Nissan Almera Tino V10. Instruction — part 836

NOTES

EM-1

ENGINE MECHANICAL

B ENGINE

CONTENTS

C

D

E

F

G

H

I

J

K

L

M

SECTION

EM

A

EM

ENGINE MECHANICAL

QG

PRECAUTIONS . . . . . . . . . . . . . . .. 5

Precautions for Drain Coolant . . . . . . . . .. 5
Precautions for Disconnecting Fuel Piping . . . .. 5
Precautions for Removal and Disassembly . . . . 5
Precautions for Inspection, Repair and Replace-
ment . . . . . . . . . . . . . . . . . . . 5
Precautions for Assembly and Installation . . . ... 5
Parts Requiring Angular Tightening . . . . . . . 5
Precautions for Liquid Gasket . . . . . . . . .. 6

REMOVAL OF LIQUID GASKET SEALING . . .. 6
LIQUID GASKET APPLICATION PROCEDURE. . 6

PREPARATION . . . . . . . . . . . . . . ... 7

Special Service Tools . . . . . . . . . . . ... 7
Commercial Service Tools . . . . . . . . . . 9

NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING . . . . . . . . . . . ...11

NVH Troubleshooting —Engine Noise . . . . . 11
Use the Chart Below to Help You Find the Cause
of the Symptom. . . . . . . . . . . . . . . 12

DRIVE BELTS . . . . . . . . . . . . . . ... 13

Checking Drive Belts . . . . . . . . . . . .. 13
Tension Adjustment . . . . . . . . . . . . 14

POWER STEERING PUMP AND WATER PUMP
BELT . . . . . . . . . . . . . . . . ... 14
ALTERNATOR AND AIR CONDITIONER COM-
PRESSOR BELT . . . . . . . . . . . . . 14

Removal and Installation . . . . . . . . . . 15

REMOVAL . . . . . . . . . . . . . . ... 15
INSTALLATION . . . . . . . . . . . . ... 15

AIR CLEANER AND AIR DUCT . . . . . . . ... 16

Removal and Installation . . . . . . . . . . 16

REMOVAL . . . . . . . . . . . . . . ... 16
INSTALLATION . . . . . . . . . . . . ... 16

Changing Air Cleaner Element . . . . . . . ... 17

INTAKE MANIFOLD . . . . . . . . . . . . . 18

Removal and Installation . . . . . . . . . . 18

REMOVAL . . . . . . . . . . . . . . ... 18
INSPECTION AFTER REMOVAL . . . . . ... 20
INSTALLATION . . . . . . . . . . . . ... 20

EXHAUST MANIFOLD AND CATALYTIC CON-
VERTER . . . . . . . . . . . . . . . . . 21

Removal and Installation . . . . . . . . . . 21

REMOVAL . . . . . . . . . . . . . . ... 22
INSPECTION AFTER REMOVAL . . . . . ... 23
INSTALLATION . . . . . . . . . . . . ... 23

Disassembly and Assembly . . . . . . . . . 24

M/T MODELS . . . . . . . . . . . . . .. 24
A/T MODELS . . . . . . . . . . . . . ... 24
DISASSEMBLY . . . . . . . . . . . . ... 24
ASSEMBLY . . . . . . . . . . . . . . . 24

OIL PAN AND OIL STRAINER . . . . . . . . . 25

Removal and Installation . . . . . . . . . . 25

REMOVAL . . . . . . . . . . . . . . ... 25
INSTALLATION . . . . . . . . . . . . ... 26
INSPECTION AFTER INSTALLATION . . . . 26

IGNITION COIL . . . . . . . . . . . . . . . 27

Removal and Installation . . . . . . . . . . 27

REMOVAL . . . . . . . . . . . . . . ... 27
INSTALLATION . . . . . . . . . . . . ... 27

SPARK PLUG (CONVENTIONAL) . . . . . . ... 28

Removal and Installation . . . . . . . . . . 28

REMOVAL . . . . . . . . . . . . . . ... 28
INSPECTION AFTER REMOVAL . . . . . ... 28
INSTALLATION . . . . . . . . . . . . ... 28

FUEL INJECTOR AND FUEL TUBE . . . . . . 29

Removal and Installation . . . . . . . . . . 29

REMOVAL . . . . . . . . . . . . . . ... 29
INSTALLATION . . . . . . . . . . . . ... 30
INSPECTION AFTER INSTALLATION . . . . 31

ROCKER COVER . . . . . . . . . . . . . . 32

Removal and Installation . . . . . . . . . . 32

REMOVAL . . . . . . . . . . . . . . ... 32
INSTALLATION . . . . . . . . . . . . ... 33

CAMSHAFT . . . . . . . . . . . . . . . .. 35

Removal and Installation . . . . . . . . . . 35

REMOVAL . . . . . . . . . . . . . . ... 35
INSTALLATION . . . . . . . . . . . . ... 38

EM-2

INSPECTION AFTER REMOVAL . . . . . . 42

Valve Clearance . . . . . . . . . . . . . .. 45

INSPECTION . . . . . . . . . . . . . ... 45
ADJUSTMENT (SHIMLESS TYPE) . . . . . 46
ADJUSTMENT (SHIM TYPE) . . . . . . . .. 47

TIMING CHAIN . . . . . . . . . . . . . . .. 50

Removal and Installation . . . . . . . . . . 50

REMOVAL . . . . . . . . . . . . . . ... 50
INSPECTION AFTER REMOVAL . . . . . . 54
INSTALLATION . . . . . . . . . . . . . 54
INSPECTION AFTER INSTALLATION . . . . 56

OIL SEAL . . . . . . . . . . . . . . . . .. 57

Removal and Installation of Valve Oil Seal . . . . 57

REMOVAL . . . . . . . . . . . . . . ... 57
INSTALLATION . . . . . . . . . . . . . 57

Removal and Installation of Front Oil Seal . . . . 58

REMOVAL . . . . . . . . . . . . . . ... 58
INSTALLATION . . . . . . . . . . . . . 58

Removal and Installation of Rear Oil Seal . . . .. 58

REMOVAL . . . . . . . . . . . . . . ... 58
INSTALLATION . . . . . . . . . . . . . 58

CYLINDER HEAD . . . . . . . . . . . . . . 60

On-Vehicle Service . . . . . . . . . . . . . 60

CHECKING COMPRESSION PRESSURE . . . 60

Removal and Installation . . . . . . . . . . 61

REMOVAL . . . . . . . . . . . . . . ... 61
INSTALLATION . . . . . . . . . . . . . 62

Disassembly and Assembly . . . . . . . . . 63

DISASSEMBLY . . . . . . . . . . . . ... 63
ASSEMBLY . . . . . . . . . . . . . . . 64

Inspection After Disassembly . . . . . . . . . 65

CYLINDER HEAD DISTORTION . . . . . . 65
VALVE DIMENSIONS . . . . . . . . . . .. 65
VALVE GUIDE CLEARANCE . . . . . . . .. 66
VALVE GUIDE REPLACEMENT . . . . . . . 66
VALVE SEAT CONTACT . . . . . . . . . . 67
VALVE SEAT REPLACEMENT . . . . . . ... 68
VALVE SPRING SQUARENESS . . . . . . . 69
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD . . . . . . . ... 69

ENGINE ASSEMBLY . . . . . . . . . . . . 70

Removal and Installation . . . . . . . . . . 70

REMOVAL . . . . . . . . . . . . . . ... 71
INSTALLATION . . . . . . . . . . . . . 72
INSPECTION AFTER INSTALLATION . . . . 72

CYLINDER BLOCK . . . . . . . . . . . . ... 74

Disassembly and Assembly . . . . . . . . . 74

DISASSEMBLY . . . . . . . . . . . . ... 75
ASSEMBLY . . . . . . . . . . . . . . . 79

How to Select Piston and Bearing . . . . . . .. 84

DESCRIPTION . . . . . . . . . . . . . 84
HOW TO SELECT PISTON . . . . . . . . . 84
HOW TO SELECT CONNECTING ROD BEAR-
ING . . . . . . . . . . . . . . . . . .. 85

HOW TO SELECT MAIN BEARING . . . . . 86

Inspection After Disassembly . . . . . . . . ..87

CRANKSHAFT SIDE CLEARANCE . . . . . 87
CONNECTING ROD SIDE CLEARANCE . . ...88
PISTON AND PISTON PIN CLEARANCE . . ...88
PISTON RING SIDE CLEARANCE . . . . . .89
PISTON RING END GAP . . . . . . . . . 89
CONNECTING ROD BEND AND TORSION . ...90
CONNECTING ROD BEARING (BIG END) . . 90
CONNECTING ROD BUSHING OIL CLEAR-
ANCE (SMALL END) . . . . . . . . . . ...90
CYLINDER BLOCK DISTORTION . . . . . ..91
INNER DIAMETER OF MAIN BEARING HOUS-
ING . . . . . . . . . . . . . . . . . ...92
PISTON TO CYLINDER BORE CLEARANCE . 92
OUTER DIAMETER OF CRANKSHAFT JOUR-
NAL . . . . . . . . . . . . . . . . . ..93
OUTER DIAMETER OF CRANKSHAFT PIN . ..93
OUT-OF-ROUND AND TAPER OF CRANK-
SHAFT . . . . . . . . . . . . . . . . .93
CRANKSHAFT RUNOUT . . . . . . . . . 94
OIL CLEARANCE OF CONNECTING ROD
BEARING . . . . . . . . . . . . . . . .94
OIL CLEARANCE OF MAIN BEARING . . . ...94
CRUSH HEIGHT OF MAIN BEARING . . . . 95
FLYWHEEL RUNOUT . . . . . . . . . . .95

SERVICE DATA AND SPECIFICATIONS (SDS) . ..96

Standard and Limit . . . . . . . . . . . . ..96

GENERAL SPECIFICATIONS . . . . . . . .96
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD . . . . . . . . . . . . . . . . ...96
DRIVE BELTS . . . . . . . . . . . . . ..96
SPARK PLUG . . . . . . . . . . . . . ..97
CYLINDER HEAD . . . . . . . . . . . . 97
VALVE . . . . . . . . . . . . . . . . ..97
CAMSHAFT AND CAMSHAFT BEARING . . .103
CYLINDER BLOCK . . . . . . . . . . . 104
PISTON, PISTON RING AND PISTON PIN . ..104
CONNECTING ROD . . . . . . . . . . ..105
CRANKSHAFT . . . . . . . . . . . . ...105
MAIN BEARING . . . . . . . . . . . . .106
CONNECTING ROD BEARING . . . . . . .106
MISCELLANEOUS COMPONENTS . . . . ..107

Tightening Torque . . . . . . . . . . . . .107

YD

PRECAUTIONS . . . . . . . . . . . . . ...109

Precautions for Drain Coolant . . . . . . . ...109
Precautions for Disconnecting Fuel Piping . . ...109
Precautions for Removal and Disassembly . . ..109
Precautions for Inspection, Repair and Replace-
ment . . . . . . . . . . . . . . . . . ..109
Precautions for Assembly and Installation . . . 109
Parts Requiring Angular Tightening . . . . . ..109
Precautions for Liquid Gasket . . . . . . . ... 110

REMOVAL OF LIQUID GASKET SEALING . .. 110
LIQUID GASKET APPLICATION PROCEDURE. 110

EM-3

C

D

E

F

G

H

I

J

K

L

M

EM

A

PREPARATION . . . . . . . . . . . . . . 111

Special Service Tools . . . . . . . . . . . 111
Commercial Service Tools . . . . . . . . . .114

NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING . . . . . . . . . . . .115

NVH Troubleshooting —Engine Noise . . . . ..115
Use the Chart Below to Help You Find the Cause
of the Symptom. . . . . . . . . . . . . . 116

DRIVE BELTS . . . . . . . . . . . . . . ..117

Checking Drive Belts . . . . . . . . . . . .117
Tension Adjustment . . . . . . . . . . . ...117

AIR CONDITIONER COMPRESSOR BELT . ..118
ALTERNATOR AND WATER PUMP BELT . . 118

Removal and Installation . . . . . . . . . ...118

REMOVAL . . . . . . . . . . . . . . ..118
INSTALLATION . . . . . . . . . . . . ..118

AIR CLEANER AND AIR DUCT . . . . . . . ..119

Removal and Installation . . . . . . . . . ...119

REMOVAL . . . . . . . . . . . . . . ..119
INSTALLATION . . . . . . . . . . . . ..119
CHANGING AIR CLEANER ELEMENT . . . .119

CHARGE AIR COOLER . . . . . . . . . . . 121

Removal and Installation . . . . . . . . . .. 121

REMOVAL . . . . . . . . . . . . . . . 121
INSPECTION AFTER REMOVAL . . . . . . 122
INSTALLATION . . . . . . . . . . . . . 122

INTAKE MANIFOLD . . . . . . . . . . . ... 123

Removal and Installation . . . . . . . . . .. 123

REMOVAL . . . . . . . . . . . . . . . 123
INSPECTION AFTER REMOVAL . . . . . . 124
INSTALLATION . . . . . . . . . . . . . 124
INSPECTION AFTER INSTALLATION . . . . 125

CATALYST . . . . . . . . . . . . . . . .. 126

Removal and Installation . . . . . . . . . .. 126

REMOVAL . . . . . . . . . . . . . . . 127
INSTALLATION . . . . . . . . . . . . . 127

EXHAUST MANIFOLD AND TURBOCHARGER .. 128

Removal and Installation . . . . . . . . . .. 128

REMOVAL . . . . . . . . . . . . . . . 129
INSTALLATION . . . . . . . . . . . . . 130
INSPECTION AFTER INSTALLATION . . . . 130

Disassembly and Assembly . . . . . . . . . 131

REMOVAL . . . . . . . . . . . . . . . 132
INSPECTION AFTER REMOVAL . . . . . . 132

Turbocharger . . . . . . . . . . . . . . 133

ROTOR SHAFT CLEARANCE . . . . . . . 134
ROTOR SHAFT END PLAY . . . . . . . .. 134
TURBINE WHEEL . . . . . . . . . . . . 134
COMPRESSOR WHEEL . . . . . . . . .. 134
TURBOCHARGER BOOST CONTROL ACTU-
ATOR . . . . . . . . . . . . . . . . 135
TROUBLE DIAGNOSIS OF TURBOCHARGER. 136

OIL PAN AND OIL STRAINER . . . . . . . ... 137

Removal and Installation . . . . . . . . . .. 137

REMOVAL . . . . . . . . . . . . . . . 137
INSPECTION AFTER REMOVAL . . . . . . 139
INSTALLATION . . . . . . . . . . . . . 139
INSPECTION AFTER INSTALLATION . . . . 141

GLOW PLUG . . . . . . . . . . . . . . .. 142

Removal and Installation . . . . . . . . . .. 142

REMOVAL . . . . . . . . . . . . . . . 142
INSTALLATION . . . . . . . . . . . . . 142

VACUUM PUMP . . . . . . . . . . . . . .. 143

Removal and Installation . . . . . . . . . .. 143

INSPECTION BEFORE REMOVAL . . . . .. 143
REMOVAL . . . . . . . . . . . . . . . 143
INSTALLATION . . . . . . . . . . . . . 144
INSPECTION AFTER INSTALLATION . . . .. 144

Disassembly and Assembly . . . . . . . . .. 145

DISASSEMBLY . . . . . . . . . . . . . 145
ASSEMBLY . . . . . . . . . . . . . ... 145

INJECTION TUBE AND FUEL INJECTOR . . . 147

Removal and Installation . . . . . . . . . .. 147

REMOVAL . . . . . . . . . . . . . . . 147
INSTALLATION . . . . . . . . . . . . . 148
INSPECTION AFTER INSTALLATION . . . .. 149

FUEL PUMP . . . . . . . . . . . . . . . 150

Removal and Installation . . . . . . . . . .. 150

REMOVAL . . . . . . . . . . . . . . . 150
INSPECTION AFTER REMOVAL . . . . . . 155
INSTALLATION . . . . . . . . . . . . . 155

ROCKER COVER . . . . . . . . . . . . ... 160

Removal and Installation . . . . . . . . . .. 160

REMOVAL . . . . . . . . . . . . . . . 160
INSTALLATION . . . . . . . . . . . . . 161
INSPECTION AFTER INSTALLATION . . . .. 161

CAMSHAFT . . . . . . . . . . . . . . . 162

Removal and Installation . . . . . . . . . .. 162

REMOVAL . . . . . . . . . . . . . . . 162
INSPECTION AFTER REMOVAL . . . . . . 163
INSTALLATION . . . . . . . . . . . . . 166

Valve Clearance . . . . . . . . . . . . ... 167

INSPECTION . . . . . . . . . . . . . 167
ADJUSTMENTS . . . . . . . . . . . . 168

SECONDARY TIMING CHAIN . . . . . . . . 171

Removal and Installation . . . . . . . . . .. 171

REMOVAL . . . . . . . . . . . . . . . 171
INSPECTION AFTER REMOVAL . . . . . . 173
INSTALLATION . . . . . . . . . . . . . 174

PRIMARY TIMING CHAIN . . . . . . . . . .. 176

Removal and Installation . . . . . . . . . .. 176

REMOVAL . . . . . . . . . . . . . . . 178
INSPECTION AFTER REMOVAL . . . . . . 180
INSTALLATION . . . . . . . . . . . . . 181

CYLINDER HEAD . . . . . . . . . . . . ... 186

On-Vehicle Service . . . . . . . . . . . ... 186

CHECKING COMPRESSION PRESSURE . ... 186

Removal and Installation . . . . . . . . . .. 187

REMOVAL . . . . . . . . . . . . . . . 187
INSPECTION AFTER REMOVAL . . . . . . 188
INSTALLATION . . . . . . . . . . . . . 188

Disassembly and Assembly . . . . . . . . .. 191

DISASSEMBLY . . . . . . . . . . . . . 191
ASSEMBLY . . . . . . . . . . . . . ... 192
INSPECTION AFTER DISASSEMBLY . . . .. 192