2003 NISSAN ALMERA N16 crankshaft

CYLINDER BLOCK
EM-79
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18. Install flywheel or drive plate.
●Install drive plate in direction shown in figure.
●Fix crankshaft with ring gear stopper (special service tool).
●Tighten mounting bolts diagonally in several steps.
19. Install oil level gauge guide.
●Press it in with punch mark for installing instruction in direction
shown in figure.
●Apply locking agent to pressed position.
20. Install knock sensor.
●Install sensor with connector facing lower right by 45° as
shown.
CAUTION:
●If any impact by dropping is applied to the knock sensor,
replace it with new one.
●Make sure that there is no foreign material on the cylin-
der block mating surface and the back surface of the
knock sensor.
●Do not tighten the mounting bolts while holding the con-
nector.
●Make sure that the knock sensor does not interfere with other parts.
21. Install crankshaft position sensor (POS).
●Tighten bolt after fully inserting crankshaft position sensor (POS) into cylinder block.
22. Tighten accessory brackets to the following tightening torque.
23. Assemble in the reverse order of disassembly.
PBIC0595E
PBIC0596E
Power steering pump bracket:
: 16.7 - 23.5 N·m (1.7 - 2.4 kg-m, 13 - 17 ft-lb)
Alternator air conditioner compressor bracket:
: 33.3 - 46.1 N·m (3.4 - 4.7 kg-m, 25 - 34 ft-lb)
PBIC0597E

EM-80
[QG]
CYLINDER BLOCK
How to Select Piston and Bearing
EBS00LQN
DESCRIPTION
*For the service parts, the grade for fitting cannot be selected between a piston pin and a connecting rod.
(Only 0 grade is available.) The information at the shipment from the plant is described as a reference.
●The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
●For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
●For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
HOW TO SELECT PISTON
When New Cylinder Block is Used
●Check the cylinder bore grade (1,2 or 3) on rear lower surface of
cylinder block, and select a piston of the same grade.
●QG15DE
Selection points Selection parts Selection items Selection methods
Between cylinder block to
crankshaftMain bearingMain bearing grade (bearing
thickness)Determined by match of cylin-
der block bearing housing
grade (inner diameter of hous-
ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Between crankshaft to connect-
ing rodConnecting rod bearingConnecting rod bearing grade
(bearing thickness)Connecting rod bearing grade
= crankshaft pin grade (outer
diameter of pin). No grade
exists for inner diameter to con-
necting rod large end.
Between cylinder block to pis-
tonPiston and piston pin assembly
The piston is available together
with piston pin as an assembly.Piston grade (piston outer
diameter)Piston grade = cylinder bore
grade (inner diameter of bore)
*Between piston to connecting
rod———
PBIC0598E
YEM055

CYLINDER BLOCK
EM-81
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●QG18DE
When Cylinder Block is Reused
1. Measure the cylinder block bore inner diameter.
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner
diameter of the “Piston Selection Table”. Select the piston of the same grade.
Piston Selection Table
QG15DE
Unit: mm (in)
QG18DE
Unit: mm (in)
CAUTION:
No stamp mark is only applied to piston side.
NOTE:
●The piston is available together with piston pin as an assembly.
●The piston pin (piston pin bore) grade is provided only for the parts installed at the plant. For service parts,
no grades can be selected. (Only 0 grade is available.)
HOW TO SELECT CONNECTING ROD BEARING
When New Connecting Rod and Crankshaft are Used
●Compare the pin diameter grade (0, 1 or 2) of the crankshaft on
front surface with the values of the selection table of connecting
rod bearing.
NOTE:
There is no grading for connecting rod big end.
When Crankshaft and Connecting Rod are Reused
1. Confirm connecting rod big end inner diameter is within the standard.
2. Measure the pin outer diameter of the crankshaft.
YEM056
Grade number (Mark) 1 2 (or no punching) 3
Inner diameter of cylinder bore73.600 - 73.610
(2.8976 - 2.8980)73.610 - 73.620
(2.8980 - 2.8984)73.620 - 73.630
(2.8984 - 2.8988)
Outer diameter of piston73.575 - 73.585
(2.8966 - 2.8970)73.585 - 73.595
(2.8970 - 2.8974)73.595 - 73.605
(2.8974 - 2.8978)
Grade number (Mark) 1 2 (or no punching) 3
Inner diameter of cylinder bore80.000 - 80.010
(3.1496 - 3.1500)80.010 - 80.020
(3.1500 - 3.1504)80.020 - 80.030
(3.1504 - 3.1508)
Outer diameter of piston79.965 - 79.975
(3.1482 - 3.1486)79.975 - 79.985
(3.1486 - 3.1490)79.985 - 79.995
(3.1490 - 3.1494)
PBIC0606E

EM-82
[QG]
CYLINDER BLOCK
3. Find measured dimension in “Crankshaft pin outer diameter” column in selective-fit service parts table,
and select connecting rod bearing of same grade number.
Connecting Rod Bearing Selection Table
Unit: mm (in)
Undersize Bearings Usage Guide
●When the specified oil clearance is not obtained with standard size connecting rod bearings, use under-
size (US) bearings.
●When using undersize bearing, measure the bearing inner diameter with bearing installed, and grind the
crankshaft pin so that the oil clearance satisfies the standard.
Bearing undersize table
Unit: mm (in)
CAUTION:
In grinding the crankshaft pin to use undersize bearings, keep
the fillet R (All crankshaft pins).
HOW TO SELECT MAIN BEARING
When New Cylinder Block and Crankshaft are Used
1. Apply main bearing housing grade (0, 1 or 2) on bottom of cylin-
der block banks to row in main bearing selection table.
Connecting rod big end ID 43.000 - 43.013 (1.6929 - 1.6934)
Crankshaft pin OD Grade (punched) 0 (no punching)
39.968 - 39.974
(1.5735 - 1.5738)0
●Bearing grade No.
●Bearing thickness
●Oil clearance
●Identification colorSTD 0
1.503 - 1.506 (0.0592 - 0.0593)
0.014 - 0.039 (0.0006 - 0.0015)
Black
39.962 - 39.968
(1.5733 - 1.5735)1
●Bearing grade No.
●Bearing thickness
●Oil clearance
●Identification colorSTD 1
1.506 - 1.509 (0.0593 - 0.0594)
0.014 - 0.039 (0.0006 - 0.0015)
Red
39.956 - 39.962
(1.5731 - 1.5733)2
●Bearing grade No.
●Bearing thickness
●Oil clearance
●Identification colorSTD 2
1.509 - 1.512 (0.0594 - 0.0595)
0.014 - 0.039 (0.0006 - 0.0015)
Green
Size Thickness
US 0.08 (0.0031) 1.542 - 1.546 (0.0607 - 0.0609)
US 0.12 (0.0047) 1.562 - 1.566 (0.0615 - 0.0617)
US 0.25 (0.0098) 1.627 - 1.631 (0.0641 - 0.0642)
PBIC0491E
PBIC0598E

CYLINDER BLOCK
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2. Apply journal diameter grade (0, 1 or 2) on crankshaft front to
column in main bearing selection table.
3. Select main bearing (STD 0 - 4) at the point where selected row
and column meet in following main bearing selection table.
When Cylinder Block and Crankshaft are Reused
1. Measure dimension of main bearing housing on cylinder block.
2. Find measured dimension in “Cylinder block main bearing housing inner diameter” row in following main
bearing selection table.
3. Measure crankshaft journal diameter.
4. Find measured dimension in “Crankshaft journal outer diameter” column in following main bearing selec-
tion table.
5. Select main bearing (STD 0 - 4) at the point where selected row and column meet in following main bear-
ing selection table.
Main Bearing Selection Table
Unit: mm (in)
Use Undersize Bearing Usage Guide
●Use undersize (US) bearing when oil clearance with standard size main bearing is not within specification.
●When using undersize (US) bearing, measure the bearing inner diameter with bearing installed, and grind
journal until oil clearance falls within specification.
PBIC0607E
Connecting block main bearing housing ID53.644 - 53.652
(2.1120 - 2.1123)53.652 - 53.660
(2.1123 - 2.1126)53.660 - 53.668
(2.1126 - 2.1129)
Crankshaft journal
ODGrade
(punched)012
49.956 - 49.964
(1.9668 - 1.9671)0
●Bearing grade No.
●Bearing thickness
●Oil clearance
●Identification colorSTD 0
1.826 - 1.830
(0.0719 - 0.0720)
0.020 - 0.044
(0.0008 - 0.0017)
BlackSTD 1
1.830 - 1.834
(0.0720 - 0.0722)
0.020 - 0.044
(0.0008 - 0.0017)
RedSTD 2
1.834 - 1.838
(0.0722 - 0.0724)
0.020 - 0.044
(0.0008 - 0.0017)
Green
49.948 - 49.956
(1.9665 - 1.9668)1
●Bearing grade No.
●Bearing thickness
●Oil clearance
●Identification colorSTD 1
1.830 - 1.834
(0.0720 - 0.0722)
0.020 - 0.044
(0.0008 - 0.0017)
RedSTD 2
1.834 - 1.838
(0.0722 - 0.0724)
0.020 - 0.044
(0.0008 - 0.0017)
GreenSTD 3
1.838 - 1.842
(0.0724 - 0.0725)
0.020 - 0.044
(0.0008 - 0.0017)
Ye l l o w
49.940 - 49.948
(1.9661 - 1.9665)2
●Bearing grade No.
●Bearing thickness
●Oil clearance
●Identification colorSTD 2
1.834 - 1.838
(0.0722 - 0.0724)
0.020 - 0.044
(0.0008 - 0.0017)
GreenSTD 3
1.838 - 1.842
(0.0724 - 0.0725)
0.020 - 0.044
(0.008 - 0.0017)
Ye l l o wSTD 4
1.842 - 1.846
(0.0725 - 0.0727)
0.020 - 0.044
(0.0008 - 0.0017)
Blue

EM-84
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CYLINDER BLOCK
Bearing undersize table
Unit: mm (in)
CAUTION:
Keep fillet R when grinding crankshaft journal in order to use
undersize bearing (All journals).
Inspection After DisassemblyEBS00LQO
CRANKSHAFT SIDE CLEARANCE
●Using a dial gauge, measure the clearance between the thrust
bearings and the crankshaft arm when the crankshaft is moved
fully forward or backward.
●If the measured value exceeds the limit, replace the thrust bear-
ings, and measure again. If it still exceeds the limit, replace the
crankshaft also.
CONNECTING ROD SIDE CLEARANCE
●Measure side clearance between connecting rod and crankshaft
arm with feeler gauge.
●If the measured value exceeds the limit, replace the connecting
rod bearings, and measure again. If it still exceeds the limit,
replace the crankshaft also.
PISTON AND PISTON PIN CLEARANCE
Inner Diameter of Piston Pin
●Measure the inner diameter of piston pin bore with an inside
micrometer.
Size Thickness
US 0.25 (0.0098) 1.960 - 1.964 (0.0722 - 0.0773)
US 0.50 (0.0197) 2.085 - 2.089 (0.0821 - 0.0822)
PBIC0491E
Standard : 0.060 - 0.260 mm (0.0024 - 0.0102 in)
Limit : 0.3 mm (0.012 in)
PBIC0608E
Standard : 0.200 - 0.470 mm (0.0079 - 0.0185 in)
Limit : 0.5 mm (0.020 in)
PBIC0609E
Standard:
QG15DE : 18.987 - 18.999 mm (0.7475 - 0.7480 in)
QG18DE : 18.993 - 18.999 mm (0.7478 - 0.7480 in)
PBIC0116E

EM-90
[QG]
CYLINDER BLOCK
3. Cut cylinder bores.
●When any cylinder needs boring, all other cylinders must also be bored.
●Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter
at a time.
4. Hone cylinders to obtain specified piston-to-bore clearance.
5. Measure finished cylinder bore for out-of-round and taper.
●Measurement should be done after cylinder bore cools down.
OUTER DIAMETER OF CRANKSHAFT JOURNAL
●Measure outer diameter of crankshaft journals.
OUTER DIAMETER OF CRANKSHAFT PIN
●Measure outer diameter of crankshaft pin.
OUT-OF-ROUND AND TAPER OF CRANKSHAFT
●Using a micrometer, measure the dimensions at 4 different
points shown in the figure on each journal and pin.
●Out-of-round is indicated by the difference in dimensions
between A and B at 1 and 2.
●Taper is indicated by the difference in dimension between 1 and
2 at A and B.
CRANKSHAFT RUNOUT
●Place a V-block on a precise flat table to support the journals on
the both end of the crankshaft.
●Place a dial gauge straight up on the No. 3 journal.
●While rotating the crankshaft, read the movement of the pointer
on the dial gauge. (Total indicator reading)Standard : 49.940 - 49.964 mm (1.9661 - 1.9671 in) dia.
Standard : 39.956 - 39.974 mm (1.5731 - 1.5738 in) dia.
PBIC0270E
Limit:
Out-of-round (A – B) : 0.005 mm (0.0002 in)
Taper (1 – 2) : 0.005 mm (0.0002 in)
PBIC0614E
Limit: : 0.10 mm (0.004 in)
PBIC0271E

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