Nissan Almera Tino V10 (2001 year). Manual

SEM188A

VALVE DIMENSIONS

NLEM0065S12

Check dimensions of each valve. For dimensions, refer to SDS
(EM-242).
When valve head has been worn down to 0.5 mm (0.020 in) in
margin thickness, replace valve.
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or
less.

SEM288A

VALVE SPRING

NLEM0065S13

Squareness

NLEM0065S1301

Measure dimension “S”.

Out-of-square “S”:

Limit 1.5 mm (0.059 in)

If it exceeds the limit, replace spring.

EM113

Pressure

NLEM0065S1302

Check valve spring pressure at specified spring height.

Standard:

Installation height 32.82 mm (1.2921 in)
Installation load 168 - 186 N (17.13 - 18.97 kg, 37.8 -
41.8 lb)
Height during valve open 24.82 mm (0.9772 in)
Load with valve open 350 - 382 N (35.7 - 37.9 kg, 78.7
- 83.6 lb)

If it exceeds the standard, replace spring.

SEM960E

VALVE LIFTER

NLEM0065S14

Check contact and sliding surfaces for wear or scratches.

SEM961E

Check diameter of valve lifter and valve lifter guide bore.

Valve lifter outer diameter:

29.960 - 29.975 mm (1.1795 - 1.1801 in)

CYLINDER HEAD

Inspection (Cont’d)

EM-209

SEM867E

Lifter guide bore diameter:

30.000 - 30.021 mm (1.1811 - 1.1819 in)

Clearance between lifter and lifter guide:

Standard 0.025 - 0.061 mm (0.0010 - 0.0024 in)

If the value is out of the range, replace valve lifter and/or cyl-
inder head, referring to the specified values for the outer diam-
eter and bore diameter.

JEM165G

Assembly

NLEM0066

Install valve oil seal.

Using valve oil seal drift (SST), install so that the dimension
shown in the figure is obtained. The dimension in the figure
shows the dimension before the valve spring seat is installed.

Different parts should be used depending on the valve oil seal
location. Identify by the rubber color.

For intake: Black
For exhaust: Brown

Always use new valve oil seal.

Before installing valve oil seal, install valve spring seat.

Install other valve component parts. Refer to “Disassembly”,
EM-202.

After installing valve collets, tap valve stem tip with plastic
hammer to assure a proper fit.

Installation

NLEM0067

Before installation, remove old liquid gasket from mating
surface of all liquid gasket applied parts.

SEM505G

CYLINDER HEAD GASKET SELECTION

NLEM0067S01

Select 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

CYLINDER HEAD

Inspection (Cont’d)

EM-210

0.900 (0.0354)

0.925 (0.0364)

0.950 (0.0374)

0.975 (0.0384)

1.000 (0.0394)

1.025 (0.0404)

*: Measured with head bolts tightened

SEM507G

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

Set piston at a point close to TDC.

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.

Move the dial gauge stand so that the tip of dial gauge can
contact the cylinder block. Read the difference.

Measure at two locations per cylinder, that is eight locations for
four cylinders. Select gasket based on the maximum protru-
sion of eight measurements.

Piston protrusion

mm (in)

Gasket thickness*

mm (in)

Identification

Number of holes

Less than 0.255 (0.0100)

0.900 (0.0354)

Less than 0.255 - 0.280

(0.0100 - 0.0110)

0.925 (0.0364)

Less than 0.280 - 0.305

(0.0110 - 0.0120)

0.950 (0.0374)

Less than 0.305 - 0.330

(0.0120 - 0.0130)

0.975 (0.0384)

Less than 0.330 - 0.355

(0.0130 - 0.0140)

1.000 (0.0394)

More than 0.355 (0.0140)

1.025 (0.0404)

*: Measured with head bolts tightened

JEM171G

CYLINDER HEAD BOLT DEFORMATION CHECK

NLEM0067S02

Measure the outer diameter of threaded area, d1 and d2, at the
points specified in the figure.

When the necked point is identified at a point other than speci-
fied points, measure at the point as d1.

Calculate the difference between d1 and d2. If the value
exceeds the limit, replace with new ones.

Limit: 0.15 mm (0.0059 in)

CYLINDER HEAD

Installation (Cont’d)

EM-211

JEM172G

CYLINDER HEAD-TO-BLOCK DIFFERENCE CHECK

NLEM0067S03

After installing cylinder head, measure dimension from the
front end surface of cylinder block to that of cylinder head.

Standard: 23.53 - 24.07 mm (0.9264 - 0.9476 in)

If the difference is out of the range, check fitting of dowel pins
and cylinder head.

JEM167G

LIQUID GASKET APPLICATION ON REAR CHAIN CASE

NLEM0067S04

Apply a continuous bead of specified liquid gasket (Refer to
EM-158, “Liquid Gasket Application Procedure”.) on the surface
shown in the figure.
A: Apply bead so that it does not protrude into oil passage.
B: Minimize the overlapping area of the bead, with start and end
areas of bead as shown in the figure.
Apply so that the portion marked * comes at an external location
but cannot be viewed externally after engine is assembled.

JEM149G

JEM166G

CYLINDER HEAD INSTALLATION

NLEM0067S05

Tighten bolts in numerical order as shown in the figure accord-
ing to the following procedure:

Apply engine oil to bolt threads and seat surfaces.

Tighten bolts to 29 to 38 N·m (2.9 to 3.9 kg-m, 21 to 28 ft-lb).

Tighten 180° to 185° [target: 180°] (angular tightening).

Loosen completely to 0 N·m (0 kg-m, 0 ft-lb) in the reverse
order of that shown in the figure.

Tighten bolts to 35 to 44 N·m (3.5 to 4.5 kg-m, 26 to 32 ft-lb).

Tighten 90° to 95° [target: 90°] (angular tightening).

Tighten another 90° to 95° [target: 90°] (angular tightening).

When an angle wrench is not used, paint an alignment
mark on the head of cylinder head bolt and cylinder head
surface before tightening. Check the angle with a protrac-
tor.

GLOW PLUG INSTALLATION

NLEM0067S06

To avoid damage, glow plugs should be removed only
when required.

Handle with care to avoid applying shock. (When dropped
from approx. 100 mm (3.94 in) or higher, always replace
with a new one.)

Before installing, remove carbon depositing on mounting hole
of glow plug with a reamer.

CYLINDER HEAD

Installation (Cont’d)

EM-212

JEM173G

CAMSHAFT INSTALLATION

NLEM0067S07

Install valve lifters and adjusting shims.

Install in the correct locations (the same places as before
removal).

Install camshafts.

Identify camshafts by the paint position and screw hole at the
rear end.

Camshaft RH: Paint is at position A without screw hole.
Camshaft LH: Paint is at position B with screw hole.

SEM516G

Install so that knock pins are positioned in the directions shown
in the figure.

JEM175G

Install camshaft brackets.

Install correctly, identifying brackets by the journal No. and
front mark on top surface.

JEM160G

Tighten bolts in the order shown in the figure according to the
following procedure:

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.

Tighten to 6 N·m (0.6 kg-m, 52 in-lb).

Tighten to 12 to 13 N·m (1.2 to 1.4 kg-m, 9 to 10 ft-lb).

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.

Before installing spill tube after installing secondary timing
chain, check and adjust valve clearance. Refer to EM-214,
“Valve Clearance”.

Hereafter, install in the reverse order of removal.

CYLINDER HEAD

Installation (Cont’d)

EM-213

JEM176G

Valve Clearance

NLEM0068

CHECKING

NLEM0068S01

Check 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.)

JEM177G

Put an alignment mark with paint, etc. on the crankshaft pul-
ley and on the oil pump as an angle indicator.

JEM178G

Check only those valves shown in the figure.

Crank position

Valve

No. 1

No. 2

No. 3

No. 4

INT

EXH

INT

EXH

INT

EXH

INT

EXH

No. 1 TDC
(Compression
stroke)

JEM179G

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)

JEM180G

Rotate crankshaft clockwise by one turn to set the No. 4 pis-
ton to TDC on the compression stroke.

Check only those valves shown in the figure.

Crank position

Valve

No. 1

No. 2

No. 3

No. 4

INT

EXH

INT

EXH

INT

EXH

INT

EXH

No. 4 TDC
(Compression
stroke)

CYLINDER HEAD

Valve Clearance

EM-214

JEM181G

ADJUSTING

NLEM0068S02

Adjust valve clearance while engine is cold.
1.

Turn crankshaft, to position cam lobe on camshaft of valve that
must be adjusted upward.

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).

SEM497G

Rotate Tool (A) (See figure.) so that valve lifter is pushed down.

SEM498G

Place Tool (B) (SST) between camshaft and the edge of the
valve lifter to retain valve lifter.

CAUTION:

Tool (B) must be placed as close to camshaft bracket as
possible.

Be careful not to damage cam surface with Tool (B).

Remove Tool (A).

JEM555G

Blow air into the hole to separate adjusting shim from valve
lifter.

To avoid engine oil spills, wipe off oil fully beforehand.
Wear safety goggles, etc. during work if necessary.

CYLINDER HEAD

Valve Clearance (Cont’d)

EM-215

JEM556G

SEM145D

JEM184G

Remove adjusting shim using a small screwdriver and a mag-
netic finger.

Determine replacement adjusting shim size following formula.

Using a micrometer determine thickness of removed shim.

Calculate thickness of new adjusting shim so valve clearance
comes within specified values.
R = Thickness of removed shim
N = Thickness of new shim
M = Measured valve clearance

Intake:

N = R + [M − 0.28 mm (0.0110 in)]

Exhaust:

N = R + [M − 0.30 mm (0.0118 in)]

Shims are available in 33 sizes from 2.10 mm (0.0827 in)
to 2.74 mm (0.1079 in), in steps of 0.02 mm (0.0008 in).

Select new shim with thickness as close as possible to calcu-
lated value.

SEM552G

Install new shim using a suitable tool.

Install with the surface on which the thickness is stamped
facing down.

10. Place Tool (A) as mentioned in steps 2 and 3.
11. Remove Tool (B).
12. Remove Tool (A).
13. Recheck valve clearance.

CYLINDER HEAD

Valve Clearance (Cont’d)

EM-216

Removal and Installation

NLEM0069

SEM554G

WARNING:

Situate 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.

For safety during subsequent steps, the tension of wires
should be slackened against the engine.

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 hoist 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 careful not to strike adjacent parts,
especially the following: Accelerator wire casing, brake
lines, and brake master cylinder.

In hoisting 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-218

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.

REMOVAL

NLEM0069S01

Remove engine undercover, and hood for hoisting.

Drain coolant from both cylinder block and radiator. Refer to
LC-59, “Changing Engine Coolant”.

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.

Disconnect vacuum hose on vacuum pump side.

Disconnect fuel feed and fuel return hoses on engine side.

Immediately put blind plugs into the openings to prevent
fuel from flowing out.

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.

SEM499G

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 ASSEMBLY

Removal and Installation (Cont’d)

EM-219

SEM189G

Make sure that support is stable with the use of safety
blocks.

16. Install hooks of lifting chain into engine slingers and tighten

chain so that engine still remains on transmission jacks with-
out being lifted up.

17. Remove engine mount insulator RH.
18. Remove through-bolt of engine mount insulator LH.
19. Remove bolts securing center member at front and rear.

JEM190G

20. Carefully lower transmission jacks in accordance with the low-

ering pace of the hoist, and remove engine and transaxle
assembly from vehicle.

While working, check that no parts of engine assembly
interfere with adjacent parts on the vehicle.

While working, make sure that parts requiring disconnec-
tion are not left connected, and that no parts interfere with
vehicle.

To prevent vehicle from falling down, perform operation
carefully so that the center of gravity of the vehicle will not
shift.

21. Remove center member.

Before starting removal operation, first place the assem-
bly on a level surface and securely support the bottom
surface with wood blocks. Using a hoist, lift engine
slingers, and make sure the assembly is stable.

22. Separate engine and transaxle.

INSTALLATION

NLEM0069S02

Install in the reverse order of removal, observing the following:

While installing, be careful to keep mount insulators free of oil
smear and damage.

When parts require specified installation directions/positions,
install by using the identifying marks indicating up or front.

While keeping the mount insulators free of twists or distortions,
start tightening from the through-bolt on the engine mount
insulator LH. This mount is used as the reference position.

ENGINE ASSEMBLY

Removal and Installation (Cont’d)

EM-220

Removal and Installation

NLEM0071

CAUTION:

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)].

Disassembly

NLEM0072

PISTON AND CRANKSHAFT

NLEM0072S01

Remove engine. Refer to “ENGINE ASSEMBLY”, “Removal
and Installation”, EM-218.

Place engine on a work stand.

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.

JEM192G

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.

Install engine attachment (SST).

The four sets of bolts and nuts are multi-purpose products.

CYLINDER BLOCK

Removal and Installation

EM-222

JEM193G

Hoist up engine and install it on the engine stand (SST).

Another method is to set engine sub-attachment and engine
attachment on engine stand beforehand, and then, install
engine.

Drain engine oil and coolant from engine.

Remove the following and the associated parts:

Exhaust manifold

Turbocharger assembly

Injection tube

Intake manifold

Oil pan (upper and lower)

Secondary timing chain

Fuel injection pump

Primary timing chain

Rocker cover

High pressure injection nozzle assembly

Camshaft

Cylinder head

Thermostat, water pipes

Oil cooler

Auxiliary component brackets

Remove fuel injection pump bracket.

SEM500G

If the replacement of pilot bushing is necessary, remove it with
pilot bushing puller (SST).

Remove rear oil seal retainer.

Insert a flat-bladed screwdriver between main bearing cap and
rear oil seal retainer to remove retainer.

Remove rear oil seal from rear oil seal retainer.

Punch out with a flat-bladed screwdriver.

Be careful not to damage rear oil seal retainer.

JEM195G

Remove piston and connecting rod assembly.

Set crankshaft pin of the removal location at a position close
to BDC.

Remove connecting rod cap.

Push piston and connecting rod assembly toward cylinder
head using a hammer handle.

Before removing piston and connecting rod assembly, check
connecting rod side clearance. Refer to EM-225, “CONNECT-
ING ROD SIDE CLEARANCE”.

10. Remove connecting rod bearings from connecting rod and

connecting rod cap.

CYLINDER BLOCK

Disassembly (Cont’d)

EM-223

Store the removed parts in sets by the cylinder No. to avoid
mixing them up.

JEM196G

11. Remove piston rings from pistons.

Use piston ring expander (Commercial Service Tool).

Avoid scratching pistons during removal.

Be careful not to damage piston rings by expanding
excessively.

CAUTION:

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

JEM197G

12. Remove piston from connecting rod.
a.

Remove snap rings using snap ring pliers.

JEM198G

With an industrial dryer, heat pistons to 60 to 70°C (140 to
158°F).

JEM199G

Push out piston pin with a rod approx. 26 mm (1.02 in) in
diameter.

CYLINDER BLOCK

Disassembly (Cont’d)

EM-224

Nissan Almera Tino V10 (2001 year). Manual - part 155