2003 NISSAN ALMERA N16 crankshaft

CYLINDER BLOCK
EM-71
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CAUTION:
Apply new engine oil to parts marked in illustration before installation.
DISASSEMBLY
1. Remove engine and transaxle assembly from vehicle, and separate transaxle from engine. Refer to EM-
67, "ENGINE ASSEMBLY" .
2. Mount engine on an engine stand with the following procedure.
a. Remove exhaust manifold and catalytic converter. Refer to EM-19, "
EXHAUST MANIFOLD AND CATA-
LYTIC CONVERTER" .
b. Remove engine front mounting bracket, alternator and air compressor bracket.
c. Install engine sub-attachment to left side of cylinder block.
d. Lift engine, and mount it onto the engine stand.
1. Rear oil seal 2. Rear oil seal retainer 3. Crankshaft position sensor (POS)
4. O-ring 5. Knock sensor 6. Oil level gauge guide
7. Cylinder block 8. Thrust bearing 9. Main bearing
10. Crankshaft 11. Key 12. Top ring
13. 2nd ring 14. Oil ring 15. Main bearing
16. Piston 17. Snap ring 18. Piston pin
19. Connecting rod 20. Connecting rod bearing 21. Connecting rod cap
22. Connecting rod nut 23. Main bearing cap bolt 24. Baffle plate
25. Main bearing cap 26. Signal plate 27. Rear plate
28. Coolant drain plug 29. Flywheel (M/T models) 30. Drive plate (A/T models)
PBIC0585E
PBIC1017E

EM-72
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CYLINDER BLOCK
●A commercial engine stand can be used.
NOTE:
●This example is an engine stand for holding at transaxle
mounting side with the flywheel or drive plate removed.
3. Drain engine oil and coolant from inside of engine.
4. Remove the following components and associated parts.
●Fuel tube and injector assembly; Refer to EM-26, "Removal and Installation" .
●Intake manifold and intake manifold collector assembly; Refer to EM-16, "Removal and Installation" .
●Ignition coil; Refer to EM-24, "Removal and Installation" .
●Rocker cover; Refer to EM-29, "Removal and Installation" .
●Oil pan and oil strainer; Refer to EM-22, "Removal and Installation" .
●Front cover and timing chain; Refer to EM-47, "Removal and Installation" .
●Camshaft; Refer to EM-32, "Removal and Installation" .
●Cylinder head assembly; Refer to EM-58, "Removal and Installation" .
●Auxiliary brackets and oil filter
5. Remove knock sensor.
CAUTION:
Avoid impacts such as a dropping.
6. Remove crankshaft position sensor (POS).
CAUTION:
●Avoid impacts such as a dropping.
●Do not disassemble.
●Keep it away from metal particles.
●Do not place sensor close to magnetic materials.
7. Remove flywheel (M/T models) or drive plate (A/T models). Fix
crankshaft with a ring gear stopper (special service tool), and
remove mounting bolts.
8. Remove rear plate.
9. Remove rear oil seal retainer.
●Insert a flat-bladed screwdriver between main bearing cap
and rear oil seal retainer to remove retainer.
10. Remove rear oil seal from rear oil seal retainer.
●Punch out with a flat-bladed screwdriver.
CAUTION:
●Be careful not to damage rear oil seal retainer.
PBIC0085E
PBIC0586E
SEM880F

CYLINDER BLOCK
EM-73
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11. Remove the piston and connecting rod assembly.
●Before removing the piston and connecting rod assembly,
check the connecting rod side clearance. Refer to EM-84,
"CONNECTING ROD SIDE CLEARANCE" .
a. Position the crankshaft pin corresponding to the connecting rod
to be removed onto the bottom dead center.
b. Remove the connecting rod cap.
c. Using a hammer handle or similar tool, push the piston and con-
necting rod assembly out to the cylinder head side.
12. Remove the connecting rod bearings.
CAUTION:
●When removing them, note the installation position. Keep them in the correct order.
13. Remove the piston rings form the piston.
●Before removing the piston rings, check the piston ring side
clearance. Refer to EM-85, "
PISTON RING SIDE CLEAR-
ANCE" .
●Use a piston ring expander (commercial service tool).
CAUTION:
●When removing the piston rings, be careful not to dam-
age the piston.
●Be careful not to damage piston rings by expanding them
excessively.
14. Remove the piston from the connecting rod as follows:
a. Using a snap ring pliers, remove the snap ring.
b. Heat piston to 60 to 70°C (140 to 158°F) with drier or equivalent.
PBIC0259E
PBIC0087E
PBIC0088E
PBIC0089E

EM-74
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CYLINDER BLOCK
c. Push out piston pin with stick of outer diameter approximately 17
mm (0.67 in).
15. Remove main bearing cap bolts.
●Loosen main bearing cap bolts in several steps in reverse
order shown in the figure, and remove them.
●Measure crankshaft side clearance before loosening main
bearing cap bolts. Refer to EM-84, "
CRANKSHAFT SIDE
CLEARANCE" .
16. Remove main bearing caps.
●Using main bearing cap bolts as shown, remove center main
bearing cap while shaking it back-and-forth.
●To remove front and rear main bearing caps, lever them off
using screwdriver or similar tool. Or, using a plastic hammer,
tap them back-and-forth.
CAUTION:
Using shop cloth or wooden block, protect oil pan mount-
ing surface on cylinder block, so that mounting surface is
not damaged.
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SEM933F
EMD0879D
EMD0222D

CYLINDER BLOCK
EM-75
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17. Remove crankshaft.
CAUTION:
●When placing crankshaft on ground, be careful not to
damage signal plate.
●Never remove signal plate unless it is necessary.
NOTE:
If it is removed, positioning dowel pin (dowel pins for crankshaft
and signal plate are specified as a single set) must be rein-
stalled.
18. Remove main bearing and thrust bearing from cylinder block and main bearing cap.
CAUTION:
Check mounting positions, and store them without mixing them up.
19. Remove baffle plate.
ASSEMBLY
1. Blow air sufficiently through engine coolant passage of cylinder block, oil passage, crank case and cylin-
der bore to remove foreign objects.
2. Install oil jet for timing chain lubrication.
●Face its flat surface upward, and push it as far as it will go.
3. Install baffle plate.
4. Install the main bearings and the thrust bearings.
a. Remove dust, dirt, and oil on the bearing mating surfaces of the
cylinder block and the lower cylinder block.
b. Install the thrust bearings to the both sides of the No. 3 journal
housing on the cylinder block.
●Install the thrust bearings with the oil groove facing the crank-
shaft arm (outside).
c. Install the main bearings paying attention to the direction.
●The main bearing with an oil hole and groove goes on the cyl-
inder block. The one without them goes on the lower cylinder
block.
●Main bearings (cylinder block side) for journal No. 1 and for
No. 2 to No. 5 are different.
●Before installing the bearings, apply engine oil to the bearing
surface (inside). Do not apply oil to the back surface, but thor-
oughly clean it.
●When installing, align the bearing stopper to the notch.
●Ensure the oil holes on cylinder block and those on the corre-
sponding bearing are aligned.
SEM928F
PBIC0588E
PBIC0264E
PBIC0590E

EM-76
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CYLINDER BLOCK
5. Install the signal plate to the crankshaft.
a. Position crankshaft and signal plate using a positioning dowel
pin, and tighten mounting bolts.
b. Remove dowel pin.
CAUTION:
Be sure to remove dowel pin.
NOTE:
●Dowel pins of crankshaft and signal plate are provided as a
set for each.
●If dowel pin is not available (when crankshaft and signal plate
are reused), use M6 bolt [length under head: 10 mm (0.39 in)
or longer] as its substitute.
6. Install the crankshaft to the cylinder block.
●While turning the crankshaft by hand, check that it turns smoothly.
7. Install main bearing cap.
●Main bearing cap is identified by identification paint No. made
on it before it is removed.
●Install it with arrow facing to front.
NOTE:
Main bearing cap cannot be replaced as a single part, because it
is machined together with cylinder block.
8. Tighten main bearing bolts in several steps in numerical order
shown in the figure.
●Apply engine oil onto thread and seat of mounting bolt.
●After tightening bolts to specified torque, make sure that
crankshaft rotates smoothly.
●Check crankshaft side clearance. Refer to EM-84, "CRANK-
SHAFT SIDE CLEARANCE" .
9. Install piston to connecting rod.
a. Using snap ring pliers, install snap ring to groove of piston rear side.
●Install with chamfered side facing piston pin side. Refer to EM-70, "Disassembly and Assembly" .
b. Install piston to connecting rod.
●Using hot-air blower, heat piston to 60 to 70°C (140 to 158°F) so that piston pin can be easily inserted
by hand. Insert piston pin into piston and connecting rod from front side of piston.
●Assemble so that front mark on piston head and oil hole in
connecting rod are positioned as shown in the figure.
c. Install snap ring to front side of piston.
●Refer to step “a” to install snap ring.
●After installation, make sure that connecting rod moves
smoothly.
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SEM933F
PBIC0591E

CYLINDER BLOCK
EM-77
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10. Install piston rings with piston ring expander (commercial ser-
vice tool).
CAUTION:
●Be careful not to damage piston.
●When installing top ring, be careful not to break end gap
step.
●Position end gaps of each piston ring to piston front mark as
shown in figure, then install rings.
●Install top ring with stamp mark side facing upward.
11. Install the connecting rod bearings to the connecting rod and the
connecting rod cap.
●When installing the connecting rod bearings, apply engine oil
to the bearing surface (inside). Do not apply oil to the back
surface, but thoroughly clean it.
●When installing, align the connecting rod bearing stopper pro-
trusion with the notch of the connecting rod to install.
●Check the oil holes on the connecting rod and those on the
corresponding bearing are aligned.
12. Install the piston and connecting rod assembly to the crankshaft.
●Position the crankshaft pin corresponding to the connecting
rod to be installed onto the bottom dead center.
●Apply engine oil sufficiently to the cylinder bore, piston and
crankshaft pin.
●Match the cylinder position with the cylinder No. on the con-
necting rod to install.
●Using a piston ring compressor, install the piston with the front
mark on the piston crown facing the front of the engine.
CAUTION:
Be careful not to damage the crankshaft pin, resulting from
an interference of the connecting rod big end.
13. Install the connecting rod cap.
●Match the stamped cylinder number marks on the connecting
rod with those on the cap to install.
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PBIC0482E
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EM-78
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CYLINDER BLOCK
14. Tighten connecting rod nuts with the following procedure.
a. Lubricate connecting rod bolts and seat of nuts with new engine
oil.
b. Tighten to a torque of 13.72 - 15.68 N·m (1.4 - 1.5 kg-m, 10.2 -
11.5 ft-lb)
c. Turn all nuts another 35 to 40 degrees (Target: 35 degrees).
CAUTION:
Always use angle wrench (special service tool). Avoid tight-
ening based on visual check alone.
●After tightening nuts, make sure that crankshaft rotates
smoothly.
●Check connecting rod side clearance. Refer to EM-84, "CONNECTING ROD SIDE CLEARANCE" .
15. Install rear oil seal.
●Use an oil seal drift (commercial service tool) to press it in. At
this time, be careful not to cause any scratches or burrs on
circumference of oil seal.
●Press oil seal into rear oil seal retainer until it does not project
from end.
16. Install rear oil seal retainer.
●Apply continuous bead of liquid gasket to parts shown in fig-
ure.
●Install rear oil seal retainer by aligning it with dowel pins on
cylinder block.
17. Install rear plate.
SEM943F
SEM897A
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