Nissan Almera Tino V10 (2001 year). Manual

SEM052G

17. Install rocker cover and oil separator.

Be sure to install washers between bolts and rocker cover.

Tightening procedure

STEP 1: Tighten bolts 1 - 10 - 11 - 13 - 8 in that order.
STEP 2: Tighten bolts 1 - 13 in that order.

: 8 - 10 N·m (0.8 - 1.0 kg-m, 69 - 87 in-lb)

18. Install the following parts:

Spark plugs and leads

Radiator
Refit hoses and refill with coolant.
Refer to LC-38, “Changing Engine Coolant”.

Front RH wheel

Engine under covers

19. Connect the following:

Vacuum hoses

Fuel hoses

Wire harnesses and connectors

Air duct to intake manifold

Front exhaust tube

CYLINDER HEAD

Installation (Cont’d)

EM-129

Removal and Installation

NLEM0137

NEM354

Stopper

Bracket

Front insulator assembly

Center member

Pad

Right insulator assembly

Bracket

Rear insulator assembly

Left insulator assembly

WARNING:

Position vehicle on a flat and solid surface.

Place chocks at front and back of rear wheels.

Do not remove engine until exhaust system has com-
pletely cooled off, otherwise you may burn yourself and/or
fire may break out in fuel line.

Before disconnecting fuel hose, release pressure. Refer to
EC-578, “Fuel Pressure Release”.

Before removing front axle from transaxle, place safety
stands under designated front supporting points. Refer to
GI-43, “Garage Jack and Safety Stand”.

Be sure to lift engine and transaxle in a safe manner.

For engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG.

CAUTION:

When lifting engine, be sure to clear surrounding parts.
Use special care near accelerator wire casing, brake lines
and brake master cylinder.

In lifting the engine, always use engine slingers in a safe
manner.

In removing drive shaft, be careful not to damage grease
seal of transaxle.

Before separating engine and transaxle, remove the

ENGINE ASSEMBLY

Removal and Installation

EM-130

crankshaft position sensor (OBD) from the assembly.

Always be extra careful not to damage edge of crankshaft
position sensor (OBD) or ring gear teeth.

SEM174D

REMOVAL

NLEM0137S01

Remove engine under covers and engine side cover.

Drain coolant from both cylinder block and radiator. Refer to
LC-38, “Changing Engine Coolant”.

Drain engine oil.

Remove air cleaner assembly and duct.

Remove the battery and battery tray.

Disconnect the following:

Vacuum hoses

Heater hoses

A/T cooler hoses

Power steering hoses

Fuel lines

Wires

Harnesses and connectors

Throttle cable

Remove the cooling fans, radiator and reservoir tank.

Remove front LH and RH wheels and drive shafts. Refer to
AX-10, “Drive Shaft”.

Remove front exhaust pipe.

10. Remove starter and intake manifold support.
11. Remove the drive belts.
12. Remove power steering oil pump and A/C compressor.
13. Set a suitable transmission jack under transaxle. Lift engine

with engine slinger.

SEM092D

14. Remove center member.
15. Remove generator and adjusting bracket.

ENGINE ASSEMBLY

Removal and Installation (Cont’d)

EM-131

Components

NLEM0138

NEM350

Rear oil seal retainer

Cylinder block

Water pump

Power steering oil pump adjusting
bar

Front cover with oil pump

Oil strainer

Thrust bearing

Crankshaft

Connecting rod bushing

10. Piston rings
11. Piston
12. Piston pin
13. Connecting rod
14. Connecting rod bearing
15. Aluminum oil pan
16. Rear cover plate
17. Oil pan drain plug

18. Steel oil pan
19. Baffle plate
20. Main bearing cap
21. Pilot converter
22. Drive plate
23. Reinforcement plate
24. Rear plate
25. Main bearing

CYLINDER BLOCK

Components

EM-133

Removal and Installation

NLEM0139

CAUTION:

When installing sliding parts (bearings, pistons, etc.),
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 sur-
faces.

Do not allow any magnetic materials to contact the ring
gear teeth of drive plate.

SEM141FA

Disassembly

NLEM0140

PISTON AND CRANKSHAFT

NLEM0140S01

Place engine on engine stand (ST0501S000).

Remove cylinder head and timing chain.
Refer to EM-97, EM-109.

Remove oil pan.
Refer to EM-91.

SEM877B

Remove pistons with connecting rods.

To disassemble piston and connecting rod, first remove snap
rings. Heat piston to 60 to 70°C (140 to 158°F) then use pis-
ton pin press to remove pin.

When piston rings are not replaced, make sure that piston
rings are mounted in their original positions.

When replacing piston rings, if there is no punch mark,
install with either side up.

Remove rear oil seal retainer.

SEM068G

Remove main bearing cap and crankshaft as shown.

Bolts should be loosened in two or three steps.

AEM023

Inspection

NLEM0141

PISTON AND PISTON PIN CLEARANCE

NLEM0141S01

Measure inner diameter of piston pin hole “dp”.

Standard diameter “dp”:

21.993 - 22.005 mm (0.8659 - 0.8663 in)

CYLINDER BLOCK

Removal and Installation

EM-134

AEM024

Measure outer diameter of piston pin “Dp”.

Standard diameter “Dp”:

21.989 - 22.001 mm (0.8657 - 0.8622 in)

Calculate interference fit of piston pin to piston.

dp - Dp: 0.002 - 0.006 mm (0.0001 - 0.0002 in)

If it exceeds the above value, replace piston assembly with pin.

SEM024AA

PISTON RING SIDE CLEARANCE

NLEM0141S02

Side clearance:

Top ring

0.040 - 0.080 mm (0.0016 - 0.0031 in)

2nd ring

0.030 - 0.070 mm (0.0012 - 0.0028 in)

Max. limit of side clearance:

0.1 mm (0.004 in)

If out of specification, replace piston ring. If clearance exceeds
maximum limit with new ring, replace piston.

SEM822B

PISTON RING END GAP

NLEM0141S03

End gap:

Top ring 0.20 - 0.39 mm (0.0079 - 0.0154 in)
2nd ring 0.35 - 0.59 mm (0.0138 - 0.0232 in)
Oil ring 0.20 - 0.69 mm (0.0079 - 0.0272 in)

Max. limit of ring gap:

1.00 mm (0.0209 in)

If out of specification, replace piston ring. If gap exceeds maximum
limit with a new ring, rebore cylinder and use oversized piston and
piston rings. Refer to SDS, EM-153.

When replacing the piston, check cylinder block surface for
scratches or seizure. If scratches or seizure are found, hone
or replace the cylinder block.

CYLINDER BLOCK

Inspection (Cont’d)

EM-135

SEM038F

SEM003F

CONNECTING ROD BEND AND TORSION

NLEM0141S04

Bend:

Limit 0.15 mm (0.0059 in)
per 100 mm (3.94 in) length

Torsion:

Limit 0.30 mm (0.0118 in)
per 100 mm (3.94 in) length

If it exceeds the limit, replace connecting rod assembly.

AEM156

CYLINDER BLOCK DISTORTION AND WEAR

NLEM0141S05

Clean upper surface of cylinder block.
Use a reliable straightedge and feeler gauge to check the flatness
of cylinder block surface. Check along six positions shown in fig-
ure.

Block surface flatness:

Standard Less than 0.03 mm (0.0012 in)
Limit 0.10 mm (0.0039 in)

If out of specification, resurface it.
The limit for cylinder block resurfacing is determined by the amount
of cylinder head resurfacing.

SEM008D

Amount of cylinder head resurfacing is “A”.
Amount of cylinder block resurfacing is “B”.

The maximum limit is as follows:

A + B = 0.2 mm (0.008 in)

Nominal cylinder block height
from crankshaft center:

211.25 - 211.35 mm (8.3169 - 8.3208 in)

If necessary, replace cylinder block.

CYLINDER BLOCK

Inspection (Cont’d)

EM-136

SEM363EA

SEM011D

PISTON-TO-BORE CLEARANCE

NLEM0141S06

Using a bore gauge, measure cylinder bore for wear, out-of-
round and taper.

Standard inner diameter:

86.000 - 86.030 mm (3.3858 - 3.3870 in)

Wear limit:

0.20 mm (0.0079 in)

Out-of-round (X − Y) standard:

0.015 mm (0.0006 in)

Taper (A − B and A − C) standard:

0.010 mm (0.0004 in)

If it exceeds the limit, rebore all cylinders. Replace cylinder
block if necessary.

Check for score and seizure. If seizure is found, hone it.

If cylinder block and piston are replaced, match piston
grade with grade number on cylinder block upper surface.

SEM085G

Measure piston skirt diameter.

Piston diameter “A”: Refer to SDS, EM-153.
Measuring point “a” (Distance from the top):

45.0 mm (1.772 in)

Check that piston-to-bore clearance is within specification.

Piston-to-bore clearance = bore measurement “C” −
Piston diameter “A”:

0.010 - 0.030 mm (0.0004 - 0.0012 in)

Determine piston oversize according to amount of cylinder
wear.

Oversize pistons are available for service. Refer to SDS,
EM-153.
6.

Cylinder bore size is determined by adding piston-to-bore
clearance to piston diameter “A”.

Rebored size calculation:

D = A + B − C

where,
D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)

SEM069G

Install main bearing caps and tighten bolts to the specified
torque. This will prevent distortion of cylinder bores, otherwise
cylinder bores may be distorted in final assembly.

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 at a time.

Hone cylinders to obtain specified piston-to-bore clearance.

10. Measure finished cylinder bore for out-of-round and taper.

CYLINDER BLOCK

Inspection (Cont’d)

EM-137

Measurement should be done after cylinder bore cools
down.

SEM316A

CRANKSHAFT

NLEM0141S07

Check crankshaft main and pin journals for score, wear or
cracks.

With a micrometer, measure journals for taper and out-of-
round.

Out-of-round (X − Y):
Taper (A − B):

Main journal: Less than 0.005 mm (0.0002 in)
Pin journal: Less than 0.003 mm (0.0001 in)

SEM434

Measure crankshaft runout.

Runout (Total indicator reading):

Less than 0.05 mm (0.0020 in)

SEM685D

SEM070G

BEARING CLEARANCE

NLEM0141S08

Use Method A or Method B. Method A is preferred because it
is more accurate.

Method A (Using bore gauge and micrometer)

Main bearing

NLEM0141S0801

Set main bearings in their proper positions on cylinder block
and main bearing cap.

Install main bearing cap and main bearing beam to cylinder
block.

Tighten all bolts in correct order in two or three stages. Refer
to EM-143.
3.

Measure inner diameter “A” of each main bearing.

CYLINDER BLOCK

Inspection (Cont’d)

EM-138

AEM026

Measure outer diameter “Dm” of each crankshaft main journal.

Calculate main bearing clearance.

Main bearing clearance = A − Dm

Standard: 0.004 - 0.022 mm (0.0002 - 0.0009 in)
Limit: 0.050 mm (0.0020 in)

If it exceeds the limit, replace bearing.

If clearance cannot be adjusted within the standard of any
bearing, grind crankshaft main journal and use undersized
bearing.

SEM964

When grinding crankshaft journal, confirm that “L” dimen-
sion in fillet roll is more than the specified limit.

“L”: 0.1 mm (0.004 in)

Refer to SDS, EM-155 for grinding crankshaft and avail-
able service parts.

SEM313D

If crankshaft is replaced, select thickness of main bearings as
follows:

Grade number of each cylinder block main journal is punched
on the respective cylinder block. These numbers are punched
in either Arabic or Roman numerals.

SEM013D

SEM203D

Grade number of each crankshaft main journal is punched on
the respective crankshaft. These numbers are punched in
either Arabic or Roman numerals.

Select main bearing with suitable thickness according to the
following table.

How to Select Main Bearings (Identification Mark and
Color)

NLEM0141S0804

Crankshaft main

journal grade

number

Cylinder block main journal grade number

(A, Black)

(B, Red)

(C, Green)

(D, Yellow)

(B, Red)

(C, Green)

(D, Yellow)

(E, Blue)

(C, Green)

(D, Yellow)

(E, Blue)

(F, Pink)

(D, Yellow)

(E, Blue)

(F, Pink)

(G, White)

For example:

Cylinder block main journal grade number: 1

CYLINDER BLOCK

Inspection (Cont’d)

EM-139

Crankshaft main journal grade number: 2
Main bearing grade number = 1 + 2 = 3 (D, Yellow)

AEM027

Connecting Rod Bearing (Big end)

NLEM0141S0802

Install connecting rod bearing to connecting rod and cap.

Install connecting rod cap to connecting rod.

Tighten bolts to the specified torque. Refer to EM-143.
3.

Measure inner diameter “C” of each bearing.

AEM028

SEM013D

SEM204D

Measure outer diameter “Dp” of corresponding crankshaft pin
journal.

Calculate connecting rod bearing clearance.

Connecting rod bearing clearance = C − Dp

Standard: 0.020 - 0.045 mm (0.0008 - 0.0018 in)
Limit: 0.065 mm (0.0026 in)

If it exceeds the limit, replace bearing.

If clearance cannot be adjusted within the standard of any
bearing, grind crankshaft journal and use undersized bearing.
Refer to EM-155 for fillet roll remarks, grinding crankshaft and
available service parts.

If crankshaft is replaced with a new one, select connecting rod
bearing according to the following table.
Connecting rod bearing grade number:
These numbers are punched in either Arabic or Roman numer-
als.

Crank pin grade number

Connecting rod bearing grade number

Identification color:

Grade 0; Black or Yellow
Grade 1; Brown or Red
Grade 2; Green or Blue

CYLINDER BLOCK

Inspection (Cont’d)

EM-140

EM142

Method B (Using Plastigage)

CAUTION:

Do not turn crankshaft or connecting rod while Plastigage
is being inserted.

If incorrect bearing clearance exists, use a thicker or
undersized main bearing to ensure specified clearance.

AEM029

CONNECTING ROD BUSHING CLEARANCE (SMALL
END)

NLEM0141S09

Measure inner diameter “C” of bushing.

AEM030

Measure outer diameter “Dp” of piston pin.

Calculate connecting rod bushing clearance.

Connecting rod bushing clearance = C − Dp

Standard:

0.005 - 0.017 mm (0.0002 - 0.0007 in)

Limit:

0.023 mm (0.0009 in)

If it exceeds the limit, replace connecting rod assembly or
connecting rod bushing and/or piston set with pin.

SEM062A

REPLACEMENT OF CONNECTING ROD BUSHING
(SMALL END)

NLEM0141S10

Drive in small end bushing until it is flush with end surface of
rod.

Be sure to align the oil holes.
2.

Ream the bushing so that clearance with piston pin is within
specification.

Clearance between connecting rod bushing and piston
pin:

0.005 - 0.017 mm (0.0002 - 0.0007 in)

SEM916AB

REPLACEMENT OF PILOT CONVERTER (CVT)

NLEM0141S13

Remove pilot converter using Tool or suitable tool.

CYLINDER BLOCK

Inspection (Cont’d)

EM-141

SEM163B

Install pilot converter as shown.

AEM100

DRIVE PLATE RUNOUT

NLEM0141S11

Runout (Total indicator reading):

Drive plate (CVT models)

Less than 0.20 mm (0.0079 in)

CAUTION:

Be careful not to damage the ring gear teeth.

Check the drive plate for deformation or cracks.

Do not allow any magnetic materials to contact the ring
gear teeth.

SEM166B

Assembly

NLEM0142

PISTON

NLEM0142S01

Install new snap ring on one side of piston pin hole.

SEM946C

Heat piston to 60 to 70°C (140 to 158°F) and assemble piston,
piston pin, connecting rod and new snap ring.

Align the direction of piston and connecting rod.

Numbers stamped on connecting rod and cap correspond
to each cylinder.

After assembly, make sure connecting rod swings
smoothly.

SEM601D

Set piston rings as shown.

CAUTION:

When piston rings are not replaced, make sure that piston
rings are mounted in their original positions.

Install new piston rings either side up if there is no punch
mark.

CYLINDER BLOCK

Inspection (Cont’d)

EM-142

SEM160B

Align piston rings so that end gaps are positioned as
shown.

SEM685D

CRANKSHAFT

NLEM0142S02

Set main bearings in their proper positions on cylinder block
and main bearing cap.

Confirm that correct main bearings are selected by using
Method A or Method B. Refer to EM-138.

Apply new engine oil to bearing surfaces.

SEM069G

Install crankshaft and main bearing caps, then tighten bolts to
the specified torque.

Prior to tightening bearing cap bolts, shift crankshaft back
and forth to properly seat the bearing cap.

Apply new engine oil to threads and seating surfaces of
bearing cap bolts before installing them.

Tightening procedure:

SEM071G

SEM072G

Tighten all bolts to 32 to 38 N·m (3.3 to 3.8 kg-m, 24 to 28
ft-lb).

Turn all bolts 30 to 35 degrees clockwise with Tool or
suitable angle wrench.

If an angle wrench is not available, mark all bearing cap
bolts on the side facing engine rear. Then, turn each bolt
specified degrees clockwise. Confirm angle of degrees
with a graduator, not by eye measurement.

After securing bearing cap bolts, make sure crankshaft
turns smoothly by hand.

CYLINDER BLOCK

Assembly (Cont’d)

EM-143

SEM073G

Measure crankshaft end play.

Crankshaft end play:

Standard

0.10 - 0.26 mm (0.0039 - 0.0102 in)

Limit

0.30 mm (0.0118 in)

If beyond the limit, replace thrust bearing with new one.

SEM159B

Install connecting rod bearings in connecting rods and con-
necting rod caps.

Confirm that correct bearings are used. Refer to EM-140.

Install bearings so that oil hole in connecting rod aligns
with oil hole of bearing.

Apply new engine oil to bolt threads and bearing surfaces.

SEM554E

Install pistons with connecting rods.

Install them into corresponding cylinders with Tool.

Make sure connecting rod does not scratch cylinder wall.

Make sure connecting rod bolts do scratch crankshaft pin
journals.

Arrange so that front mark on piston head faces engine
front.

Apply new engine oil to piston rings and sliding surface
of piston.

SEM074G

Install connecting rod caps.

Apply new engine oil to threads and seat surfaces.
Tighten connecting rod cap nuts using the following procedure:

Tighten nuts to 14 to 16 N·m (1.4 to 1.6 kg-m, 10 to 12 ft-
lb).

Turn all nuts 60 to 65 degrees clockwise. If an angle
wrench is not available, tighten nuts to 38 to 44 N·m (3.9
to 4.5 kg-m, 28 to 33 ft-lb).

SEM075G

Measure connecting rod side clearance.

Connecting rod side clearance:

Standard

0.20 - 0.35 mm (0.0079 - 0.0138 in)

Limit

0.50 mm (0.0197 in)

If beyond the limit, replace connecting rod and/or crankshaft.

CYLINDER BLOCK

Assembly (Cont’d)

EM-144

Nissan Almera Tino V10 (2001 year). Manual - part 150