2003 NISSAN ALMERA N16 crankshaft

JEM143G
12. Install chain case cover (for opening for power steering pump
removal/installation) to oil pump.
Apply a continuous bead of specified liquid gasket (Refer to
EM-3, “Liquid Gasket Application Procedure”.) as shown in the
figure.
Apply liquid gasket on oil pump-side surface.
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13. Install oil pump.
a. Apply a continuous bead of specified liquid gasket (Refer to
EM-3, “Liquid Gasket Application Procedure”.) on locations
shown in the figure.
A: Leave the start and end areas of the bead slightly protrud-
ing from the surface.
B: Apply liquid gasket along upper end surface of oil pump.
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b. Install oil pump drive spacer to crankshaft.
Install with the front mark (punched mark) facing the front of
the engine.
c. Install O-ring into the groove of rear chain case.
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d. Install oil pump.
When installing, align the inner rotor in the direction of the two
facing flats of the oil pump drive spacer.
When installing, align the dowel pin with the pin hole.
e. Tighten fixing bolts in the numerical order shown in the figure.
f. After tightening all the bolts, re-tighten in the same order.
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14. Check gaps on upper oil pan mounting surface.
Using straightedge and feeler gauge, measure gaps between
the locations of the following parts:
Standard:
Oil pump and rear chain case
–0.14 to 0.14 mm (–0.0055 to 0.0055 in)
Rear chain case and cylinder block
–0.25 to 0.13 mm (–0.0098 to 0.0051 in)
If the measured value is out of the above range, install again.
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TIMING CHAINYD
Primary Timing Chain (Cont’d)
EM-31

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15. Install crankshaft pulley.
a. Install crankshaft pulley to crankshaft.
b. Hold crankshaft pulley with the pulley holder (SST).
c. Tighten bolt to 20 to 29 N·m (2.0 to 3.0 kg-m, 15 to 21 ft-lb).
d. Put an alignment mark on crankshaft pulley that aligns with
one of the punched marks on the bolt.
e. Tighten fixing bolt another 60° - 66° [target: 60° (turn by one
notch)].
16. Install secondary timing chain and the associated parts.
Refer to EM-22, “Secondary Timing Chain”, “INSTALLATION”.
17. Install in the reverse order of removal hereafter.
TIMING CHAINYD
Primary Timing Chain (Cont’d)
EM-32

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-43, “Changing Engine Cool-
ant”.
2. Remove exhaust manifold. Refer to EM-38, “Removal”.
3. Remove intake manifold. Refer to EM-34, “Removal”.
Apply paint to camshaft sprockets for alignment during
installation.
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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
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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.
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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-46

Installation=NJEM0067Before installation, remove old liquid gasket from mating
surface of all liquid gasket applied parts.
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CYLINDER HEAD GASKET SELECTIONNJEM0067S01Select 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
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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 “0” 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.
CYLINDER HEADYD
Installation
EM-56

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3. Install camshaft brackets.
Install correctly, identifying brackets by the journal No. and
front mark on top surface.
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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. Tightento12to13N·m(1.2to1.4kg-m,9to10ft-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-59,
“Valve Clearance”.
7. Hereafter, install in the reverse order of removal.
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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.)
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2. Put an alignment mark with paint, etc. on the crankshaft pul-
ley and on the oil pump as an angle indicator.
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CYLINDER HEADYD
Installation (Cont’d)
EM-59

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3. Check only those valves shown in the figure.
Crank positionValve
No. 1 No. 2 No. 3 No. 4
INT EXH INT EXH INT EXH INT EXH
No. 1 TDC
(Compression
stroke)
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Using a feeler gauge, measure clearance between valve lifter
and camshaft.
Record any valve clearance measurements which are out of
specification. They will be used later to determine the required
replacement adjusting shim.
Valve clearance for checking (Cold):
Intake
0.24 - 0.32 mm (0.0094 - 0.0126 in)
Exhaust
0.26 - 0.34 mm (0.0102 - 0.0134 in)
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4. Rotate crankshaft clockwise by one turn to set the No. 4 pis-
ton to TDC on the compression stroke.
5. Check only those valves shown in the figure.
Crank positionValve
No. 1 No. 2 No. 3 No. 4
INT EXH INT EXH INT EXH INT EXH
No. 4 TDC
(Compression
stroke)
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ADJUSTINGNJEM0068S02Adjust valve clearance while engine is cold.
1. Turn crankshaft, to position cam lobe on camshaft of valve that
must be adjusted upward.
2. Place Tool (A) around camshaft as shown in figure.
Before placing Tool (A) (SST), rotate notch toward center
of cylinder head (See figure.), to simplify shim removal
later.
CAUTION:
Be careful not to damage cam surface with Tool (A).
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3. Rotate Tool (A) (See figure.) so that valve lifter is pushed down.
CYLINDER HEADYD
Valve Clearance (Cont’d)
EM-60

crankshaft position sensor (TDC sensor) from the assem-
bly.
Always pay extra attention not to damage edge of crank-
shaft position sensor (TDC sensor) or ring gear teeth.
REMOVALNJEM0069S011. Remove engine undercover, and hood for hoisting.
2. Drain coolant from both cylinder block and radiator. Refer to
LC-43, “Changing Engine Coolant”.
3. Remove the following parts:
Battery
RH and LH front wheels
RH and LH splash covers (combined with undercover)
Auxiliary belts
Alternator
Alternator brackets
Radiator and cooling fan
Engine cover
Air ducts and air cleaner case
LH side of engine room:
4. Disconnect all harnesses and grounds that are connected to
components on vehicle.
5. Disconnect vacuum hose on vacuum pump side.
6. Disconnect fuel feed and fuel return hoses on engine side.
Immediately put blind plugs into the openings to prevent
fuel from flowing out.
7. Disconnect heater hose. Plug opening of hose to prevent cool-
ant from flowing out.
RH side of engine room:
8. Remove air conditioner compressor from brackets and move
it toward vehicle side. Secure compressor on vehicle side with
rope.
Vehicle underside:
9. Remove exhaust front tube.
10. Disconnect two hoses from power steering pump and plug to
stop fluid.
11. Remove M/T control rod and support rod.
12. Remove ABS wheel sensor, and temporarily hang brake cali-
per with rope on vehicle side.
13. Remove RH and LH drive shafts.
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14. Install engine slingers to cylinder head.
: 30 - 37 N·m (3.0 - 3.8 kg-m, 22 - 27 ft-lb)
Use engine slingers and securing bolts of the specified
service parts.
15. Lift up vehicle to appropriate level where work can be per-
formed efficiently. Using two transmission jacks, securely sup-
port engine oil pan and bottom surface of transaxle.
ENGINE ASSEMBLYYD
Removal and Installation (Cont’d)
EM-64

Removal and InstallationNJEM0071CAUTION:
When installing bearings, pistons, or other sliding parts,
lubricate contacting surfaces with new engine oil.
Place removed parts such as bearings and bearing caps
in their proper order and direction.
When installing connecting rod nuts, and main bearing
cap bolts, apply new engine oil to threads and seating
surfaces.
Do not allow any magnetic materials to contact the signal
plate of flywheel.
Do not remove the signal plate at back.
Do not place the signal plate side facing under.
Handle with care so as not to damage the signal plate
[especially four places on protrusions for signal of crank
position sensor (TDC sensor)].
DisassemblyNJEM0072PISTON AND CRANKSHAFTNJEM0072S011. Remove engine. Refer to “ENGINE ASSEMBLY”, “Removal
and Installation”, EM-63.
2. Place engine on a work stand.
a. Remove flywheel.
Hold ring gear with ring gear stopper (KV10105630,
KV10105610). Then, loosen securing bolts with TORX socket
(size: Q8 E20, Commercial Service Tool) and remove them.
As an alternative method, hold the crankshaft pulley with a
pulley holder (SST) to remove the flywheel.
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b. Install engine sub-attachment (SST) to rear surface of cylinder
block.
To install, align the hole on the sub-attachment with the knock
pin on the cylinder block.
The engine sub-attachment has five bolts.
c. Install engine attachment (SST).
The four sets of bolts and nuts are multi-purpose products.
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CYLINDER BLOCKYD
Removal and Installation
EM-67