Content .. 152 153 154 155 ..

Nissan Almera Tino V10 (2001 year). Manual - part 154

Removal and Installation

NLEM0102

JEM265G

PREPARATIVE WORK

NLEM0102S01

Remove the following parts.

Engine coolant (drain)
Refer to LC-59, “Changing Engine Coolant”.

Air duct, air inlet pipe

Water inlet pipe

Catalytic converter

Exhaust manifold cover

Insulator

Each wiring and piping (disconnect/move)

JEM266G

EXHAUST MANIFOLD AND TURBOCHARGER

NLEM0102S02

Removal

NLEM0102S0201

Loosen exhaust manifold mounting nuts in the reverse order
specified in the figure.

Rotate the exhaust manifold and turbocharger assembly so
that the rear side (EGR tube mounting side) faces upward. And
then pull out the assembly from between the engine and the
air conditioning piping.

CAUTION:

Be careful not to deform each turbocharger piping when pull-
ing out the assembly.

EXHAUST MANIFOLD, TURBOCHARGER

Removal and Installation

EM-193

Installation

NLEM0102S0202

When a stud bolt is pulled out, tighten it to the following torque:

: 18 - 21 N·m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)

Tighten the exhaust manifold mounting nuts in the following
procedure:

Tighten the nuts in the order specified in the figure.

Re-tighten the nuts 1 to 4.

EXHAUST MANIFOLD GASKET

NLEM0102S03

Installation

NLEM0102S0301

Install the gasket so that the alignment protrusion faces the No. 4
port.

Disassembly and Assembly

NLEM0103

SEM268G

TURBOCHARGER

NLEM0103S01

Disassembly

NLEM0103S0101

After applying penetration lubricant (Lucen, etc.) to the mounting
nuts, check for the penetration of the lubricant, and then loosen the
nuts to remove.

EXHAUST MANIFOLD, TURBOCHARGER

Removal and Installation (Cont’d)

EM-194

CAUTION:

Do not disassemble or adjust the turbocharger body.

Assembly

NLEM0103S0102

When a stud bolt is pulled out, tighten it to the following torque:

: 24 - 27 N·m (2.4 - 2.8 kg-m, 18 - 20 ft-lb)

JEM267G

Inspection

NLEM0104

EXHAUST MANIFOLD

NLEM0104S01

Check the distortion on the mounting surface in the six directions
using a straightedge and a feeler gauge.

Limit: 0.3 mm (0.012 in)

TURBOCHARGER

NLEM0104S02

SEM269G

CAUTION:

When the compressor wheel, turbine wheel, or rotor shaft is
damaged, remove all the fragments and foreign matter left in
the following passages in order to prevent a secondary failure:

Suction side: Between turbocharger and air cleaner
Exhaust side: Between turbocharger and catalytic con-
verter

EXHAUST MANIFOLD, TURBOCHARGER

Disassembly and Assembly (Cont’d)

EM-195

SEM270G

Rotor Shaft

NLEM0104S0201

Check that the rotor shaft rotates smoothly without any resis-
tance when it is rotated by your fingertips.

Check that the rotor shaft is not loose when it is moved verti-
cally or horizontally.

Standard value for rotor shaft oil clearance:

0.086 - 0.117 mm (0.0034 - 0.0046 in)

SEM271G

Rotor Shaft End Play

NLEM0104S0202

Place a dial gauge at the rotor shaft end in the axial direction to
measure the end play.

Standard: 0.036 - 0.090 mm (0.0014 - 0.0035 in)

SEM272G

Turbine Wheel

NLEM0104S0203

Check that there is no oil adhesion.

Check that there is no carbon accumulation.

Check that blades of the turbine wheel are not bent or broken.

Check that the turbine wheel does not interfere with the turbine
housing.

SEM273G

Compressor Wheel

NLEM0104S0204

Check that there is no oil adhesion inside the air inlet.

Check that the compressor wheel does not interfere with the
compressor housing.

Check that the wheel is not bent or broken.

SEM274G

Waste Gate Actuator

NLEM0104S0205

Connect the handy pump to the actuator, and check that the
rod strokes smoothly in compliance with the following pres-
sure.

Pressure to be applied at actuator part to move rod end as
follows:

Standard (Pressure/rod stroke amount):

115.44 - 120.76 kPa (1,154 - 1,208 mbar, 866.0 - 906.0
mmHg, 34.1 - 35.7 inHg)/0.38 mm (0.0150 in)
140.54 - 149.86 kPa (1,405 - 1,498 mbar, 1,054.3 -
1,124.2 mmHg, 41.5 - 44.3 inHg)/4.0 mm (0.157 in)

EXHAUST MANIFOLD, TURBOCHARGER

Inspection (Cont’d)

EM-196

Trouble Diagnosis of Turbocharger

=NLEM0104S0206

Preliminary check:

Check that the engine oil level is between MIN and MAX of the
dipstick. (When the engine oil amount is more than MAX, the
oil flows into the inlet duct through the blow-by gas passage,
and the turbocharger is misjudged failure.)

Ask the customer if he/she always runs the vehicle in idle
engine speed to cool the oil down after driving.

Replace the turbocharger assembly when any malfunction is
found after unit inspections specified in the table below.

If no malfunction is found after the unit inspections, judge that
the turbocharger body has no failure. Check the other parts
again.

Inspection item

Inspection result

Symptom (when each inspection item meets

each inspection result)

Oil leak-

age

Smoke

Noise

Insuffi-

cient

power/

accelera-

tion failure

Turbine wheel

Oil leaks.

Carbon is accumulated.

Friction with housing.

Blades are bent or broken.

Compressor wheel

Inside the air inlet is seriously con-
taminated by oil.

Friction with housing.

Blades are bent or broken.

After checking both turbine and compressor,
inspect rotor shaft end play.

There is resistance when the rotor
shaft is rotated by your fingertips.

The rotor shaft sometimes does
not rotate by your fingertips.

There is too much play in the
bearing.

Oil return port

Carbon or sludge is accumulated
in the waste oil hole.

Operation of Waste gate actuator

The actuator does not operate
smoothly when vacuum pres-
sure is gradually applied.

Stroke amount is not in compli-
ance with the vacuum pressure.

: Large possibility

: Medium possibility

: Small possibility

EXHAUST MANIFOLD, TURBOCHARGER

Inspection (Cont’d)

EM-197

Removal and Installation

NLEM0099

SEM503G

PREPARATIVE WORK

NLEM0099S01

Remove engine cover.

JEM247G

ROCKER COVER

NLEM0099S02

Removal

NLEM0099S0201

Loosen holding bolts in the reverse order of that shown in the fig-
ure and remove.

CAUTION:

Do not remove mass damper on top. If damper must be
removed, remove all traces of old locking sealant from threads
of bolts and holes, and apply new locking sealant on the bolts
before tightening.

Installation

NLEM0099S0202

Tighten holding bolts in the numerical order shown in the fig-
ure.

Re-tighten to the same torque in the same order as above.

ROCKER COVER

Removal and Installation

EM-198

JEM248G

Apply 3.0 mm (0.118 in) dia. of specified liquid gasket (Refer
to EM-158, “Liquid Gasket Application Procedure”.) on locac-
tions shown in the figure.

ROCKER COVER

Removal and Installation (Cont’d)

EM-199

Components

NLEM0062

SEM504G

CYLINDER HEAD

Components

EM-200

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.

Removal

NLEM0063

PREPARATIVE WORK

NLEM0063S01

Drain engine coolant. Refer to LC-59, “Changing Engine Cool-
ant”.

Remove exhaust manifold. Refer to EM-193, “Removal”.

Remove intake manifold. Refer to EM-189, “Removal”.

Apply paint to camshaft sprockets for alignment during
installation.

JEM152G

CAMSHAFT

NLEM0063S02

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

JEM159G

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.

JEM160G

Remove camshafts.

Loosen bolts holding the camshaft bracket in several stages in
the reverse order of that shown in the figure, and remove them.

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 HEAD

Components (Cont’d)

EM-201

JEM149G

CYLINDER HEAD

NLEM0063S03

Loosen bolts in the reverse order of that shown in the figure
and remove them.

Be careful not to damage the tips of glow plugs project-
ing out of the bottom surface of the cylinder head. To
avoid damage to glow plugs, either remove them
beforehand, or support cylinder head with wooden blocks
to create a space below the bottom surface.

Disassembly

NLEM0100

JEM150G

Remove adjusting shims and valve lifters. Confirm the correct
location of each part removed. Store them in order to avoid
mixing them up.

JEM151G

Remove valve collets.

Compress valve spring with a valve spring compressor, and
remove valve collet with a magnet hand.

Remove valve spring retainers, and valve springs.

Push valve stem toward combustion chamber and remove
valve.

Before removing valves, check valve guide clearance. Refer to
EM-205, “VALVE GUIDE CLEARANCE”.

Confirm the correct location of each valve. Store them so they
do not get mixed up.

CYLINDER HEAD

Removal (Cont’d)

EM-202

JEM152G

For the locations and arrangement of intake and exhaust
valves, refer to the figure.

JEM153G

Remove valve oil seals.

Use a valve oil seal puller (SST) for removal.

Remove valve spring seats.

When removing valve seats, check valve seat contact. Refer
to EM-207.

Before removing valve guides, check valve guide clearance.
Refer to EM-205, “VALVE GUIDE CLEARANCE”.

Remove glow plugs.

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.)

SEM496G

Inspection

NLEM0065

CYLINDER HEAD DISTORTION

NLEM0065S01

Clean surface of cylinder head.
Use a reliable straightedge and feeler gauge to check the flatness
of cylinder head surface.
Check along six positions shown in the figure.

Head surface flatness: Limit 0.04 mm (0.0016 in)

If beyond the specified limit, resurface or replace it.
The limit for cylinder head resurfacing is determined by the
cylinder block resurfacing.

Resurfacing limit:

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

The maximum limit: A + B = 0.07 mm (0.0028 in)

After resurfacing cylinder head, check that camshaft rotates freely
by hand. If resistance is felt, cylinder head must be replaced.

Nominal cylinder head height:

153.9 - 154.1 mm (6.059 - 6.067 in)

CYLINDER HEAD

Disassembly (Cont’d)

EM-203

CAMSHAFT VISUAL CHECK

NLEM0065S02

Check camshaft for scratches, seizure and wear.

JEM161G

CAMSHAFT RUNOUT

NLEM0065S03

Place V-blocks on a work bench and support camshaft at No.
1 and No. 5 journal.

Set dial gauge perpendicularly at camshaft No. 3 journal.

Turn camshaft by hand in one direction and read runout on dial
gauge.

Runout (Total indicator reading):

Limit 0.02 mm (0.0008 in)

If it exceeds the limit, replace camshaft.

SEM549A

CAMSHAFT CAM HEIGHT

NLEM0065S04

Measure camshaft cam height.

Standard cam height:

Intake

39.505 - 39.695 mm (1.5553 - 1.5628)

Exhaust

39.905 - 40.095 (1.5711 - 1.5785)

Cam wear limit:

0.2 mm (0.008 in)

If wear is beyond the limit, replace camshaft.

JEM162G

CAMSHAFT JOURNAL CLEARANCE

NLEM0065S05

Install camshaft bracket and tighten bolts to the specified
torque.

Measure inner diameter of camshaft bearing.

Standard inner diameter:

No. 1: 30.500 - 30.521 mm (1.2008 - 1.2016 in)
No. 2, 3, 4, 5: 24.000 - 24.021 mm (0.9449 - 0.7882 in)

SEM012A

Measure outer diameter of camshaft journal.

Standard outer diameter:

No. 1: 30.435 - 30.455 mm (1.1982 - 1.1990 in)
No. 2, 3, 4, 5: 23.935 - 23.955 mm (0.9423 - 0.9431 in)

If clearance exceeds the limit, replace camshaft and/or cylin-
der head.

Camshaft journal clearance:

Standard

No. 1 - 5: 0.045 - 0.086 mm (0.0018 - 0.0034 in)

Limit

0.045 - 0.086 mm (0.0018 - 0.0034 in)

CYLINDER HEAD

Inspection (Cont’d)

EM-204

JEM163G

CAMSHAFT END PLAY

NLEM0065S06

Install camshaft in cylinder head.

Measure camshaft end play.

Camshaft end play:

Standard

0.070 - 0.148 mm (0.0028 - 0.0058 in)

Limit

0.24 mm (0.0094 in)

If the value exceeds the limit, replace camshaft and measure
again.

If the measurement exceeds the limit again, replace cylinder
head.

JEM164G

CAMSHAFT SPROCKET RUNOUT

NLEM0065S07

Install sprocket on camshaft.

Measure camshaft sprocket runout.

Runout (Total indicator reading):

Less than 0.15 mm (0.0059 in)

If it exceeds the limit, replace camshaft sprocket.

JEM155G

VALVE GUIDE CLEARANCE

NLEM0065S08

Check that valve stem diameter is within the specified range.

Push out valve approx. 25 mm (0.98 in) toward combustion
chamber. Swing valve in the direction of the dial gauge to
measure the runout.

This inspection should be performed before removing valve
guides.

Half of the runout reading on the dial gauge is the valve guide
clearance.

Standard:

Intake 0.020 - 0.053 mm (0.0008 - 0.0021 in)
Exhaust 0.040 - 0.073 mm (0.0016 - 0.0029 in)

If it exceeds the limit, check valve to valve guide clearance.

Measure valve stem diameter and valve guide inner diameter.

Check that clearance is within specification.

Valve to valve guide clearance limit:

Intake 0.08 mm (0.0031 in)
Exhaust 0.1 mm (0.004 in)

If it exceeds the limit, replace valve or valve guide.

CYLINDER HEAD

Inspection (Cont’d)

EM-205

SEM008A

VALVE GUIDE REPLACEMENT

NLEM0065S09

When a valve guide is removed, replace with an oversized [0.2
mm (0.008 in)] valve guide.

To remove valve guide, heat cylinder head to 110 to 130°C
(230 to 266°F) by soaking in heated oil.

SEM931C

Drive out valve guide with a press [under a 20 kN (2 ton, 2.2
US ton, 2.0 Imp ton) pressure] or hammer and suitable tool.

SEM932C

Ream cylinder head valve guide hole.

Valve guide hole diameter (for service parts):

10.175 - 10.196 mm (0.4006 - 0.4014 in)

JEM156G

Heat cylinder head to 110 to 130°C (230 to 266°F) and press
service valve guide onto cylinder head.

Projection “L”:

10.4 - 10.6 mm (0.409 - 0.417 in)

Ream valve guide.

Finished size:

6.000 - 6.018 mm (0.2362 - 0.2369 in)

CYLINDER HEAD

Inspection (Cont’d)

EM-206

SEM934C

JEM157G

VALVE SEATS

NLEM0065S10

Before starting this check, confirm that the dimensions of valve
guides and valves are as specified.

Apply red lead primer on contacting surfaces of valve seat and
of valve face to examine the conditions of contacting surfaces.

Check that the paint on contacting surfaces is continuous
along the entire circumference.

If there are abnormal indications, grind the valve and check the
contact again. If abnormal indications still persist, replace
valve seat.

SEM795A

REPLACING VALVE SEAT FOR SERVICE PARTS

NLEM0065S11

Bore out old seat until it collapses. Boring should not continue
beyond the bottom face of the seat recess in cylinder head. Set
the machine depth stop to ensure this.

Ream cylinder head recess for service valve seat.

Oversize [0.5 mm (0.020 in)]:

Intake 30.500 - 30.516 mm (1.2008 - 1.2014 in)
Exhaust 29.500 - 29.516 mm (1.1614 - 1.1620 in)

Be sure to ream in circles concentric to the valve guide
center.
This will enable valve seat to fit correctly.

CYLINDER HEAD

Inspection (Cont’d)

EM-207

JEM158G

SEM301G

Heat cylinder head to 110 to 120°C (230 to 248°F) by soaking
in heated oil.

Sufficiently cool valve seat with dry ice. Force fit valve seat into
cylinder head.

WARNING:

Do not touch cold valve seat with your bare hands.
5.

Cut or grind valve seat using suitable tool to the specified
dimensions as shown in SDS (EM-245).

CAUTION:

Use the valve seat cutter properly. Securely gripping the cut-
ter handle with both hands, press the cutter down onto the
entire circumference of the contacting surface and finish cut-
ting at one time. Improper pressing of the cutter or cutting in
several steps may result in staged surface on the valve seat.
6.

After cutting, lap valve seat with abrasive compound.

Check valve seating condition. Refer to EM-207, “Valve Seats”.

JEM253G

Use a depth gauge to measure the distance between the
mounting surface of the cylinder head spring seat and the
valve stem end. If the distance is shorter than specified, repeat
step 5 above to adjust it. If it is longer, replace the valve seat
with a new one.

Valve seat resurface limit “L”:

Intake 36.53 - 36.98 mm (1.4382 - 1.4559 in)
Exhaust 36.53 - 37.01 mm (1.4382 - 1.4571 in)

CYLINDER HEAD

Inspection (Cont’d)

EM-208

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