56 - 73)*
2
Heated oxygen sensor 58.8 - 78.4 (6.0 - 7.9, 44 - 57)
Ground nut79.4 (8.1, 59)
Oil pan
6.28 - 8.34 (0.64 - 0.85, 56 - 73)*
2
Oil pan drain plug29.4 - 39.2 ( 3.0 - 3.9, 22 - 28)
Oil strainer
6.28 - 8.34 (0.64 - 0.85, 56 - 73)*
2
Ignition coil
3.8 - 5.0 (0.38 - 0.51, 33 - 44)*2
Spark plug19.6 - 29.4 (2.0 - 3.0, 15 - 21)
*1 Fuel tube1) 11.8 - 13.8 (1.2 - 1.4, 9 - 10 )
2) 17 - 23 (1.7 - 2.4, 13 - 17)
Rocker cover
6.9 - 9.5 (0.70 - 0.97, 61 - 84)*
2

Parts Requiring Angular TighteningNJEM0047Use an angle wrench for the final tightening of the following
engine parts:
a) Cylinder head bolts
b) Main bearing cap bolts
c) Connecting rod cap nuts
d) Crankshaft pulley bolt
Do not use a torque value for final tightening.
The torque value for these parts are for a preliminary step.
Ensure thread and seat surfaces are clean and coated with
engine oil.
SEM164F
Liquid Gasket Application ProcedureNJEM00481.Use a scraper to remove all traces of old liquid gasket
from mating surfaces and grooves. Also, completely clean
any oil from these areas.
2.Apply a continuous bead of liquid gasket to mating sur-
faces. (Use Genuine Liquid Gasket or equivalent.)
Be sure liquid gasket diameter is as specified.
AEM080
3.Apply liquid gasket around the inner side of bolt holes
(unless otherwise specified).
4.Assembly should be done within 5 minutes after coating.
5.Wait at least 30 minutes before refilling engine oil and
engine coolant.
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PRECAUTIONSYD
Parts Requiring Angular Tightening
EM-3

InstallationNJEM00911. Install each belt on pulley in reverse order of removal.
2. Adjust belt tension. Refer to EM-11, “Adjustment”.
3. Tighten nuts and bolts provided for adjustment to the specified
torque.
4. Check again that each belt tension is as specified.GI
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DRIVE BELTSYD
Installation
EM-13